What to Look for When Selecting a New Plasma Cutting System

Choosing a new plasma-cutting system can be somewhat overwhelming. First, you must decide whether automation is truly the way to go for your business. Then, find the right machinery to meet your needs. There is a chance that a laser cutter will be better for your fabrication needs but, then again, when it comes to versatility and per-part cost, it is often found that an automated plasma cutting system will be the best bet.

When Is Automation Best?

If you are a fabricator, you may find that you need a set and regular parameter of cuts and pieces. This makes automation a great saver of man hours and money. In what instances should a fabricator consider automation?

·         If you find that you are repeatedly making the same cuts and not having to change dimensions, then automation would be a time-saving benefit.

·         If you find that manual cuts require a lot of rework, then a more stable and faster cutting system could be the answer.

·         Having issues with fit-up after manual cuts could mean that you need a more cookie-cutter type production.

·         Having a limited labor budget may slow your productivity, as you have to pay employees to manually cut. Using an automated cutter will reduce your payroll and increase productivity.

·         If your final goal is that of weld-ready parts, then manual cutting is not the way to go. Automated plasma cutting produces parts that are ready to weld.

Automation addresses all of these issues while improving productivity and lowering the cost per part. Speed seems to be the most touted feature of plasma cutting. Compared to waterjet and laser cutters, the quality may be a bit less, with rougher edges and less precision, but, for mass production, the automated plasma cutting system is more cost-effective and efficient.

What to Ask Before Purchasing

Once you make the decision to start looking into automated plasma cutting systems, there are several things that you will want to consider and ask about before you decide on a machine. Will you need a standard machine or a high-precision setup? A knowledgeable salesperson will be able to answer your questions and even provide samples for you to compare. Cut quality should be a major consideration when deciding on a plasma cutter.

You will need to find out about:

·         Smooth cut surface

·         Minimal top edge rounding

·         Top spatter problems

·         Bottom dross evaluation

·         Kerf width options

·         Cut bevel angle

·         Nitride contamination

When you compare a variety of samples, you will be able to choose the best automated plasma cutter for your fabrication needs.

Investment

The initial layout for an automated plasma cutting machine is not small. Basically, you are looking at between $80,000 and $120,000 for a high-precision plasma cutter and up to $80,000 for a standard plasma cutter.  This is one reason why it is very important to decide whether automation is truly a feature that your business needs. If you are considering an automated plasma cutting system versus a laser cutter, then you also have to weigh the cut cost per piece and increased productivity, as well as the amount paid for the system to determine your benefit.  

Contact Quantum Machinery today to find out what cutting system will best meet your fabrication needs.

How to Properly Maintain Your Waterjet System

There are many reasons why people may choose to use a waterjet cutting system. In some instances, the materials to be cut are temperature sensitive and wouldn’t do well with a standard laser cutter. The use of nothing more than a high-pressure jet of water allows for accuracy and temperature control as well as minimizing dust and fumes.

Waterjet systems are used to cut glass, rubber, copper, titanium, stainless steel, and stone, among other materials. A waterjet system is a piece of equipment that requires proper maintenance in order to remain functional.

Unmaintained System Problems

If your waterjet system is not properly maintained, you may end up with some of the following problems:

·         Inaccurate cutting

·         Increased use of consumables

·         Excess water usage

·         Replacement part costs

·         Operational downtime

·         Loss of business

·         Total machine failure

If you’ve invested in a waterjet system, it is important to also invest in preventive maintenance software and plan for scheduled maintenance.

Basic Maintenance

Each manufacturer issues their recommended maintenance procedures differently. Owners and operators need to be familiar with the manual and the procedures for maintenance. Even failing to clean the equipment can cause major problems. All shop workers should be competent in three areas of waterjet systems. The first would be software programming, the second, operating the equipment, and the third, maintenance. There are some waterjet systems that are more complex than others and may require more training in different aspects of maintenance.

Pump and Table

The pump and table have several components, such as seals, valves, swivels, and hoses. Some tables may require lubricant while others do not perform well when lubed. This is where knowing your system and the manufacturer’s recommended maintenance program is important.

Nozzle and Tank

In order to avoid uneven wear, minimize tapering, and extend the life of the mixing tube, it is important to make sure that the jewel orifice and nozzle body are correctly aligned, and that the mixing tube is rotated after 8 hours of cutting. Water quality, filters, and the solids removal system are all part of maintaining a well-running waterjet system. Temperature control is also important in maintaining the high-pressure seals and nozzle assemblies, as water that is consistently run through at high temperatures can damage rubber components.

No matter what company manufactures your waterjet system, it is important that every operator knows how to perform basic maintenance and to configure the settings for longevity and machine accuracy. If you’re counting on your investment in a waterjet cutting system to pay off and allow your business to grow, you have to maintain it to ensure the best performance.

The benefit of using a waterjet system over a cold saw or laser cutter may be negligible, depending upon what materials and accuracy you will be cutting, but, in some cases, it may be impossible to achieve accurate and non-damaging cutting with other tools. Understanding both the machinery and your industry as a whole will help you decide whether a waterjet system is beneficial.  

If you are looking for the best in waterjet systems, visit Quantum Machinery and see what we have to offer to help your company offer the highest possible quality cutting services.

The Pros and Cons of Shop Floor Automation

Automation and manufacturing can seem like a great pairing, which has been around for well over three decades, thanks in part to the rise of the computer and related computing technologies, like robotics. While there are several advantages of automating a shop floor, there are some key considerations and reasons why certain tasks, like working with a press brake or plate roll, are better performed by human beings.

If you are considering updating your production environment, we invite you to review the following pros and cons to help determine the most appropriate investment of your resources.

Shop Floor Automation Pros

·         Improved Quality Control and Product Accuracy – Machines can perform precision work and increase overall quality.

·         Reduced Materials Waste – Automation helps reduce waste and associated costs.

·         Improved Production Times and Output – You are able to generate higher volumes in a shorter period of time.

·         Easy to Repeat Processes Numerous Times – Machines are able to replicate processes for an endless amount of time and deliver the same quality.

·         Better Safety – Machine can perform more dangerous tasks and reduce risks to employees.

·         Reduces the Number of Employees Needed – You need fewer employees to perform the same tasks.

·         Reduction in Production Costs – Total materials costs are reduced with automation.

·         Frees Up Employees to Work on Other Vital Tasks – You can have employees work on more detailed work machines cannot duplicate or on other such tasks.

Shop Floor Automation Cons

Just like there are advantages to automating certain processes on your shop floor, there are also disadvantages, depending on the size of your operation and available resources, as follows:

1.      Automating your shop floor could require a large initial upfront investment to purchase machines and equipment. In some cases, there are other options that can help lower the amount needed upfront, such as exploring leasing options or taking out a loan and making smaller monthly payments. Just remember, with leases and loans, the total cost of ownership will be more, in the long run, due to interest payments.

2.      Machines are limited in the types of tasks they can perform. With human employees, you can have them perform multiple and different types of work, as needed. In addition, certain processes could require more versatility than the machine is capable of performing.

3.      You could increase your carbon footprint. Some types of machines translate to using more energy and generating more pollution than using human workers. If you are concerned about your impact on the environment, spend some time researching and asking questions about how the new machine would impact your business’s carbon footprint.

4.      The total costs to purchase a new piece of equipment could cost more than you budgeted. You may have to pay to have your employees trained to use and operate the machine. There are maintenance costs associated with each piece of machinery you purchase. Furthermore, you have to also include the costs to automate your shop floor and update your production costs.

As you can see, there are pros and cons for automating your shop floor. For more information about equipment and machinery for automation and precision work output, please feel free to contact Quantum Machinery at (909) 476-8007 today!

Why Invest in a Welding Table?

For metal fabricators and machine shop owners, a welding table is a vital investment in order to complete welding jobs in-house. Welding requires a variety of methods, and some processes can be extremely complex to complete. Depending upon your shop’s needs, it is often more advantageous to invest in a single high-quality superior table that can be used for multiple welding jobs, rather than multiple tables of a variety of sizes, designs, and quality.

Welding Table

Choosing the most appropriate table for your business should focus on what types of welding jobs you perform frequently. It can be tempting to consider multiple tables for each of these jobs, but there are custom-designed tables available that will support a wide array of jobs and only require a single investment. As such, this allows you to make wise, effective, and efficient decisions to maximize your return on your investment.

Here at Quantum Machinery Group, we are pleased to offer the Siegmund line of professional welding tables. These tables have been put through extreme tests to ensure they meet the highest quality standards to provide years of service for your fabrication or machine shop business. Siegmund developed a brand new design with numerous features, including:

• Increased Load Capacity
• More Stability
• Better Flexibility
• Rounded Bore Holes
• Tool Steel Plasma Nitrided

To demonstrate the durability of their superior welding tables, Siegmund developed some rather extreme test conditions.

CNC Bending Machine

Test 1

The first test was to drop a compact car from an elevated height directly onto the table. While the car’s roof collapsed and the windows shattered, the table did not receive any damage, as it is also scratch-proof.

Test 2

For the second test, a Vickers hardness test was performed, where two front-end loaders dumped rocks and gravel onto the table, completely burying it underneath the rubble. The table was then lifted out and inspected for damage. Again, the table received no damage, thanks to its 700 Vickers protection rating.

Test 3

The third durability test was how the table held up when exposed to moisture. To illustrate the rust-proof feature, a hammer was placed on top of the table throughout the duration of the test. While the hammer developed rust, the table did not. Furthermore, rust stains from the hammer did not absorb into the tabletop and were easily wiped away with a cloth.

Test 4

To test just how durable the table was, three sticks of dynamite were secured underneath the table and detonated. After this, dust and residue left from the explosion were wiped away using a cloth.

In conclusion, if you are looking for the world’s hardest welding table, then a Siegmund table from Quantum Machinery Group is a great investment for your fabrication business or machine shop. In addition to Siegmund products, we feature a wide array of equipment and machines, including:

• 2, 3, and 4 Roll and Variable Geometry Plate Benders
• Basic to Full-Blown CNC Roll Benders
• Basic, Semi-Automatic, and Fully-Automatic Cold Saws
• Hydraulic, Hybrid, and All-Electric Press Brakes
• CO2 and Fiber Lasers
• Basic, Semi-Automatic, and Fully-Automatic Band Saws
• Basic, Entry Level to Full-Blown Mandrel and CNC Mandrel Rotary Benders
• Heavy-Duty and Versatile Shears

For more information about our metal fabrication machinery, which is stocked here in the United States, call Quantum Machinery Group at (909) 476-8007 to speak with a representative today!

Cold Saws vs. Band Saws: What’s the Difference?

If you’re in the market for a saw, it’s important to know what your options are. Different types of saws have different uses and knowing which one is right for the job at hand is an incredibly important part of making sure that job gets done quickly and correctly. In particular, understanding the difference between cold saws and band saws – two of the most popular and most used types of saws – will help make sure that you are using the right tools for the task at hand.

Cold saw vs band saw

Cold Saw or Band Saw?

To quickly sum up the difference between these two types of saws, it’s easiest to say that band saws are more versatile and can cut a wider variety of materials and volumes, whereas cold saws create a cleaner and more accurate cut. There are other differences (which we will go into below), but this difference is the most basic and the best place to start in understanding what sets them apart.

While band saws can cut a wider variety of materials, using one will leave a burr on the edges of whatever surface it is that is being cut. On the other hand, cuts made with cold saws are cleaner (leaving smoother edges) and tend to be more accurate.

Another crucial difference between the two is that band saw blades are disposable, and cannot be sharpened after they become dull. When a band saw blade has reached the end of its life, it should be discarded and replaced. Once a cold saw blade becomes dull, however, it can be sharpened. Cold saw blades can be sharpened between 30 to 40 times before the blade becomes too small to be used effectively, at which point it will have to be replaced.

Accuracy vs. Versatility

Because band saws don’t require as much expertise or scientific understanding to use, they tend to be more popular with beginners and for tasks that don’t require a high level of accuracy or mechanical specialization. Despite being easier to use, however, correct use of a band saw still requires using the right blade for the task at hand. Using blades with the wrong teeth per inch will either damage the material being cut or strip the teeth from the blade.

Cold saws, on the other hand, are popular with metal fabricators and other tradesmen that need a combination of precise handling with horsepower and torque. When using a cold saw, having a firm understanding of factors like chip load, blade teeth per inch, and rotations per minute are incredibly important; failure to understand all the factors will result in a botched job at best, and broken equipment or personal injury at worst.

Band saw or cold saw

Looking for quality saws, milling equipment, and other machinery? Quantum Machinery Group has a wide array of machine lines for jobs big and small, simple or complex. Find out more by speaking to one of our Sales Engineers today by calling 909-476-8007.