BM45 - BM65: STEP 5
We show you how to setup a tooling on the machines.
Hi! I’m Stefano from Italy. Thanks for watching our Pedrazzoli video tutorials. In these videos we show you how to setup a tooling on the machines.
Here (fig. 1) we set the tooling. We have the tooling divided for all the different stacks: first stack, how we define the tools? This (fig. 2) is the radius of the former, so radius 85 in this case. This (fig. 3) is the distance from the rear of the wiper die to the center of the former: in this case, there is no wiper die so we put a minimum quote just to avoid the carriage don’t go in collision with the former; this (fig. 4) is the height of the first stack that is majored from this plate to the center of the former, 66.5 in this case.
This (fig. 5) is the clamp lenght, This (fig. 6) is the pressure die lenght. This (fig. 7) is the maximum opening strok of the clamp: you can edit the value by insert it in the field. This (fig. 8) is the closing position of the clamp.
How I set this value? You go in manual mode, you select the axis (fig. 9) and put the piece of tube inside (fig. 10). Now, manually (and make sure the key is on manual mode!), you close the clamp. Attention: do it always at a minimum speed! So, once you reached the correct closing position, you set this value in the toolset file. If you press too much against the former, the machine goes in error (fig. 11), so it is important to define the correct closing position. To reset the error, turn on the machine and the reset button. 388,5 is our closing position. The criteria is applied in here (fig. 12).
This (fig. 13) is the maximum opening position of the pressure die; this (fig. 14) is the short opening position, so the open short of the pressure die; this (fig. 15) is my closing position of the pressure die.
Same procedure: you go in manual mode, you select the axis (this is ax 5 – fig. 16), you move slowly against the tube until you find the correct closing position and then you put the value in this field (fig. 17). Here (fig. 18) is the lenght of the mandrel; this (fig. 19) is my mandrel retraction value. Attention: so after each bend, I want that the mandrel go out of 16 mm.
These two values (fig. 20) are the following movements of the booster and of the carriage, very important values: you see that if I change a number here (fig. 21), I put for example 98, this value (fig. 22) changes in negative. What does it mean? If I have it at 100%, it follows at the same pit of the bend arm, but due to the material elongation it might be necessary to break the carriage a little bit, so I try to find the correct value due to the elongation of the material: this is a factor of experience, there is nothing written about, so if you push for example too much, you will have wrinkles on the tube, so you try to decrease the value till the wrinkles disappear. The same criteria is applied on the pressure die (fig. 23).
This is our first level of tooling. Then the same must be done on the second stack (fig. 24), so again the height from the plate to the center of the former, if the tooling have the same diameter and radius, the value, as you see, will not change that much, they will remain the same. Our last tooling stack (fig. 25) are the rolls, so the same criteria: the radius of the bigger roll (fig. 26), the distance (fig. 27) from the rear rolls to the center of the former (each field can be edit), the height (fig. 28) of the third stack (always from the plate to the third stack);
opening and closing position of the rolls (fig. 29), the radius of the small rolls (fig. 30) and the distance between the first roll and the rear rolls (fig. 31). This is my multi-stack tool. Everything can be saved on here (fig. 32):
you select your tool (fig. 33), program name (fig. 34): if you don’t change the name, “program already exist, do you want to overwrite it?”, you press “Yes” (fig. 35). Then we have this page (fig. 36), so there is a help button (fig. 37), to click on the control you see the description.
For example, this (fig. 38) is the loading measure (where I want my carriage to come and make the load of the tube), this (pag. 39) is the packing position, the maximum bend angle the machine can perform (fig. 40), the number of stacks (if you have only 2 stacks, you put 2 in there – fig. 41, in this case we have 3 levels), where is my push bending stack (in this case, my push bending stack is on the third level – fig. 42). If I want the device close at the end of the program, the collet close at the end of the program. Lenght of the rod and this is tecnically my mandrel in position, 5834 (fig. 43).
5980 is the mandrel extraction value after the last bend (fig. 44), so the mandrel retract to 5980 in this case. This is the lubrication, these (fig. 45) are the torques of the machine (they are not affecting the machine functioning). “Mis-alignement 5 mm” (fig. 46): what does it mean? After each angle the head will move 5 mm out of the axis, this is also to allow to change of the stack (if you have to change from left to right or to the push bending stack). So the head will move 5 mm out of the axis. “Slide thrust dis-alignment” 190 mm (fig. 47) is the value we have here at ax 6 (fig. 48), that is pratically the minimum distance between the pressur die and the bend arm, that we see here (fig. 49). So you go forward as close as possible but not in contact with the bend arm. This value, 190 mm, will be set in the toolset file.
The “end of cycle mis-alignment” (fig. 50) means that at the end of the cycle the head moves 10 mm out of the axis to allow the tube extraction. If you press here (fig. 51) and then F6 (fig. 52), you have the IMS manual where you can see all the descriptions and functions of the IMS. The minimum and maximum values of the axis movements, for example. Here we see the mandrel, 5980 (fig. 53). They are defined on this page: here we can see the minimum and maximum movements of the axis.
If there is programmed, 5980 and here (fig. 54) I write 600 mm the machine can not move to 600 mm and will give you an error. This is the same for each axis: the bend arm, for example, if you have a maximum position of 180° (fig. 55) I can not program over this value. Then never change the torque (fig. 56) set by the factory! If I have here 185, I can not reach this position, so it makes no sense to have this value, or you must increase the value (fig. 57).
So, once all the parameters has been inserted on the different stacks, here you can put the tube diameter (fig. 58), the lenght (fig. 59) of the collect (if there is a stop inside), the wall thickness (if it’s a square, you can put the second dimension – fig. 60), the tube lenght (fig. 61) and this (fig. 62) is what the machine calculate according to the program.
So, once all this have been done, you can click on here (fig. 63): it is already in “tooling” (fig. 64), you save (fig. 65) and you have here (fig. 66) the name of the tooling you have saved.