Bevel Cutting for the Future
The topic of bevel cutting has been a huge priority and an integral part with MicroStep’s Research and Development for many years. We have always acknowledged the importance of this technology offering for streamlining of the production process. As MicroStep, we are aware that many fields of the engineering industry greatly benefit from the proper development of bevel cutting. Due to our long-term focus and experience we are continuously able to innovate and develop new technologies that secure a stable place among market leaders in bevel cutting.
According to field studies, up to 50 % of parts produced in the CNC cutting industry worldwide need to have bevelled edges, yet only a considerably smaller percentage of machines is equipped with bevel tool stations. The reason for this is mainly due to a relatively low awareness, from decision makers, of this technology. If you way up the costs versus the output you will soon realize that it is an affordable addition to your machine. There is also a misconception that contemporary bevel stations are not reliable.
However, the benefits easily outweigh the higher initial investment as the outcome. With the addition of a bevel tool station you are guaranteed greater work precision as well as significant savings of production time and capacities. Moreover, in automated preparation of bevelled edges on 3D objects such as domes, pipes, rectangular or IPE profiles, the use of specialized tool stations on gantry-based machines brings a great financial benefit compared to the commonly used robots.
Throughout the years, improvements of mechanics and motion control of our rotary- and 3D tilting tool stations have gone hand in hand with third-party development of energy-beam sources and our implementation of the latest cutting technologies developed by our suppliers. We are now able to offer a comprehensive bevel cutting solution for a wide range of materials and thicknesses. Furthermore, our unique features of our specialized in-house developed control system iMSNC and a profound knowledge of different cutting technologies, MicroStep machines are capable of combining various technologies (e.g. plasma and waterjet) within a single cutting plan.
Three machine types are used for 3D cutting of sheets from 3.5 up to 200 mm
Since 2016, MicroStep systems have been involved in the construction of ships for the German Naval Yards Kiel.
The first part of the cutting process, the “birth” of the ship is the cutting of the first individual part that forms the ship. This supporting pillar is cut with MicroSteps’ MG series. The plasma cutting system has a working area of 52,500 x 3,500 mm and is fitted with two gantries. Both gantries are equipped with a plasma rotator for 3D processing of metal sheets. One gantry is also equipped with an inkjet marking unit, the other gantry with a laser marker. Mild steel but also high-alloy steels are cut with this versatile cutting system. This monster machine replaced a plasma cutting system from another supplier as the precision in 3D cutting of the MG series was necessary. In their cutting process with the width and length of a 12-meter cut, the deviation may not be more than 0.5 mm. “The accuracy is excellent, the dimensional stability of the machine is unbeatable”, says Fust, who has gained experience at various shipyards over the years.
In recent years, the shipbuilding company has invested in three different types of MicroStep systems for processing of various cutting tasks. A MG plasma cutting system with two gantries and tools for bevel cutting and marking, a DRM-PL panel cutting system with oxyfuel rotator, sandblaster and marker as well as an EasyCut flame cutting system with four oxyfuel torches.
Since mid-2019, the EasyCut cutting system from MicroStep has been taking care of the Yards cutting jobs in the higher material thickness range. This flame cutting system is equipped with four oxyfuel torches. Many items are cut on this machine and this includes flanges with blind holes for mechanical engineering. Together with the MG plasma cutting machine, cutting tasks in the thickness range from 3.5 to 200 mm are processed.
A DRM-PL gantry from Microstep, which was built on top of an existing panel line, is also available for the processing of large-format sheets. Panels form the basic framework of decks and the external skeleton and can reach a size of up to 16 x 18 m. The MicroStep gantry of the panel cutting line has a width of more than 18 m with technology options for bevel cutting using an oxyfuel rotator, a primer removing sandblasting system, and a marking unit.
The EasyCut is a robust and precise CNC guiding machine, which has been specially developed for cost-effective continuous use in oxyfuel flame cutting. The working area is 16.500 x 3.000 mm.
“The accuracy is excellent, the dimensional stability of the machine is unbeatable,” said Jan Fust – Manager Steel Construction at German Naval Yards Kiel.
The entire cutting operation is supported by MicroStep machines, which shows the flexibility of our machines and the adaptability of the MicroStep Cutting Systems. No matter the size needed, MicroSteps’ technology team is able to assist and is constantly working on new angles to be more innovative. Technology is ever changing and so are the MicroStep Cutting System offerings.
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Main Office: Unit B1B & Warehouse C1, Isando Business Park, Cnr Hulley and Gewel Street, Isando, 1601.
Office: 011 397 6356
Ludwig Oellermann: +27 (0) 83 463 0999
Email: info@microstepsa.co.za
