The Fabricator - November 2013

for an existing part, he enters the part number to pull up the program. After loading the tube into the machine and running a simulation to verify the tube won’t collide with the bender, he starts the bending sequence.

Then: When changing sizes, the bender operator always had to change the bend die.

Now: ;e new machine holds a stack of tools;
the operator completes several work orders before
changing the tooling. For example, it can bend a hy-
draulic system part (1⁄ 4 in. OD) and a handrail compo-
nent ( 2 in. OD) without a tool change (see Figure 3).
Kress keeps the most commonly used die at the
bottom because it is the least frequently replaced.

Then: It was impossible to determine interferences ahead of time. After making several bends, if interference looked likely, the operator often would have to remove the tube, turn it around, and bend from the other end. If that didn’t work, he’d have to try a di;erent bending sequence.

Now: ;e bender’s simulation software looks for interferences to prevent collisions.

Then: ;e manual protractor was fairly accurate, but not exact. A variance of just a degree or two on one bend followed by a degree or two on a subsequent bend would result in a poor fit. In some cases, especially long parts, the part wouldn’t fit at all, and would need to be rebent or scrapped.

Now: Every lot of tubing has unique characteristics, but within a single heat, the bend angle precision is approximately ±0.1 degree.

;e cumulative benefit is the biggest benefit of all, which is the productivity enhancement. Kress estimates that the CNC machine is about 10 times faster than the manual process.

Beyond Kress

Another benefit is meeting its own manufacturing standards. Kress developed and uses a standard which keeps it on target for its products and, just as importantly, for the work it does for another OEM. ;e CNC machine enabled Kress to tighten up its manufacturing standards, improving its products and solidifying its business relationship with its customer.

Kress Corp., 227 Illinois St., Brimfield, IL 61517, 309-446- 3395, sales@kresscarrier.com, www.kresscarrier.com J&S Machine Inc., W6009 490th Ave., Ellsworth, WI 54011, 715-273-3376, sales@jsmachine.com, www.js machine.com

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CSU-201311-Fabricator 1-2 pg Fabtech_CSU-Fabricator Half 10/2/13 4: 20 PM Page 1

Figure 2

Simulating the bend process allows the bender sta; to see how the bend will progress. ;e machine checks for interferences and collisions, ensuring the tube doesn’t damage the machine.

Figure 3

In addition to bending hydraulic lines, Kress also fabricates ladders and handrails, which are necessary for most of its products. ;e company’s CNC tube bender handles tube diameters from ¼ in. to 2 in.