Page 18 - MetalForming November 2010

Hydraulic Presses
Double-sided Deburring of Sheet Metal up to .2"Thick
VFD installed on the motor allows the factory to run 415 V into the press and put out 460 V on the other side, avoid- ing the big investment needed for a transformer.”
In another recent case, a military- equipment supplier purchased a large hydraulic press with a 150-hp motor and calculated its ROI for a VFD at 18 months. “Cycle rates were low, and the company operates in a high-energy- cost area of the country,” says Bisbee.
Where won’t a VFD make sense? “In applications where the runs are 15 cycles/min. or greater, it can be hard to justify the cost of a VFD, which can range from two to 10 percent of the overall price of the press (the larger the press, the lower the option cost as a percentage), because there is relatively little press idle time,” Bisbee says. “Con- versely, on presses running under 15 cycles/min., we begin to see opportu- nities to take advantage of the electric- ity savings.”
Why Not Something Else?
“Some say, ‘Why not use a contactor (or large relay) to turn the motor on and off?’” Bisbee notes. The reason: “While there can be some cost savings because the motor will be turned off while the press is idle, the contactor will not help reduce the inrush currents created by the motor switching on. This can be a very large part of overall energy costs.
“Others say, ‘Why not use a motor soft-start device?’” he continues. Rea- son: “While a motor soft-start device can be less expensive then a VFD and it can help to eliminate inrush currents when the motor turns on and off, the device cannot control motor speed. During idle time, it’s important to be able to keep the oil flowing through the chiller. If the oil gets too hot (above 150 F), the metalformer will begin to experience premature degradation of the hydraulic-system components. The first to go usually is the pump—the seals and gaskets won’t last. Also, a soft- start device cannot communicate intel- ligently with a PLC to provide fault indications, etc.” MF
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Deburring o
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n f s
“We Love FortiPhy’s Performance for Heavy Gauge Deep Drawing Challenges and Forming
441 Stainless Steel.”
Michael Stull, Tooling Manager Pentaflex, Inc., Springfield, Ohio
The Tooling Challenge
Draw heavy truck brake drums from 5/16” thick high strength, low alloy steel — 12” diameter by 5.5” deep draw and 􏰀.005” ID tolerance. Solve quality and galling issues with prior coatings (TD, TiN and others) that had a major impact on downtime, production rates and tooling costs.
The Phygen Solution
FortiPhyTM UltraEndurance Coating has given Pentaflex:
• More than 4000% uptime improvement from 900 to nearly 40,000 parts between polishings.
• Repeatable 1.67 Cpk, with no wall diameter structural or thickness changes.
• Minimum $65,000 yearly savings – less overtime, press down time & tooling replacement costs caused by excessive galling & premature tool wear.
• Improved quality in large transfer die stampings (example in left photo)...galling downtime & required polishing in tough form areas reduced by 80%.
• A cold coating process that doesn’t generate material distortion or dimensional change like a hot coating. FortiPhy’s application temperature eliminates the guess work/problems and also allows multiple recoating of the same tool eliminating the need to scrap tools after a single production run.
• Visit www.phygen.com/Success_Pentaflex.htm for the full story
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Phygen Coatings, Inc. / Toll Free 888.749.4361 / phygen.com / email: tech@phygen.com METALFORMING / NOVEMBER 2010
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