TPT September 2024

The international magazine for the tube & pipe industries

ISSN 0953-2366

SEPTEMBER 2024

VOL 37 NO 5

US$33

min

max

4 - 8 Number of cameras

5 Min. object diameter (mm)

720 Max. object diameter (mm)

PROFILEMASTER® SPS Profile Measuring System The PROFILEMASTER® SPS is a light section measuring device for measuring contours and dimensions on profiles of all kinds in cold and hot steel applications.

Benefits:

Highest measuring accuracy due to thermally stabilised measuring unit Surface defect detection based on intelligent software algorithms (Utilising machine learning) Detection of smallest defects due to high sampling rate Designed for measuring complex profiles from rebar’s to train rails Easy maintenance and quick cleaning thanks to proven concept

Zumbach Electronic AG | Hauptstrasse 93 | 2552 Orpund | Schweiz Telefon: +41 (0)32 356 04 00 | Fax: +41 (0)32 356 04 30 | sales@zumbach.ch | www.zumbach.com

INDEX Editorial

BLM Group...........................................................................24 Combilift............................................................................... 16 Corinth Pipeworks................................................................66 Danieli Centro Tube.............................................................12 Dietronic Srl.........................................................................25 EMMEDI............................................................................... 42 ESAB Welding & Cutting Products......................................46 EuroBLECH 2024................................................................10 EWM GmbH.........................................................................49 FABTECH 2024...................................................................23 Fluxtrol................................................................................. 39 GCE Group..........................................................................50 Haeusler AG.........................................................................26 Hart BV................................................................................63 Inductotherm Group...............................................................8 ISEND.................................................................................. 26 Jepson Power......................................................................32 Kasto.................................................................................... 38 Kent Corporation..................................................................40 Friedrich Kocks GmbH & Co KG..........................................17 Paul Leibinger GmbH & Co KG...........................................29 Moreschi Srl.........................................................................34

Otto Junker GmbH.................................................................9 Pipelife................................................................................. 66 Primetals Technologies........................................................21 Randolph Tool Co Inc...........................................................38 Sikora AG.............................................................................27 Sofratest............................................................................... 52 STHEMMA Srl......................................................................33 Strategic Partnerships Inc....................................................68 TechnipFMC......................................................................... 62 Tenaris. ................................................................................ 64 Tenova. ................................................................................ 64 TRUMPF Ltd..........................................................................8 Unison Ltd............................................................................22 Unison Tube LLC.................................................................18 Van Leeuwen Pipe and Tube Group....................................63 Wafios AG ............................................................................ 14 Welding Alloys......................................................................48 Wellube................................................................................ 65 Xiris Automation...................................................................44 Yamazaki Mazak..................................................................36 Zekelman Industries.............................................................62 Zumbach Electronic AG.......................................................30

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SEPTEMBER 2024

MAJOR PRODUCT: HIGH STRENGTH AND PRECISION STRAIGHT-SEAM WELDED PIPE MILL LINE WELDED SQUARE AND RECTANGULAR PIPE DIRECT-FORMING MILL LINE HIGH SPEED AND HIGH PRECISION SLITTING LINE

Add: Cross of Xinzhao Road and Shiji Road, R-1202 No.707, Lianmeng Road, Shijiazhuang, Hebei, China Website: www.kdsz.cc E-mail: info@hebeisz.com Tel: +86 311-85028506 Add: R-1202 No.707, Lianmeng Road, Shijiazhuang, Hebei, China Website: www.kdsz.cc E-mail: info@hebeisz.com Tel: +86 311-85028506

CONTENTS

Editor

Rory McBride

Design & production

Lisa Wright

Sales & marketing

Jason Smith UK, Italy, USA, Canada, India & ROW jason@intras.co.uk Tel: +44 1926 834684 Linda Li Asia 亚洲 linda@intras.co.uk Tel: +44 1926 834685

2 Editorial index 8 Industry news 9 Diary of tube events 24 Technology news

Advertising co-ordinator

Liz Hughes

Subscriptions

Louise Jennings

Accounts manager

Louise Jennings

Web Design/Developer

Andrew Barnes

Social Media Administrator Milly Harrison

32 Cutting technology, sawing & saw blades 40 Tube welding machines & technology 54 Industry 360 56 Interview: Santiago Urbina Castilleja, Orbia Polymer Solutions (Alphagary) 72 Advertisers index 61 Tube Products INTERNATIONAL www.read-tpi.com The trade magazine for tube and pipe products www.read-tpi.com September 2024

Founder

John C Hogg

All rights reserved – © Intras Ltd ISSN 0953-2366

Published by Intras Ltd Unit 32, Tangent Business Hub,

Shirebrook, Nottinghamshire NG20 8RX UK Tel: +44 1926 334137 • Fax: +44 1926 314755 Email: tpt@intras.co.uk • Website: www.read-tpt.com

Intras USA Danbury Corporate Center, 107 Mill Plain Road, Danbury CT 06811, USA Tel: +1 203 794 0444 • Email: doug@intras.co.uk

This publication and its full contents of layout, text, images, and graphics is copyright protected. No part of this publication may be reproduced in any form or by any means, electronic or mechanical including photocopying, recording or any other storage or retrieval system without the publisher’s written permission. The publisher, owners, agents, printers, editors and contributors cannot be held responsible for and hereby exclude all liability whatsoever for errors, omissions or the accuracy and claims printed or inferred in the editorial or advertisements published in this, previous or subsequent editions or for any damages, costs or losses caused thereby. Tube & Pipe Technology reserves the right to edit, reword and subedit all editorial submissions in accordance with editorial policy. Tube & Pipe Technology expressed graphically or by text is a registered name and style trademark of Intras Ltd, UK. All matters relating to this disclaimer are governed by the laws of England. US Copies only: Tube & Pipe Technology (ISSN No: 0953-2366, USPS No: 023-507) is published six times a year: January, March, May, July, September and November by Intras Ltd and distributed in the USA by Asendia USA, 701 Ashland Ave, Folcroft PA. Periodicals postage paid at Philadelphia, PA and additional mailing offices. POSTMASTER: send address changes to Tube & Pipe Technology, 701 Ashland Ave, Folcroft PA 19032.

September issue • Business & market news • A multi-billion dollar water industry segment not to be overlooked by the tube and pipe industry

Photo credit: Ra Dragon

70 ARTICLE

Physical simulation of soft magnetic composite impeder performance for use in induction tube welding systems By Sean Muyskens and Robert Goldstein from Fluxtrol Inc

Tube & Pipe Technology magazine is available in print and online. Go to www.read-tpt.com for more information.

The Professional Publishers Association Member

When you have finished with this magazine please recycle it

The September Issue Welcome to the latest issue of Tube & Pipe Technology magazine. We have features on cutting technology, sawing & saw blades and tube welding machines & technology. The Industry 360 column (page 54) looks at the growing semiconductor market and the role that

September 2024 Vol 37 No 5

Rory McBride – Editor

thousands of miles of tubes play in their production. We also have a fascinating interview (page 56) with Santiago Urbina Castilleja of Orbia Polymer Solutions (Alphagary) as he explains its latest innovative tube products and gives his insights into the global market. Next issue we have features on tube mills & rollforming lines and tube bending, end forming & swaging. The Tube Products INTERNATIONAL section focus will be on steel & stainless steel pipes and fittings, valves, flanges & connectors. TPT November is being distributed at both Tube India 2024 and STEELFAB 2025, which are two important trade events in regions with huge ongoing infrastructure projects and development. There is, therefore, growing demand for tube and pipes products and the machinery and technology required to manufacture them. The editorial deadline for the November issue is 27 September. Please send any articles or news to me at: rory@intras.co.uk if you would like to connect with both our extensive global readership and the decision makers and visitors to the international trade fairs in India and the UAE. I hope that you enjoy the magazine.

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The international magazine for the tube & pipe industries

On the cover . . . Randolph Tool Co Inc offers high quality tube cut off blades and die jaws, manufactured to exact specifications to best suit the production needs of its customers. The blades are manufactured by experienced craftsmen using the best manufacturing procedures and have a reputation for exceeding expectations. Randolph Tool, which was established in 1968, deals direct to reduce customer costs.

SEPTEMBER 2024

VOL 37 NO 5

US$33

ISSN 0953-2366

32

You can fax a drawing of the blades, dies, jaws or repair parts for your tube mills that you require. You will then receive a quote and will find that the pricing is competitive, with a fast turnaround time. When you receive the blades they will be flat within 0.002 and the surface of the blade will be extremely smooth, which will help the blade last longer. Randolph Tool also offers services such as resharpening of used blades and die jaws as well as precision machining, and uses only top-grade tool steel to produce the best industrial knives and die jaws in the business. Visit www.randolphtoolco.com or email info@randolphtool.com for more information.

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INDUSTRY Inductotherm Group announces leadership transition as Gary Doyon steps down as CEO INDUCTOTHERM Group, which

knowledge and a fresh perspective to the company, positioning Inductotherm Group for a positive future. “We are pleased to announce that Mick Nallen and Satyen Prabhu have been selected to be co-leaders,” added Ms Rowan Smith. “This management strategy fits perfectly with the fact that our business is large, growing fast and becoming wider in product technologies around the world. Mick and Satyen have come up with strong business plans that meet our family’s goal of maintaining a stable, customer-focused and technology-centric business. We have an exciting future ahead of us.” As part of their new roles, Mr Nallen and Mr Prabhu will focus on thought leadership, market comprehension and a deep understanding of the thermal processing industry’s various sectors. Their strategic vision will ensure that Inductotherm Group continues to deliver cutting-edge induction technologies while preserving the core values and vision of its founder, Henry Rowan.

Under his guidance, Inductotherm Group has expanded its global footprint, diversified its product offerings and strengthened its market position. Although he is stepping down as CEO, Mr Doyon will remain actively involved with the company. He will continue to serve as the only non-family member on the parent company board, assisting with specific operational needs of other businesses owned by the Rowan family and pursuing new business avenues and opportunities for the Inductotherm Group. “We greatly appreciate and thank Gary Doyon for his exceptional leadership over the past 15 years,” said Virginia Rowan Smith, chairman of Inductotherm Group. “The Inductotherm Group is positioned for great things in the future based on its strength today. As we move forward with our succession plans, we are confident that the new leadership will continue to uphold the high standards and legacy that Gary has established.” Mick Nallen and Satyen Prabhu have taken over as co-leaders of Inductotherm Group. Together, they bring a wealth of Luton to form the new UK headquarters of TRUMPF Ltd. Today, more than 100 employees work at the Luton facility, which includes a 1,000m² showroom for hosting holistic customer experience activities such as time studies, feasibility studies and sample creation.​ To mark such a milestone, TRUMPF Ltd organised a festive gala in Luton on 4 July. Nicola Leibinger-Kammüller (CEO) and Mathias Kammüller (CDO) from TRUMPF’s parent company in Germany attended the celebrations. Addressing the more than 50 invited guests, Nicola

specialises in thermal processing technologies, has announcing a leadership transition. After 15 years as CEO, and 38 years with the company, Gary Doyon has stepped down from his role as CEO, effective 1 July 2024. This transition is part of Mr Doyon’s planned succession strategy to ensure the continued growth and success of the Inductotherm Group. Mr Doyon’s tenure as CEO has been marked by a commitment to innovation, delivery of quality products and a focus on process development and end-to end customer care.

Inductotherm Group www.inductothermgroup.com Gary Doyon will remain actively involved in the company TRUMPF celebrates 50 years of manufacturing

Leibinger-Kammüller said: “I would like to thank you, our customers and partners, for your loyalty over the years. Without you, none of us would be here today.” Lee Moakes, the managing director of TRUMPF Ltd, who has led the subsidiary since 2018, said: “We especially celebrate our customers. They are the reason we strive to give our best every day. We also have a duty to keep investing in our employees, processes and products.”

TRUMPF Ltd, based in Luton, UK, is celebrating 50 years of providing manufacturers across the country with the latest innovations in machine tools and lasers. The company has been busy in recent weeks hosting celebratory events with customers, partners and employees as it looks forward to further decades of market and technology leadership. It was in 1974 when TRUMPF Machine Tools Ltd began trading in St Albans, UK with a team of just five employees. The company demonstrated both success and growth and in 1989 relocated to

TRUMPF Ltd www.trumpf.com

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SEPTEMBER 2024

DIARY OF EVENTS

Otto Junker celebrates its 100 th anniversary in business

2024

SINCE its foundation in 1924, Otto Junker has made a name for itself as a pioneer in building equipment for foundries as well as for rolling mills and pressworks. It plays a leading role as an international furnace manufacturer and system supplier for metallurgical processes and the refining of metals. This year, the company celebrates its 100-year anniversary and looks back at a time of technological and entrepreneurial milestones, including major contributions to a sustainable industry. Several thousand industrial furnaces made by Otto Junker are in operation all over the world. These are required wherever there is a demand for high quality castings and forgings as well as semi-finished products such as slabs, plates, sheets, strips, foils, billets, rods, profiles, wires and tubes of all kinds of metal. Otto Junker plants are used for melting, pouring and heat treatment of metallic materials. Over the years, the company has not only maintained its position as technological market leader but even expanded it. 100 years ago, Otto Junker founded his company in Lammersdorf in the Eifel region of Germany and specialised in metal processing. His aim was the marketing of the water-cooled mould for the production of brass rolling plates, an invention by his father, Andreas Junker. The committed company founder worked hard for the expansion of the company and the development of new machines and equipment. In doing so, he built up a close relationship with the Technical University of Aachen, which was and still is founded upon the principle that a continuous technical development is indispensable for the success of a company. Since 1982, after the death of Otto Junker, Otto Junker has been owned by the Otto Junker foundation, which supports the education of young engineers and promotes research projects at the Technical University of Aachen. The cooperation has led to numerous technological breakthroughs and has helped to maintain the technological leadership of the company. The challenges to industrial furnace building have evolved. Apart from meeting exactly specified process

25-28 September Tube China 2024 Shanghai, China www.tubechina.net 15-17 October FABTECH Orlando, Florida, USA www.fabtechexpo.com 22-25 October EuroBlech Hanover, Germany www.euroblech.com 27-29 November Tube India Mumbai, India www.tube-india.com 3-5 December ValveWorld Expo Düsseldorf, Germany www.valveworldexpo.com 2025 13-16 January SteelFab Sharjah, UAE www.steelfabme.com 11-14 March Global Industrie Lyon, France www.global-industrie.com 6-9 May Lamiera Milan, Italy www.lamiera.net 6-8 May Made In Steel Milan, Italy www.madeinsteel.it 8-11 September FABTECH Chicago, IL, USA www.fabtechexpo.com

parameters and the ongoing increase in capacity and reliability, today’s main focus is on questions of energy efficiency. This has become an integral part of everyday work and continuously pushes on the innovative spirit of the entire Otto Junker group of companies. “The capability to adapt to market requirements continuously and quickly – both from a technical and organisational point of view – remains an important success factor for us. This is guaranteed by the technical competence and flexibility of our employees, which is what characterises our company,” said Erik Míček, CEO of Otto Junker. “Our focus is not only on dealing with the challenges faced by customers, but also on contributing to an environmentally friendly industry in a pro-active manner. The next 100 years will be characterised by our pursuit to continuously redefine the boundaries of what is technically possible,” Mr Míček added. The pronounced innovative strength of Otto Junker has led to it also offering competent solutions with regard to sustainability outside of the metal industry. In cooperation with the Technical University of Aachen, industrial partners and with support from the German government, innovative energy storage and recovery technologies have been developed. These plants make a significant contribution to increasing the share of cost-effective, regenerative energy for providing industrial process heat and decoupling the processes from the volatility of regenerative power generation by wind and solar energy. “We are proud of this milestone. For 100 years we have been spurred on by the passion for equipment building and by the commitment to provide machinery for foundries, rolling mills and pressworks,” said Sabine Höfer, Otto Junker CFO.

Otto Junker GmbH www.otto-junker.com

All shows are correct at the time of going to print, but are subject to change. Please check to ensure the event is going ahead

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INDUSTRY

EuroBLECH 2024: exploring the power of productivity EUROBLECH, the global event on sheet metal working, is expecting a large turnout this year. Spread over nine exhibition halls and covering more than 90,000m 2 , this year’s event will be a unique opportunity to see the largest collection of sheet metal working technology in one place. From 22 to 25 October 2024, the 27 th International Sheet Metal Working Technology Exhibition, EuroBLECH, will open its doors again at the Hanover Exhibition Grounds in Germany. It is the world’s largest exhibition for sheet metal processing, covering the entire supply chain in 15 different technology sectors. Visitors can look forward to an impressive number of live demonstrations and world premieres, giving opportunity to explore, assess and discuss the benefits and gains of specific technology solutions for their own production process. EuroBLECH 2024 will be occupying nine halls at Hanover Exhibition Grounds, the world’s largest exhibition centre. The uptake on stand space has been positive, in particular from international exhibitors, with more than 60 per cent of exhibitors joining from outside Germany. As such, the show mirrors the global significance of the sheet metal sector in the wider economy. Besides Germany, the major exhibitor countries are Italy, Turkey, China, Spain, the Netherlands, Switzerland, Taiwan, Belgium, Austria, France and the US. EuroBLECH provides numerous opportunities to watch innovative machinery live in action. It is worth noticing that more than a quarter of EuroBLECH visitors do not attend any other trade shows as they feel EuroBLECH offers access to the broadest possible spectrum of tech suppliers, with exhibits covering anything to do with the processing of metal sheet, tubes, profiles, plastic hybrids and related applications. On display at the event are: stamping presses, CNC punching machines, press brakes and other machines and tools for cutting, punching and forming; joining; welding and fastening; surface treatment and finishing; process control and quality assurance; machine elements and components; CAD/ CAM/CIM systems; warehouse and factory equipment; and material recycling. For the first time, visitors will be able to book curated visitor tours. Also reflected in this year’s motto for EuroBLECH, ‘the power of productivity’, the organised visitor experiences focus on productivity-enhancing technology. The tours will include 10-minute presentations at each stop, followed by a short Q&A session. In addition to the innovations and numerous live demonstrations on the exhibition stands, attendees can benefit from the popular EuroBLECH 2024 Speaker Forum, two dedicated presentation theatres for expert talks and panel discussions. Sessions run on all four show days and offer exciting insights into the latest projects and product developments, as well as valuable networking opportunities and meaningful exchange amongst peers. The speaker agenda will be published closer to the show.

DFT

SAVE ROLLERS

SAVE TIME

SAVE WORKERS

AUTO ADJUST

EuroBLECH 2024

www.euroblech.com

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SEPTEMBER 2024

INDUSTRY

Two Danieli Centro Tube ERW mills commissioned for Mexican company

part of Monterrey and will produce tubes to be commercialised in Mexico through the well-established commercial network of Achv Aceros. The new mills will operate through a Danieli Automation L1 system. The start-up of the two electrical resistance welding mills is foreseen by end of 2025. Danieli Centro Tube provides a wide range of tube and pipe processing technologies: seamless plants, ERW plants, CRA plants, including reheating and heat-treating systems and electrics and automation. With a highly qualified and experienced engineering team it manufactures and supplies technologically advanced complete plants and equipment for the hot rolling and cold finishing of high-quality seamless pipes.

7.3mm (0.287") at speeds up to 140m/ min (460fpm). The new ERW mills will feature automatic coil loading, on-line metallisation, eddy current testing, tube stencilling, quick-change mill system, bundle packaging lines and full automation system. The mills will be installed in a new facility in the western

ACHV Aceros has awarded Danieli Centro Tubes a contract for two modern ERW tube mills for its new facilities in Monterrey, Mexico. The new mills will produce welded structural tubes with yield strength up to 800Mpa with an OD ranging from 19 to 193mm ( 3 / 4 " to 7 9 / 16 "), and equivalent square and rectangular sections, with wall thicknesses up to

Achv Aceros has awarded Danieli Centro Tubes a contract for two modern ERW tube mills in Mexico

Danieli Centro Tube www.danieli.com

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SEPTEMBER 2024

DFT - DIRECT FORMING TUBE

ERW Tube Mills able to produce square or rectangular tubes directly from sheet metal, without the need to make a round tube from which shape profiles are later derived. This technology, together with the ‘universal roll’ design, allows for certain advantages over traditional forming: > Reduction in the number of tooling required, as ONE set of rollers allows all sizes included in the range to be made seamlessly, enabling special profiles to be made without the need for ad hoc tooling. > Reduction in change-over time or, by comparison with traditional profiles equipped with quick change-over, reduction in the labour required for size change-over. > Savings in the material needed to form the tube.

FIMIGroup will exhibit at: Aluminium | October 08-10, 2024 | Düsseldorf - Germany | Hall 4 - Stand F44 Euroblech | October 22-25, 2024 | Hanover, Germany | Hall 17 - Stand E100

INDUSTRY

Wafios to exhibit its bending machines at Tube China 2024

The FUL 16+ combines optimum output and drive technologies

production of hairpins, electromagnetic coils and stator connection assemblies on one machine. The patented tool system combines active rotary-draw bending with the agility of conventional wire bending tools, and actively prevents thickening of the material. The newly developed feed unit prevents deformations in the profiled material, and a simulation of the bending process allows checks for feasibility and collisions. The new HQ bending technique combines the advantages of forging tools with the flexibility of a CNC bending process. The RBV 60 ST is a stabiliser bar bending machine for tube diameters of 20 to 35mm and was designed to meet the requirements of the cold-forming industry for processing pre-hardened tubes. All machines are equipped with the latest version of the Wafios programming system WPS 3.2 EasyWay, which

AT Tube and wire China, Wafios will exhibit the FMU 40 E bending machine designed for components for the e-mobility sector, as well as the RBV 60 ST stabiliser bar bending machine, the FUL 16+ compression spring machine and the BMZ 6 tube bending machine for small parts. Wafios develops, designs and produces specialist machinery for the wire and tube processing industry and for cold-forging applications, and has more than 130 years of. The range of products includes more than 130 types of machine, equipped with the latest software, artificial intelligence and IoT. The FMU 40 E is a powerful bending machine for producing hairpins and electromagnetic coils. It offers a revolutionary bending technique and straightforward operation with the WPS 3.2 EasyWay programming system. It has a unique machine concept for the

features functions for the production of stabiliser bars and an integrated real-time simulation for increasing the machine’s availability based on a secure data basis. The FUL 16+ compression spring machine is the successor to the FUL 16. Optimum output and drive technologies are combined in a modern and functional design to provide increased dynamics, speed and performance. The BMZ 6 CNC tube bending machine offers modularity for complex workpieces by combining different bending techniques with additional operations such as free-form bending, cutting, forming and winding.

Wafios AG www.wafios.com

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SEPTEMBER 2024

The Industry Standard Since 1910

Leaders in Roll Forming Solutions

Wide range of mill lines : Most economical M-style, quick change QVW-style, and heavy duty WH-style roll stand products Various welding technologies available : Forge welding (HF solid state or ERW) and fusion welding (laser, TIG, and plasma Ability to fit special accessories: Single point adjustment (SPA), SPA Plus, and the latest TruPosition Auto SPA (servo driven top shaft adjustment with linear transducer feedback)

With over 100 years of experience, the American made and locally sourced Yoder brand remains a leader in the development of new tube and pipe mill lines, innovative roll forming techniques, and precision tooling. Formtek continues production of Yoder’s exceptional tube and pipe mill technology designating its position as the largest, dependable mill machinery designer and manufacturer in the world. The versatility of Yoder technology allows it to accommodate varying pipe lengths, end conditions, and budgets. Formtek is also recognized as an industry leader with its utilization of specialized drive train platforms to extend and maximize product life, while minimizing maintenance. Yoder tube and pipe mill products employ several different welding technologies to provide the most customized machines available. Yoder products are efficient and adaptable with unsurpassed quality and reliability providing a competitive edge.

Schedule a No Obligation, 1-on-1 Consultation with a Yoder Technical Advisor today to learn more our tube and pipe solutions and see how we can help you achieve your operational objectives.

Join Us | Booth S26045 Orlando, FL October 15-17, 2024

Visit FormtekGroup.com/TubeandPipe

Leading Metal Forming & Fabrication Solutions formtekgroup.com | +1 216.292.4460

INDUSTRY

Combilift pipe handling solutions on display at FABTECH and EuroBLECH

products such as coils, pipes and metal sheets. This new model is equipped with award-winning ‘Independent Traction’, eliminating long-load momentum twisting when travelling sideways. To reduce driver strain, it also features a gas strut suspension cab and a patent pending ‘Auto Swivel Seat’, which automatically swivels the seat and armrest 15° to the right or left following the direction of travel. The new Combi Eco-Green is an added safety feature as this bold, fresh green shade will make the trucks more easily visible in their operational environment. This forklift offers next-gen performance, long battery life and exceptional ergonomics, making it the most powerful compact electric multidirectional forklift to date. You can visit Combilift at its booth at FABTECH S26059 and at EuroBLECH 12F156. tight spaces and narrow aisles, and to transport long steel billets, bars and pipes Compact size and sideways movement capability make it easier to navigate through

1 /3 Page Horizontal and it also features exceptional manoeuvrability. Its compact size and its sideways movement capability make it easier to navigate through tight spaces, narrow aisles and transport long steel billets and bars as well as other steel centres and the metal industries, which typically handle long loads. The design is based on the electric, manually operated Combi-GTE model, known for its efficiency in rail-guided narrow aisles. The Combi-AGT is equipped with laser based sensors to create an anti-collision safety system, as mandated by the American National Standards Institute. When the sensors detect an obstacle in the truck’s path, the machine will automatically slow down and come to a stop in case of an emergency. Once the obstacle is no longer in the sensor’s range, the Combi-AGT will resume driving automatically. The adaptive safety system can adjust the size of the obstacle detection zones based on the forklift’s steering angle and speed. Another forklift catering to the steel industry’s needs is the fully electric Combi-CB70E/Combi-CB 155E. It is the shortest 15,500lbs capacity counterbalance truck available

COMBILIFT annually invests 7 per cent of its revenue in R&D, with about 98 per cent of it focused on the development of new electric material-handling solutions. Evidence of this investment can be seen in the five new products that were launched in 2023, to mark Combilift’s 25 years in business. These products are the Combi-Cube, the Combi-CB70E and the Combi AGT, all of which are fully electric; and a further two innovative solutions in the form of the Combi-LC Blade and the Combi-Connect. 2024 has already seen two other innovations unveiled: the Combi-SafeLift and the Combi-CLL (Log Loader). Combilift has a solid presence in the steel industry. The Combi-AGT, unveiled at last year’s edition of FABTECH, demonstrates the commitment to the metal forming and fabricating sector. Developed by Combilift’s dedicated automation team, the Combi-AGT is a 4-wheel electric stand-on model, making it the world’s first autonomous dual operational sideloader for long loads. With a lift capacity of 5,000kg/ 11,000lbs, the Combi-AGT addresses the requirements of steel service

Combilift www.combilift.com

Equipment carrier for electroslag welding (ES-Welding)

Equipment carrier with control station for electroslag welding GT500F-Z4.250K-X1.500Z-ZT4.200SP Xs250-Ys100 vertical welding of pipes and plates

Machine

Type

Application

Wall thickness Stroke range welding heads

50-400 mm

650-5000 mm (Weld length approx.4000mm)

approx. v=10 - 100 mm/min, infinitely adjustable 400V/3P/N/PE/50Hz, 35 kW, 63 amps

Welding speed

Power supply Welding heads

3 pcs.

Payload

3.000 kg (3x welding wire reel) Coesterweg 45, 59494 Soest, Germany

Tel.: +49 2921/3690 223 email: info@mechacon.de Website: www.mechacon.de

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SEPTEMBER 2024

INDUSTRY

iF Design Award for Kocks Reducing and Sizing Blocks

in the event of bars breaking out. The block’s overall appearance underscores the special relevance of the 3-roll block for the quality of the final product. The jury awarded Kocks RSB ® product family an award in the category ‘industry product`. This recognition by one of the most prestigious design competitions worldwide honours the outstanding achievement of the team of engineers and designers. From the beginning, the RSB ® was developed to achieve top performance and has been consistently optimised up to the current 5th generation. “The iF Design Award is also a valuable recognition of our pursuit of excellence in rolling mill technology,” said Günther Schnell, managing director sales and marketing at Kocks. The award-winning design extends across the entire RSB ® sizing family. “The rolling blocks now form a consistent visual unit

KOCKS’ Reducing and Sizing Blocks (RSB ® ) have been awarded the renowned iF Design Award. The award also demonstrates Kocks’ commitment to innovation in the steel production sector. The redesigned appearance of the rolling mills was developed in collaboration with the experienced team from Budde Industrie Design. The Kocks Reducing & Sizing Blocks are an integral part of special steel production, enabling highly precise rolling processes. In addition to their technical performance, the advanced equipment of the current generation is also distinguished by its striking design. With its clean lines, the RSB ® from Kocks emphasises the central factor of precision in the impressive rolling mill environment. The fully automatic cover ensures maximum safety under the demanding conditions in industrial environments

that clearly stands out in the mill line,” he explained. Three RSB ® ’s in the award winning design have already been put into operation by Chinese steel producers. Additional blocks in various configurations are already under construction or in the planning stages and will be put into operation in rolling mills worldwide in the near future. Since 1954, the iF Design Award has been recognised as an arbiter of quality for excellent design. The iF Design brand is renowned worldwide for outstanding design services.

Friedrich Kocks GmbH & Co KG www.kocks.de

DRAWING STRAIGHTENING PEELING

BARS TUBES PROFILES

Bültmann GmbH www.bueltmann.com

Contact us: +49 2394 180 info@bueltmann.com

INDUSTRY

Tube bending technologies at FABTECH 2024 UNISON Tube LLC, the North American division of UK-based Unison Ltd, will be presenting a range of tube and wire bending technologies at FABTECH.

Visitors to Unison’s booth at FABTECH will be able to discover the company’s EvBend machines. Designed for low volume, high accuracy production and prototyping, Unison EvBend models are used widely across the aerospace, MRO, Formula 1 and oil & gas industries where they provide CNC-controlled, manually operated 3-axis mandrel, multi-plane bending at a fraction of the cost of fully automated machines. While the EvBend 1000 has been designed for bending tube of up to 16mm in diameter (22mm in copper) a larger machine, the EvBend 2000, is also available. Built to bend tube of up to 50mm in diameter, its bending function is servo-assisted. “Add the latest advances in Unison’s Unibend CNC, tube bending simulation software and advanced tube bending application app and we’ve a good deal to show customers old and new,” added Mr Singleton.

bore tube bending machines in the autumn of 2023 – and has been working hard to ensure the brand continues to lead the way in the wire bending machinery market. Like all Pneuform machines, the model on show at FABTECH will be equipped with Yaskawa drives and Unison’s user-friendly software for easy programming and operation. Developed to make Unison quality and reliability accessible to even more companies involved in tube manipulation, Unison Synergy hybrid-electric, dual stack tube bending machines combine precise electric control with advanced, near-silent operation. “Our Synergy models have proved highly popular with manufacturers and subcontractors who carry out repetitive tube bending tasks,” added Mr Singleton. “As well as the 50mm model we’ll have on show, there’s also a larger 80mm machine. Both have our user-friendly Unibend control and industry leading motors and drives. They offer exceptional power and rigid mechanical design.”

Visitors to Booth S34035 at Orlando’s Orange County Convention Center, will be able to view one of Unison’s recently launched Synergy hybrid-electric tube bending machines, a Unison EvBend 1000 manually operated, CNC-controlled tube bending machine and a Pneuform rotary head wire and tube bending machine. “FABTECH is always a key event on our calendar,” said Stuart Singleton, VP of Danville, VA-based Unison Tube LLC. “The 2024 event, however, is going to be extra special for us. Not only because 2024 marks the 30th anniversary of Unison Ltd launching the world’s first all-electric tube bender, but because it’s also the first year we’ll be showcasing Pneuform wire and small-bore tube bending machines.” Unison Ltd acquired Pneuform – a manufacturer of wire forming and small

Unison Tube LLC www.unisonltd.com

HF Col Slit Dire

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F OREVER Shijiazhuang Forever Machinery Co., Ltd.

F OREVER Shijiazhuang Forever Machinery Co., Ltd.

HF Tube/Pipe Mill Line Cold Roll Forming Machine Slitting Line and Cut-to-length Line Directly Forming to Square and Rectangular Tube Mill Line Tube/Pipe Mill Line ld Roll Forming Machine tting Line and Cut-to-length Line ectly Forming to Square and Rectangular Tube Mill Line

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Finishing and bending equipment commissioned PRIMETALS Technologies has received an order from Baowu Aluminium Technology for an additional finishing mill stand for its aluminium hot rolling mill line in Sanmenxia, located in the Henan province of China. The upgrade will change the layout of the current aluminium hot mill finishing line from a 3-stand to a 4-stand design, allowing the plant to achieve improved product quality and increase production capacity from 300,000 tons to 600,000 tons annually. Primetals Technologies will be responsible for the engineering, supply of equipment, as well as overall supervision of the installation and implementation of the new stand F0, which will be processing aluminium heavy plate and strip. systems. The bending of work rolls acts in conjunction with the existing smart crown system ensuring that the strip profile remains constant throughout the process regardless of the rolling load. The integral solenoid valves are designed to apply zone cooling and lubrication to the work rolls, controlling the bulk temperature of the mill and addressing the residual flatness errors during the rolling process. Hydraulic automatic gauge control cylinders are driven by high response servo valves, controlling the thickness of the product being rolled. These cylinders are also used to modify the pass line height, in order to match the size of the roll diameters. Primetals Technologies was responsible for the engineering, supply of equipment, supervision, training and commissioning of the aluminium plate mill and F1-F3 stands hot finishing mill, which has a production capacity of 300,000 tons per year. The plant produces heavy plate and hot rolled coils and processes various aluminium alloys. Baowu has issued the final acceptance certificate, confirming the successful completion of the project in May 2023. Baowu Aluminium Technology, a company of Baowu Group, is a leader in the steel industry. The company was developed as a scientific and technological enterprise, by joint investments from Baowu steel, Henan Energy and Sanmenxia municipal government. The main products processed are high grade aluminium plate and strip designed for the automotive, aerospace, military and rail markets. The combination of work roll bending technology, integral solenoid valves, and hydraulic automatic gauge control system allows the producer to reach their key objectives of surface, profile, and flatness quality. As a result, Baowu will be able to supply key markets including automotive, can packaging and construction applications. Primetals Technologies www.primetals.com The project scope will include the supply of work roll bending and shifting equipment, roll coolant spray bars incorporating integral solenoid valves, hydraulic automatic gauge control cylinders, hydraulic equipment, pneumatic controls and all related fluid

The stationary PBM pipe end preparation machines, for fast beveling of all types of materials, are the strongest bevel machines in the market.

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Unison marks 30 years since it launched the world’s first all-electric tube bending machine

bend arm; the challenge was all the other axes. It took a few years to achieve what we wanted, but by pushing the servo actuators of the day to their limits, we developed a process where low-friction slide adjusting mechanisms powered by an electric motor with torque control, brought absolute pressure control to bending machine components such as the clamping die, pressure die, mandrel and powered follower. “All-electric tube manipulation had been invented – with the assurance of accuracy and repeatability at the tightest of bending parameters for large and small production runs, and with no concern over hydraulic oil or even external temperatures,” he said. Called the Unison Breeze, due to the speed and ease it brought to achieving repeatable tube manipulation, the world’s first all-electric three-axis tube bending machine was launched by Unison in 1994. UK and German patents were registered and ‘right first time’ tube bending was born. Over the following years, Unison developed and launched the world’s first all-electric five-stack tube bending machine, followed by the world’s first 76mm, 115mm, 150mm and 180mm multi-stack machines, as well as robotised benders and twin-head tube benders for producing symmetrical, simultaneous bends. Today, with facilities in the UK and US, Unison offers the world’s largest range of ultra-precise, all-electric tube and pipe bending machines for diameters ranging from 4mm to 275mm, in single stack, multi-stack and right/left versions. For more straightforward, repetitive applications, it has also recently

UNISON Ltd, a UK-based manufacturer of tube bending technologies, is celebrating 30 years since it invented and launched the world’s first all-electric tube bending machine in 1994 – an invention that has changed the way tube is bent by precision industries around the globe. Convinced there was a better, more precise way of bending tube than by using the hydraulically operated machines of the day, in the late 1980s Unison’s founder, Terry Pickering, along with his son, Alan (who is now the company’s joint managing director), set about reinventing the process of tube manipulation. “It was no great secret that the accuracy of hydraulic tube bending machines could be affected by changing oil temperature,” said Alan Pickering. “In other words, a machine with cold hydraulic oil at the start of a shift might well perform differently later in the day when its oil was hot. The greater viscosity of the cold oil, compared to that of hot oil, would typically result in the machine operator having to make temperature-related adjustments during the day to ensure satisfactory levels of repeatability. With all those manual adjustments to make – particularly on the clamp and pressure die – each operator would keep a black book of how they managed to get a good part out of their tube bending machines.” Unison’s goal was to take the ‘black art’ out of tube bending as much as possible, by letting a CNC capture all the correct machine axis settings – in order to repeat them on future bends and get to a point where ‘right first time’ results were possible. During the R&D process, it also became clear that to achieve this, it was important to not only control axis position, but also the force of each axis. Following a 1991 Brite Euram feasibility study into automatic setup tube bending, in 1992 Unison secured a SMART award to develop three all electric tube bending machines. “At that point we were already well on the way to understanding what we would need to do to create the world’s first-ever all-electric tube bender,” added Alan Pickering. “The easy axis to do was the

introduced a range of high-accuracy hybrid machines. “All-electric tube bending was a difficult sell for us at first,” said Alan Pickering. “In fact, it took a number of forward-thinking customers to put their faith in our technology before others would make the switch. “However, our big breakthrough came when Airbus ordered their first all electric tube bender from us – a machine that paid for itself in 16 weeks, in reduced scrap alone. As all-electric tube manipulation caught on, competition from the bigger players was inevitable, but we kept our heads down and kept on pushing forward. “Today, of course, all-electric tube bending machines are commonplace offerings from manufacturers from around the world. But I am proud to say that we remain the preferred choice of countless organisations from all manner of industry sectors. Whether it’s aerospace, performance automotive, marine, oil & gas, energy or general manufacturing, we take pride in building powerful, highly energy efficient machines that meet the challenges faced by our customers head on. “Thanks to our build quality, uncompromising customer support and user-friendly control systems – not to mention our tube bending simulation software and innovative tube bending application app – I truly believe that 30 years on from the first Unison Breeze machine, we still have, and always will have, the edge,” he concluded. From left: Unison’s joint managing directors, Alan Pickering and Julian Kidger, alongside an all-electric Unison Breeze 80mm multi stack tube bending machine

Unison Ltd www.unisonltd.com

Unison’s Alan Pickering with an early Unison Breeze all-electric tube bending machine

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FABTECH 2024 speaker line-up to highlight manufacturing innovation and resilience

and half-day workshops covering advanced fabrication and welding technology, workforce development and management topics. Attendees can customise their agenda from 14 tracks, gaining practical knowledge to address specific manufacturing and production challenges. The new FABTECH emerging leaders program has been designed to equip young professionals and rising stars with the tools and confidence to shape their future and drive positive change in their organisations and the industry. The three day program will act as a launchpad for those ready to elevate their careers. FABTECH 2024 will feature a show floor with over 1,500 exhibitors showcasing the latest products and technologies across the industry.

“FABTECH 2024 is designed to ignite change and drive advancements across the manufacturing sector. With an extensive line-up of influential speakers, we aim to provide attendees with the knowledge and inspiration to embrace new technologies and practices. Our mission is to empower every participant to overcome industry challenges.” The FABTECH 2024 special events schedule includes talks such as ‘Embracing change: lessons from immigration stories’ applied to manufacturing transformation from Andrew Kossowski, owner of Veterans Metal LLC; and ‘Tackling the fear, uncertainty and doubt that limit manufacturing’ from Rhonda Dibachi, CEO and founder of HeyScottie. FABTECH offers a compre- hensive conference with 60 to 90-minute sessions as well as full-

FABTECH, North America’s leading event for metal forming, fabricating, welding and finishing, will take place in Orlando from 15 to 17 October 2024. This year’s special events (most are free to all attendees) will feature a dynamic line up of industry leaders, innovators and visionaries who will challenge attendees to rethink their approaches and embrace innovative practices. The sessions will explore the rise of women in manufacturing leadership, advanced manufacturing techniques, digital solutions, AI and robotics, steel production and strategies for workforce development, while also offering insights into global economics and the current state of the industry. Attendees will gain valuable insights and practical tools, empowering them to excel in the evolving manufacturing landscape. Tracy Garcia, CEM, group director, FABTECH Series at SME, said:

FABTECH 2024 www.fabtechexpo.com

Unison Breeze Ultra-precise and all-electric • British-built CNC tube and pipe bending machines • All-electric control for right-first-time repeatability • Machines for diameters from 4 mm to 275 mm • User-friendly control with advanced 3D simulation software • Automatic setup, fast tooling changes and robust design • Single machines to fully automated work cells • From the inventors of all-electric tube manipulation Tube bending for subcontractors? It’s a Breeze.

Contact us now to discuss your needs: +44 (0) 1723 582 868 I sales@unisonltd.com

unisonltd.com

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