National Machinery’s FORMAX® Models XXV, FXP7, and FXP8, have been engineered to utilise the proven features of FORMAX including quick change, high production speed and efficient net shape part production.
Ranging from a 25mm to 34mm cut-off, these machines also feature National’s Pick-Move-Place transfer (PMP). This transfer provides excellent control of difficult to transfer parts, with high-speed and precision, as well as a wide finger opening to clear large diameter tools with exceptional positioning accuracy.
The FX models also feature an expanded die space with the use of bullnose dies/punches and an individual tool/die cassette design. Cassettes give the machines more flexibility and allow for special cassettes, such as a high-pressure lever for segmented tooling, internal die coolant or slug discharge. These machines are available in different length ranges of five or six dies, with XXV even available in seven dies.
The large diameter models also have the FORMAX® exclusive sealed heading slide liners, which are pressure lubricated – providing exceptional liner life that enables the zero clearance heading slide system. This heading slide guidance system improves part accuracy and increases tool life.
Just like all modern FORMAX, the machines come equipped with a Formatrol-PC touchscreen and ethernet controls, making KO and feed adjustments, production/tool counters, fault/maintenance notices, job storage, history log, as well as manuals and schematics, available at a tap of a button on the touchscreen. The Formatrol-PC also provides the user interface for the recently added Industry 4.0 features and sensors that come standard on all new FORMAX – taking users to another level of functionality. Additional sensors can be added for a complete Industry 4.0 option if desired.
Another capability of XXV, FXP7, and FXP8, is alternate blow forming – a feature that allows the feeding of every other stroke of the machine for high tonnage jobs. The forming loads are spread over two cycles so that every other die is empty, which allows for new forming opportunities and the ability to make a larger part on a smaller machine.
The original FORMAX machines pioneered the quick change concept with a Formapak system that can be removed from the machine and set-up externally. National Machinery LLC has taken this concept further with the option for these new machines to come equipped with a state of the art robotic tool changer.
FORMAX XXV also features a robot that accesses an external set-up fixture to make tool/die cassette, IFO camshaft, cutter/quill cassette, and transfer slide changes, automatic – without requiring a person to enter the die area of the machine. Robotic changeovers take approximately 13 minutes to complete with custom changeover options available. The FXP7 and FXP8 have similar robot functions, except the IFO camshaft is an automated adjustment in the machine; the transfer rotates to the operator for set-up; and the heading wedge position is automated.
A particularly convenient feature of the changeover robot is the ‘present mode’, where the robot will remove a punch or die cassette from the die block and place it directly at the operator window, where it can easily access the cassette for inspection or tooling replacement. Furthermore, digital machine positioning is available for ‘dial in’ to the number set-up. The handheld pendant allows exact heading slide position adjustments while viewing the die area and watching the changes in action, which is particularly helpful during job development.
Additionally, the XXV machines feature servomotors that control the adjustments on the feed and kickout mechanisms and ethernet controls, both which yield improved efficiency and repeatable adjustments. The mechanism for soft discharge is also servo driven. This optional device lowers one part at a time reducing the length the parts drop for delicate handling of complex parts to eliminate damage after forming.
Large diameter FORMAX Plus® and XXV with robotic tool changer utilise cutting-edge technology to make tool changes faster, safer and more repeatable. While the proven PMP transfer and zero clearance heading slide easily forms the most difficult parts for production.
Having spent a decade in the fastener industry experiencing every facet – from steel mills, fastener manufacturers, wholesalers, distributors, as well as machinery builders and plating + coating companies, Claire has developed an in-depth knowledge of all things fasteners.
Alongside visiting numerous companies, exhibitions and conferences around the world, Claire has also interviewed high profile figures – focusing on key topics impacting the sector and making sure readers stay up to date with the latest developments within the industry.
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