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IRONWORKERS Comb. Punching, Shearing & Coping
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Details to look for during new and used machinery inspection:
Tonnage capacity
Length of punch stroke
Strokes per minute
Throat depth
Punching capacity
Length of cutter blades
Capacity of notcher & coper I-beams,
Channels, notch angles & tees, depth of notcher
Flat bar cutter cap.
Section cutter capacity
ACCESSORIES
Architectural jaw, angle shear, extra knives, square
coper, plate shearing slot
How to select the right IRONWORKER for your application.
An Ironworker can be an important and versatile machine
in a metal fabricating shop. Quite often ironworking
is the first step in the manufacturing process, and
one ironworker typically can provide enough fabricated
material to keep up to seven welders or assemblers
busy.
Since its invention in the late 1800s, the ironworker’s
main strength has been its ability to perform a variety
of operations. It can punch a range of materials with
punches of various sizes and shapes. It also can shear
rod, flat bar, angle, and channel. In addition, it
can notch angle iron, pipe, channel, and flat bar.
Many ironworkers are available with special tooling
to bend, stamp, and form too.
As versatile as the ironworker is, however, it is possible
to purchase the wrong machine-or at least not the best
machine-for your application. Important considerations
for selecting a machine include its capacity, versatility,
safety features, and quality.
The material thickness you process will indicate whether
to use an ironworker or a turret punch press. An ironworker
punches plate up to 1 inch, and sometimes even thicker.
Typically, turret punch presses are used on sheet metal
material ¼ in. and thinner. Ironworkers
usually are used for shorter production runs and applications
for which tolerances are not as critical.
Determining Capacity
Ironworkers typically are rated by tonnage
at the punch station. A 40-ton ironworker
should punch a 1” hole in ½” material;
a 60-ton machine should punch a 1” hole
in ¾” material; and an
80-ton machine should punch a 1” hole
in 1” material (see figure 1)
- Punching Capacity by Tonnage (U.S)
- Punch Material Hole
- Capacity Thickness Size
- (tons) (inch) (inch)
- 40 Tons =½" Material 1" Hole
- 60 Tons= ¾" Material thru 1" Hole
- 80 Tons =1" Material Thru1" Hole
The first step, therefore, is to determine
the maximum material thickness so you can
establish the tonnage range needed for
your punching application. Examine the
steel rack and the product that you are
fabricating. Determine the maximum hole
diameter to be punched; the maximum thickness
of the material to be punched; and the
maximum thickness and width of the channel,
angle, and rod to be sheared or bent.
The material or part width plays a part
in your ironworker selection. The throat
depth of an ironworker punch station should
be greater than half of the part or material
width. Material length, however, really
is not an issue. An ironworker can process
almost any material or part length.
Because many different types of steel and
ranges of hardness in mild steel exist,
it is advisable to get a machine that is
at least 20 percent larger than you think
your everyday use requires to avoid getting
a machine that is too small. Most machines
are rated for material with tensile strengths
between 60,000 and 65,000 pounds.
Many mild steels have tensile strengths
between 50,000 and 70,000 lbs. or higher,
and your machine may not have the power
to punch the material at the higher end
of the hardness values. When punching hard
steel, such as stainless steel, it is better
to increase the estimated tonnage by 50
to 100 percent, depending on the grade
of steel.
Beware! Not all tons are created equal.
A metric ton actually is heavier than a
U.S. ton (2,200 lbs. versus 2,000 lbs.).
A machine rated for metric tons should
be able to punch a larger hole than a machine
rated on the same number of U.S. tons.
For example, 80 tons of pressure by U.S.
standards can punch a 1” hole through
1” material; 80 metric tons should
be able to punch a 1 3/32” hole through
the same material thickness.
Be sure to compare the rating of the machine
not only in tons, but also the diameter
of the hole and thickness of material it
can punch. Ironworker tonnage ratings can
vary form ironworker.
Assessing Versatility Needs
All ironworkers are equipped with flat
bar shears. The main differences between
flat bar shear stations are the length
and the approach of the blade to the
metal. Some ironworkers use a guillotine,
or fixed-rake-angel shear, and others
use a scissors-type shear (see figure
2).
Figure 2
The advantage or the fixed-rake-angle shear
is that the blade angle remains constant
throughout the cut, sometimes offering
larger capacity without increasing machine
tonnage. The advantage of the scissors-type
shear is that it can vary the rake angle
of the blade, thereby minimizing distortion.
The advantage of the fixed-rake-angle shear
is that the angle of the blade as it approaches
the work remains constant throughout the
cut, sometimes offering larger capacity
without increasing machine tonnage. The
disadvantage is that without the ability
to vary the rake angle, the distortion
of the drop piece will remain the same
throughout the cut.
The advantage of a scissors-type shear
is that it can vary the rake angle of the
blade. Thicker material is cut closer to
the pivot point, and thinner material is
cut farther from the pivot point, where
the rake angle of the blade is flatter,
thereby minimizing distortion. Scissors
machines typically have a longer flat bar
shear, some up to 24” long.
On some ironworkers, the rake angle of
the bar shear blade is adjusted by inserting
and removing wedge-shaped shims above the
shear blade. This may require substantial
mechanical ability and substantial time.
Also, if the shims are not adjusted each
time material thickness changes, the machine
could be damaged.
Ironworkers are available
with different designs to enhance versatility.
For example, the stations on some machines
are permanently built in. These machines
offer punching stations, angle shears,
rod shears, notchers, and short flat bar
shears.
Ironworkers are available with different
designs to enhance versatility. For example,
the stations on some machines are permanently
built in. These machines offer punching
stations, angle shears, rod shears, notchers,
and short flat bar shears.
If you are structural steel fabricator,
you may prefer these machines because the
stations cover the majority of the materials
you process and do not require tooling
changes.
If you are a general welding, fabrication,
maintenance, and structural steel fabricator
who does not know what a customer will
bring in the door tomorrow, you may want
an iron worker that offers the capability
to adapt to all customer needs. Tabletop
tooling concepts, which provide a wider
variety of tooling, may suit your needs.
In addition to angle shears, rod shears,
notchers, and flat bar shears, tabletop
ironworkers offer options such as larger
press brake bending attachments, tube shears,
channel shears, pipe notchers, V notchers,
picket tools, square tube shears, and a
variety of special tooling. Although these
machines can use a larger variety of tooling
than those with built-in stations, time
is required to switch from one operation
to the next.
Addressing Safety
Issues
Safety is an important factor when choosing
an ironworker. Be sure to choose an ironworker
that meets ANSI B11-5 standards.
Examine the guarding. Be sure it can be
adjusted down to within ¼” form
the top of the material to be punched,
and to the bottom of the guard or stripper
(this is an ANSI standard). This will prevent
operators from placing any part of their
bodies between the material being punched
and the stripped mechanism. All other stations
should offer complete safeguarding as well.
Beware of machines with automatic urethane
hold-downs. Most operators realize the
danger of the blade but do not expect to
be hurt by safety guards and may not watch
them. Automatic urethane hold-downs, if
not adjusted properly, also come down with
many tons of force and can be dangerous
pinch points.
For productivity as well as safety, the
machine you choose should offer an infinitely
adjustable stroke control to minimize machine
movement, decrease the number of pinch
points, and increase strokes per minute
and production. This is especially important
in bending applications and for special
tooling for which the upstroke must be
adjusted in addition to the downstroke.
Electric stoke controls offer advantages
over mechanical linkage controls. Electric
stroke controls have quicker cycle times
and more precise stopping because they
use switches that send signals to the control
valve almost instantly. Machines that use
mechanical linkage stroke controls must
be in motion to cause the linkage to close
the control valve. As the valve closes,
the machine slows down and is more difficult
to regulate.
Safety instructions should include proper
alignment of the punch and dies. Because
punches are usually hardened to 58 Rockwell,
the punch will not bend as it collides
with a die. If it is out of alignment,
it is more likely to flake or even explode,
causing serious harm to the operator.
The preferred and most widely used method
of aligning the punch and die is similar
to the way punch pressed have been aligned
for many years. This is done by bringing
the punch ram to the bottom of the stroke
and installing the punch and dies with
the stroke down. This way, the punch already
has been entered into the die, the alignment
can be checked, and guards may be replaced
without machine movement.
Assessing Quality
In trying to determine quality, consider
the size of the pivot points and beam strength
of the steel that is under pressure. Since
your ironworker produces many tons of force,
the force must be generated and transferred
through the pivot points as well as the
beam.
Another good indicator of quality is how
much shock is produced when the ironworker
punches. Excess shock, which can be identified
by a loud popping or banging noise as the
punch goes through the material, could
indicate the beam or side frame is stretching
and snapping back into place. Continued
shock can cause welds to break, as well
as other failures. Higher-quality machines
control this by increasing side frame,
beam, and pin size.
The number of grease points also can be
an indicator of quality. Although all machines
have grease points on pivot points and
guide assemblies, some machines have an
excessive number of grease points-as many
as 20 or more. Usually these additional
grease points have been added in an effort
to correct galling problems. It is unrealistic
to expect operators to grease more than
five or 10 grease points, and machine failure
or galling most likely will occur,
The hydraulic system also should be a consideration.
You are buying the machine for the tons
of pressure it produces, not for the motor’s
horsepower rating. Some ironworkers are
designed through mechanical advantages
to produce more tonnage with less horsepower,
thus making the machine more efficient.
Machines with higher-horsepower motors
usually operate at a higher hydraulic pressure,
or pounds per square inch, and this increased
pressure can produce more wear on hoses,
pumps, and valves.
Because an ironworker is am important part
of most shops, when even one ironworker
breaks down, the negative impact on production
is significant, even paralyzing. Before
purchasing an ironworker, take the time
to analyze your needs and carefully assess
the quality of the ironworker. It will
be time well spent.
*By Jim Hoag via The Fabricator Dec 2002
Ironworker Comparison Chart
| Brand | Construction Type | Shear Capacity | Angle Shear Capacity | Punch Capacity | Notcher | Tool Table Area | Standard Equipment | Country of Orgin | Dimensions | Price |
| Scotchman 6509-24M | Welded | 24" x 1/4" or 12" x 1/2" |
6" x 6" x 3/8" |
1 1/16" Thru 3/4" | Optional | 29"x16" x15" |
Keyed Punch Ram, Punch Table w/ Fence & Scale,
Punch Jog Ctrl, Adj. Elec. Stroke Control,
24" 4 Way Shear Blade,
Angle Shear, 1 Punch & Die. Machine comes with a Punch Jigging Table w/Scale & Fence. Shear Jigging Table w/Fence. Electric Stroke & Jog Controls. 24” wide brake available, with no throat restriction. Tool Table area allows multiple tools to be installed together (ie: Angle Shear & Pipe Notcher, etc.). Punch tooling does NOT have to be removed to use shear or tool table. Ships with all fluids included. All electric & hydraulic components are standard off-the-shelf items, available at any industrial hardware store. |
USA | 24"x60" x66" 2750 lbs |
$14690 |
| Piranha P70 | Welded | 1/2" x 18" | 5" x 5" x 1/2" |
1-3/16" Thru 3/4" | 3-1/2" x 5" x 3/8" | N/A | 12" Bending Attach., Plate & Bar Shear, Electric Stroke Control, Coper/Notcher, Material Bins, 10 Punches & Dies | USA | 31 "x79"x64" 4250 lbs | $23000 |
| Baileigh SW-62 | Welded | 5/8 x 13.25" | 4" x 4" x 3/8" | 1-1/8" Thru 5/8" | 2" x 3.5" x 5/16" | N/A | Oversized Tables, Material Bins, Manual Backgauge,
Three position foot switch, Adj. Stk. Control, T-Slot Punching Base, Shear table, Angle iron, Flat bar, Round and Square stock Shearing, Rectangular Notching, 7 Punches & Dies |
Turkey | 45" x 30" x 68" 2310 lbs | $13995 |
| Acra HIW60 | Welded | 12" x 5/8" | 4 3/4" x 4 3/4" x 1/2" | 1 1/16" Thru 5/8" | 2 3/8" x 5/8" | N/A | Heavy Tables With Guides, Shear Backgauge, Rod Cutter | Tawian | 60" x 24" x 60" 4000 lbs | $12650 |
| Edwards Jaws V | Bolt | 3/8" x 24" |
5" x 5" x 1/4" | 1-1/16" Thru 3/4" | 2-1/2" x 6" x 3/8" |
11-1/2" x 9-3/4" |
USA | 43" x 42" x 55" 4220 lbs |
$11996 |
