Punch press bolsters architectural fabrication specialist

Solutions reports. The turret punch was supplied by sole agent, Tamworth-based Press & Shear which claims that the machine cost considerably less than equivalent models on the market and was the first of its type to be installed in the UK, following its certification for use in Europe.

Incorporating technology from one of the world's premium turret punch press manufacturers, Nisshinbo, Yawei turret punch presses are manufactured using high quality components from Japan and Germany. The company produces some 3,000 machine tools per year at its 160,000m² facility in Jiangsu Province, China.

Established in May 1988, Weldall is jointly owned by Andy O'Farrell and Alan Blower. The company originally specialised in welding exotic materials such as titanium, nickel alloys and stainless steels for diverse industries including oil, gas, defence, cryogenics, nuclear and medical.

Early work in 1992 centred on producing prototypes for the BR90 project, a family of bridges built from aluminium alloy for the British Army. During this period the fabricator was subcontracting out its sheet metalworking but then decided to bring it in-house, installing its first press brake and guillotine following the acquisition of a supplier.

Into architecture

By the time the BR90 project was phased out in the late 1990s, Weldall had been planning for the transition and had entered the building and architectural sectors. Work in these industries continued side by side with other general fabrication projects.

Andy O'Farrell comments: “We are now best known for this work, particularly the manufacture of high quality fabrications, bracketry and aluminium flashings for curtain walling, at competitive prices in short leadtimes.”

Over the past six years, the founders' sons, Matt O'Farrell, Gareth O'Farrell and Ryan Blower have all joined the company. The family-run firm set about increasing its architectural business, which resulted in a succession of prestigious contracts.
An early success was supplying the builders of Quebec House, a development of 252 one- and two-bedroom units in Kingston-upon-Thames, with 2mm gauge aluminium pods to finish each of the windows. Other significant projects undertaken included a weather beater wall for Guy's Hospital in London, new aluminium detail for the upgrade to the pier in Weston-Super-Mare and window feature reveals for the Hilton hotel at Heathrow airport's terminal five. During this time, Weldall was using a six station CNC turret punch press. As it was equipped with a manual tool change carousel, a lot of operator intervention was needed and non-productive time was high. The requirements for higher pressworking productivity as well as increased capacity to process sheets longer than 2.5m led the subcontractor to look around for a replacement machine.

Mr O'Farrell continues: “The Yawei-Nisshinbo servo-electric punch press was the obvious choice due to its high specification and competitive price. We have dealt with the UK and Ireland distributor Press & Shear for many years and they have always provided excellent aftersales support.

“The use of thick turret tooling means that we will be able to produce accurate components on the machine for many years to come. Additionally, the optional 5m length capacity of the brush table is more than enough for our needs, as we have standardised on 4m by 1.5m sheet.”

Since it was installed in November 2014, the Yawei-Nisshinbo HPE-3058 punch press has fulfilled numerous contracts at the Cannock factory. Three sporting venues: the training ground at Chelsea FC and rugby union clubs Leicester Tigers and Northampton Saints have been refurbished using the subcontractor's components.

A recently completed job was the production of a 12m long lion logo for the wall of Birmingham University. It was designed in SolidWorks 3D CAD and produced in sections from 3mm J57S anodising quality aluminium prior to being anodised and attached to the front of the university building.

Holes and more holes

For another contract nearly six million 5.5mm diameter holes have been punched through 2mm stainless steel for the production of engine intake louvres to protect military vehicles used in UN peace keeping missions. A special punch and die set was sourced from Wilson Tool complete with the addition of Optima Coating on the punch, which greatly extends tool life by increasing the hardness of the tool to 95 Rockwell.

A current project is feature panel manufacture for student accommodation in the Eastside Locks area of central Birmingham, a further ongoing job requiring the manufacture of over 1,000 feature grilles from 3mm aluminium.
Ryan Blower affirms: “Our use of the new punch press coupled with purchase of Jetcam software, also through Press & Shear, has resulted in an increase in productivity.

“The parts we manufacture are more accurate so our customers do not have to worry about onsite fit-up, improving their productivity as well. As a consequence, we have been able to win a lot of new business as well as retain existing customers and we have seen a rise in the company's annual turnover.” Weldall is currently being assessed for compliance with EN 1090 parts two and three, the European standards that regulate the fabrication and assembly of steel and aluminium structures for the construction industry, and hopes that this will be in place in early 2016.

Servo-driven power

Weighing 16 tonnes, the multi-axis CNC machine has a Nisshinbo-manufactured turret with 36 stations for thick turret tooling, although alternative configurations are available. The servo-driven ram has a nominal force of 300kN, allowing holes up to 88.9mm to be punched. Turret indexing speed is 30rpm and Nisshinbo's patented ‘Keeping-touch' auto index system is included. The use of wheel-type tools, taps and multi tools is supported.

The brush table accommodates sheet up to 5m by 1.5m with one reposition, traverse speed being up to 102m/minute. Maximum sheet thicknesses that can be processed are 6.35mm for carbon steel, 4mm for stainless steel. Hit rate is up to 1,500 strokes per minute and accuracy of punched features is ±0.1mm.

Standard equipment includes a Siemens CNC control, brush tables, three work clamps and soft punch. Options such as multi-tools and a load/unload system are also available.

PRESS & SHEAR
www.pressandshear.com

WELDALL
www.weldall.co.uk