A fibre-laser CNC profiling machine installed in January at the Darwen, Lancashire, factory of WEC Group has resulted in significant cost savings when processing stainless-steel sheet 1.5-4mm thick. Indeed, Gareth Taylor — assistant general manager of the laser division — says some nests can be cut 50% quicker.
Furthermore, the 3 x 1.5m-capacity machine from Coventry-based Bystronic
(www.bystronic.com) — WEC’s first fibre laser — can cut highly reflective and thermally conductive materials, notably copper and brass, that CO2 lasers are not able to process without damaging the optics.
Even small flashbacks from aluminium can damage the lens and mirrors on a CO2 laser, and this material can be cut more economically on the Bystronic, if it is reasonably thin. The machine also cuts mild steel up to 20mm thick. Other advantages of using fibre-laser technology are that there is no need for costly gases and electricity consumption is less, resulting in lower running costs.
Employing more than 400 people across north-west England and with a 2012 turnover of £37 million (11% up on the previous year), WEC is a major success story within Britain’s manufacturing sector. It has seven operational divisions — due to increase to eight this month with the opening of new premises in Blackburn, where WEC will install its first water-jet profiler (capable of cutting material up to 4 x 2m and 200mm thick). Moreover, in June the group started two new ventures — the manufacture of outdoor furniture and aircraft swing doors.
Aerospace manufacture
The sub-contract production of aircraft components is another area that WEC is seeking to expand, as it is within the North-West aerospace cluster — the largest such industry group in Europe. Already a supplier of non-flying components, the company is currently in the process of gaining AS9100 accreditation (the quality management system for the aerospace industry). The Bystronic fibre laser, which produces very-high-quality cut edges with minimal heat-affected zone, will be important in increasing WEC’s aerospace business. The group’s tube laser cutting and water jet divisions will further strengthen its position in this sector.
An on-going requirement to cut thin-gauge stainless steel was the main driver for investing in the Bystronic fibre-laser machine. It was apparent to Mr Taylor, who has over 20 years’ laser cutting experience, that big savings were possible using a fibre laser to machine this material in the thickness range 1.5-4mm.
He said: “We are cutting up to 50% quicker when using the Bystronic on stainless steel, which is on the machine for about 70% of the time (the machine runs 24hr a day). The material is ideal for extracting maximum benefit from fibre lasers, so the machine will pay for itself quickly. For the other 30% of its time, the BySprint is available for cutting reflective metals that we could not previously quote on.”
Cost-effective production
Explaining the group’s policy on the purchase of capital plant and its reasons for sourcing the fibre laser machine from Bystronic, marketing manager Jean-Yves Dziki said: “We always look at where components can be produced most cost-effectively and expediently, whether it is in-house or bought in; but given the choice, we always prefer to make parts ourselves so that we have maximum control. Bystronic was already known to us, as we have been using one of the company’s 4m press brakes daily for five years, during which time it has only been out of action a couple of times. That gave us confidence in the supplier and the quality of its products.”
The 3kW BySprint Fiber 3015 has a compact footprint (slightly over 10 x 6m), a 3,048 x 1,524mm cutting area, a maximum simultaneous positioning speed of 140m/min, and an axis acceleration of up to12m/sec2.
The machine purchased by WEC includes an optional conveyor for small parts; this runs underneath the machine from the working area to the rear of the loading table. Off-line sheet nesting and programming is provided by Bystronic’s Bysoft CAD/CAM software, with editing at the touch-screen control by the operator to optimise cutting parameters if necessary, particularly on long-running jobs.