Robust trio makes skeleton-free punching a reality

With TRUMPF machines, software and tools true skeleton-free punching is now possible

Skeleton-free processing is the biggest saver when it comes to punching because the material makes up almost three-quarters of the parts costs
(PresseBox) ( Ditzingen, )
Skeleton-free used to mean that despite the best possible parts nesting, an L-shaped scrap skeleton would be left over after processing. TRUMPF has now put an end to this - thanks to a unique concept that perfectly aligns machines, software and new tools with one another.

Smaller carbon footprint

This leads to better process reliability and more efficient use of materials. It also makes skeleton-free processing a ground-breaking environmental solution for the future since manufacturing a metal sheet consumes about 30 to 80 times more power than is needed to operate a punching machine for one hour. This means over one year, skeleton-free processing leads to energy savings equal to the power needed to operate a punching machine for 40 years. Here's another way to look at it: The CO2- emissions saved per machine equal the carbon footprint that is a by-product of powering 11 to 16 average homes in Germany.

Intelligent software

Nesting parts to enable common punching strokes is nothing new. Thanks to the innovative TRUMPF concept, however, on average 10 percent more finished parts are cut right up to the edge on each metal sheet. One test customer increased their parts yield by 50 percent and decreased scrap by 20 percent. To achieve these results, customers need the MiniNest and TwinLine functions that are included in the latest version of TruTops software, TruTops 2.2. The first of these functions, MiniNest, allows for any arrangement of all angular positions as part groups. The second function, TwinLine, supports the first by reducing the distance between the parts so that an average increase in material use of 10 percent is guaranteed. The programming system also specifies an intelligent separation sequence and increases process reliability by showing waste parts in color.

Chocolate strategy

The parts are then punched out of the metal sheet row by row - just as you would eat a bar of chocolate - and immediately sorted and discharged, regardless of whether it is a finished part or a reject. An open parts flap makes this approach possible. A sorter located below separates the finished parts from the waste and sorts them into different containers. In order to discharge parts that would not tip in order to go through the open flap by themselves, TRUMPF has developed the bi-level stripper.

Special stripper

The stripper is milled down on one side by half a millimeter. During the last separating stroke, it clamps the parts into the die with the raised surface. The parts are then rotated into the correct angled position using the electrically rotating punching head in the TruPunch 3000 or the TruPunch 5000. At the same time, the bi-level stripper enables the metal sheet to move freely. The machine can even discharge the clamp strip without interference from the operator: In conjunction with the clamps that open separately, the clamp strip is cut up in sections with a few strokes and removed. At the end of the process, the machine, software and tools have worked to-gether to leave literally none of the metal sheet, not even an L.

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