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Factory fabrication aluminum rolling

Factory fabrication aluminum rolling

To meet the beverage industry's growing demand for light gauge, tight-tolerance aluminum sheet stock, Logan Aluminum committed to a major capital expansion project. A critical requirement during the project execution was the continual operation of the existing mill without production disruption. Fluor was selected to provide engineering, design, procurement, construction, start-up, and maintenance. The new facility included a ,square-foot building with state-of-the-art high-speed production and material handling equipment. The Logan Expansion project was completed on schedule and under budget. The goal of the large-scale expansion project was to build a state-of-the-art mill to supply the light gauge, tight tolerance sheet metal for the beverage market.

VIDEO ON THE TOPIC: Aluminum strip sheet band hot roll machine equipment casting processing forming platevbv

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Aluminum Manufacturers

Walk onto the floor at BEPeterson BEP and nothing looks particularly out of the ordinary for a contract manufacturer specializing in large fabrications. There' the foot-long, ft. But a closer look at one rolling system reveals that this isn't a typical operation. Adjacent to the plasma table is a four-roll machine that processes between and parts a week.

A first glance at these specs indicates that these requirements call for two machines, one with crowning for the stainless steel and one without for the soft aluminum. Managers were ready, in fact, to buy two machines, but they ultimately found they were able to purchase just one that was highly customized and, most important, oversized for the job.

The job involves rolled shells that make up complicated, tight-tolerance medical equipment subassemblies. BEP, an employee contract manufacturer in Avon, Mass. These two sectors call for products that require some of the same fabricating operations: high-definition and conventional plasma cutting, bending with some heavy-duty press brakes, welding, and, of course, rolling. But as Sales Account Manager John Adams explained, there' another reason these product lines share a space. Before the company brought in its current CNC rolling system, operators used an 8-ft.

The method sufficed for several years, but it certainly hindered efficiency. So the company picked up an unusual machine, one oversized for the material and with no crowning.

The machine is a Faccin model 25 is 2. The job calls for several requirements that make this specific plate rolling application especially unusual.

One, the rolls are large enough so they can handle the stainless without crowning, which would distort the soft aluminum. So why, exactly, does oversizing the roll eliminate the need for crowned rolls? Steve Bonnay, the Tampa, Fla. An average man walking out to a dock platform consisting of 2-by-4s may experience some bend, or "give," in the wood.

The man would walk out there and nothing would happen. It would be rock-solid. In most rolling applications, crowning allows fabricators to get away with 2-by-4s instead of that expensive block of oak. Like on a press brake, deflection is most pronounced in the center, the farthest away from the rigid ends attached to the machine base.

A slight bulge, or crown, in the center of the roll accounts for that slight deflection, so the position of bend from one side to the other remains true. In reality, the same logic behind press brake crowning applies to crowning in roll bending.

The second unusual set of features relate to the extreme accuracies. Like many newer systems, the machine has a CNC, but this one has a digital readout to three decimal places.

Getting it just right requires some training, because even though these applications use aluminum and stainless, material variation remains an issue because the tolerances are so tight. So roll values the pressure exerted by the rolls must change ever so slightly—which is why that third decimal place in the digital readout matters.

Extreme accuracy also calls for another unusual rolling requirement: All four rolls are driven. It' not unusual to drive the top pinch and bottom center rolls. And many pressure vessel shops, wind tower manufacturers, and similar firms use systems with three drive rolls: the top, bottom, and outboard roller the one opposite the material feed side.

The third drive roll provides a little extra "grab" for shops that may store plate out in the elements and don't shotblast or otherwise treat it. Oily or rusty plates have less chance of slipping in these three-drive-roll systems. The third drive roll also acts as a safeguard in certain applications, Bonnay explained.

The machine allows for prebending. Rolls must grab the lead-in plate edge, an initial pinch point that' not bent but remains flat. Prebending eliminates the narrow, flat portion by feeding the plate in, then out and back in again.

But this doesn't prevent the system from leaving an ever-so-narrow flat portion at the end of the plate, because the machine has to hold on to the metal somewhere at the end of the roll bend. This is where re-rolling comes into play—shops roll, weld, grind the weld down, and then roll it again to get that last bit of flatness out of the can. A third drive roll can prevent a system crash because "you're not loading your material as much on a single point," Bonnay said.

Besides greater control and flexibility, the four drive rolls also allow the rolling pressure to be spread out to the maximum extent. As Bonnay explained, about 60 percent of the pressure comes from the top and bottom rolls, while the remaining 40 percent is divided evenly between the outboard and feed-side rolls. He reiterated that such an arrangement makes sense only if a shop either works with extremely soft metal, such as aluminum or even more of a rarity brass, extremely tight-diameter parts which are more likely to slip during the operation , or has extraordinarily tight tolerances.

BEP's rolling operation has two of those three—tight tolerances and soft metal. The rolling machine' guidance system—the tables that support the can on either side and the roll support on top—is about as rare as having four drive rolls. Even rarer is how these supports, which articulate, contact the can being rolled in up to five places. As the material is rolled through, entering from the right, the left support table rises and contacts the metal at about the position.

As the roll continues up, the table articulates in the middle to contact the work again at 10 o'clock. The guidance system can contact the material at up to five points, depending on the material and application requirements.

All this prevents the material, particularly the soft aluminum, from distorting because of the effects of gravity. Without those supports, the can diameter would grow on the side and shrink on top—not by much, but enough to bring this application out of tolerance. In a shop area dedicated to medical and water filtration products, workers at BEPeterson send raw stock to the company's ft. The system cuts two plates at a time, which then are moved with overhead cranes to the rolling stations the company has two four-roll systems, including a newer CNC-based machine, and an older manual system.

Smaller parts go on to the company' and ton press brakes. Then, it' on to welding and assembly see The portion of the plant dedicated to medical and water filtration products has, among other things, a ft.

The Avon, Mass. John Adams, sales account manager, works with the section devoted to the medical and water filtration sectors, an area of the plant employing about 15 people, all of them cross-trained.

Other areas focus on various markets including the pharmaceutical and power generation sectors. It's a tough time for anyone selling capital equipment, so even the demand for some high-end medical equipment has dipped a bit, by more than 10 percent. Some fabricators in the automotive sector would kill for such a slight drop in business, but Adams said managers hope their market strategy—including the focused-factory approach—will help the company emerge from the current historic downturn only slightly bruised.

Elgin, IL Email Tim Heston. Read more from this issue. View the Digital Edition. The magazine delivers the news, technical articles, and case histories that enable fabricators to do their jobs more efficiently.

This magazine has served the welding community in North America well for more than 20 years. Today, it remains the only North American publication devoted to this industry, and it has become the most trusted source of information for tube and pipe professionals. Since the publication has been dedicated to covering the cutting-edge technologies, industry trends, best practices, and news that help stamping professionals run their businesses more efficiently. The Additive Report focuses on the use of additive manufacturing technology in the real world of manufacturing.

Their stories will be covered here. Not yet registered? Sign up. Categories Additive Manufacturing. Aluminum Welding. Assembly and Joining.

Automation and Robotics. Cutting and Weld Prep. Manufacturing Software. Materials Handling. Oxyfuel Cutting. Punching and Other Holemaking. Shop Management. Testing and Measuring. Tube and Pipe Fabrication. Tube and Pipe Production.

Waterjet Cutting. Digital Edition. Our Publications. A Focused-factory Approach In a shop area dedicated to medical and water filtration products, workers at BEPeterson send raw stock to the company's ft. About the Author. Tim Heston Senior Editor. About the Publication. You May Also Like. Sign up and be the first to know about the latest industry news, products, and events! This Week's Trending Articles 1. Welcome back! Please sign in to your acccount Email. Remember Me.

Custom Fabricated & Finished Aluminum Extrusions

Walk onto the floor at BEPeterson BEP and nothing looks particularly out of the ordinary for a contract manufacturer specializing in large fabrications. There' the foot-long, ft. But a closer look at one rolling system reveals that this isn't a typical operation. Adjacent to the plasma table is a four-roll machine that processes between and parts a week.

In metalworking , rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. The concept is similar to the rolling of dough. Rolling is classified according to the temperature of the metal rolled.

Aluminum is one of the most widely used metals in the world. On the periodic table, it has the symbol Al and the atomic number Unalloyed aluminum is a silvery-white color. Refined from an ore called bauxite, aluminum is, in its pure form, incredibly soft and pliable.

Logan Aluminum Rolling Mill

Our goal is to completely and competitively satisfy the needs of our customers. We believe in the importance of being selective of the markets we wish to serve as a foundation to the skills and capabilities required to better assist our customers. Bonnell Aluminum's primary markets consist of building and construction, automotive and specialty. Bonnell Aluminum manufactures custom aluminum extrusions in a variety of alloys and sizes up to 16 inches wide. Bonnell Aluminum offers a variety of finishes and coatings, including paint, and anodize. Our services include thermally broken and fabricated extrusions and packaging. Our Suppliers page includes our supplier application, contact information for our procurement offices, and a list of major commodities used.

Rolling it just so

Его лицо казалось растерянным. - Обычно я напиваюсь только к четырем! - Он опять засмеялся. - Как быстрее добраться до аэропорта. - У входа возьмешь такси.

Кроме того, тот старик вроде бы обо всем позаботился. - Канадец.

Однако одиночество не принесло ей успокоения. В голове у Сьюзан беспрестанно крутилась мысль о контактах Танкадо с Хейлом. Кто будет охранять охранников.

Rolling (metalworking)

Агент Смит начал доклад. - По вашему приказу, директор, - говорил он, - мы провели в Севилье два дня, выслеживая мистера Энсея Танкадо. - Расскажите, как он погиб, - нетерпеливо сказал Фонтейн. Смит сообщил: - Мы вели наблюдение из мини-автобуса с расстояния метров в пятьдесят.

SEE VIDEO BY TOPIC: Amazing Automatic Melting Aluminum Manufacturing Factory, Cast Aluminum Process Using Sand Mold

Они обернулись. Сотрудник отдела обеспечения системной безопасности Фил Чатрукьян, приникнув лицом к стеклу, отчаянно барабанил по нему, стараясь разглядеть, есть ли кто-нибудь внутри.

Он что-то говорил, но сквозь звуконепроницаемую перегородку слов не было слышно. У него был такой вид, словно он только что увидел привидение. - Какого черта здесь нужно Чатрукьяну? - недовольно поинтересовался Стратмор.

Увы, ангар был пуст. О Боже. Где же самолет. Мотоцикл и такси с грохотом въехали в пустой ангар. Беккер лихорадочно осмотрел его в поисках укрытия, но задняя стена ангара, громадный щит из гофрированного металла, не имела ни дверей, ни окон. Такси было уже совсем рядом, и, бросив взгляд влево, Беккер увидел, что Халохот снова поднимает револьвер. Повинуясь инстинкту, он резко нажал на тормоза, но мотоцикл не остановился на скользком от машинного масла полу.

Golden Aluminm. Gulf Aluminium Rolling DVD “Rolling Aluminum: From the Mine Through the Mill”. Manufacturing (CIM), Statistical Process Control. (SPC).

Как весенний лед на реке, потрескивал корпус ТРАНСТЕКСТА. - Я спущусь вниз и отключу электропитание, - сказал Стратмор, положив руку на плечо Сьюзан и стараясь ее успокоить.  - И сразу же вернусь. Сьюзан безучастно смотрела, как он направился в шифровалку. Это был уже не тот раздавленный отчаянием человек, каким она видела его десять минут .

Сначала используемые пароли были довольно короткими, что давало возможность компьютерам АНБ их угадывать. Если искомый пароль содержал десять знаков, то компьютер программировался так, чтобы перебирать все комбинации от 0000000000 до 9999999999, и рано или поздно находил нужное сочетание цифр.

Этот метод проб и ошибок был известен как применение грубой силы. На это уходило много времени, но математически гарантировало успех.

- Может, вы знаете имя этой женщины. Клушар некоторое время молчал, потом потер правый висок. Он был очень бледен. - Н-нет… Не думаю… - Голос его дрожал.

Он закрыл глаза, и воспоминания хлынули бурным потоком.

Оказавшись в условиях подлинного разведывательного затемнения, АНБ выпустило секретную директиву, одобренную президентом Соединенных Штатов. Заручившись поддержкой федеральных фондов и получив карт-бланш на все необходимые меры для решения проблемы, АНБ приступило к созданию невозможного - первой универсальной машины для вскрытия шифров.

Вопреки широко распространенному мнению о том, что такой компьютер создать невозможно, АНБ осталось верным своему девизу: возможно все; на невозможное просто требуется больше времени. Через пять лет, истратив полмиллиона рабочих часов и почти два миллиарда долларов, АН Б вновь доказало жизненность своего девиза. Последний из трех миллионов процессоров размером с почтовую марку занял свое место, все программное обеспечение было установлено, и керамическая оболочка наглухо заделана.

Клушар задумался, польщенный оказанным вниманием. - Если честно… - Он вытянул шею и подвигал головой влево и вправо.  - Мне не помешала бы еще одна подушка, если вас это не затруднит. - Нисколько.  - Беккер взял подушку с соседней койки и помог Клушару устроиться поудобнее.

И оба идете со. - В качестве заложников? - холодно усмехнулся Стратмор.  - Грег, тебе придется придумать что-нибудь получше.

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  1. Fenrik

    Rather quite good topic