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More about KleenCut Supported Shear Cut Technology for Tube Cutting Overview
To remain competitive in today’s metal tube market, tube manufacturers must meet their customer’s increasingly difficult demands for tubes with diverse applications. Tubes are used in products across a broad range of industries, including automotive, aerospace, appliances, medical, health and fitness, HVAC, furniture, and storage. There are numerous applications, with more being developed all the time, resulting in various shapes, lengths, and materials. This variety does not reduce the demand for high quality, fast delivery, and competitive prices. Tube manufacturers must respond to each customer’s ever changing requirements while controlling production costs in order to achieve the margins needed to invest in their business. Today’s metal tube market poses a very complex set of problems for tube manufacturers.
The increasing applications for metal tubes results in a demand for many shapes and sizes. New materials are being developed to provide end-users with innovative solutions to meet their performance criteria. In today’s highly automated world, components must be designed to precise specifications to ensure a seamless integration into the final assembly of the finished item and minimize failure rates.
Achieving these mutually exclusive objectives can be difficult and maintaining cost, quality, and delivery continues to pressure companies in the competitive global marketplace. Successful tube manufacturers require a high quality cutting system that produces accurate, burr-free cuts. It must be efficient, with
easy changeover, and integrated into the total tube processing operation. Additionally, companies must solve the problems of producing a wide variety of high quality tubes from different materials and having short production runs with minimal changeover time. They must also control costs by minimizing secondary operations, reducing material loss, and requiring less expensive machine operators.
Haven Manufacturing, a worldwide leader in supported shear tube cutting technology, offers a series of automatic high-speed cutting systems called “KleenCut” that meets the challenges today’s metal tube manufacturer’s face. Haven’s KleenCut products deliver near burr-free cuts that usually require no secondary finishing operations. The cut is made by shearing across the cut plane and there is no material loss. This technology is ideal for drawn-over-mandrel (DOM) or equivalent dimensional tolerance tubes, but it is also used in a variety of as-welded applications. The tube is supported from two external die rings and an internal punch assembly that form a shear plane. Half of the tool set is stationary and the other half moves both vertically and horizontally.
Once the raw tube is in position, the moveable side shears and separates the tube from the stationary side. This cycle repeats for the length of the raw tube and then another is automatically fed into position. Upstream operations, like a bundle unscrambler, can be added to the KleenCut. The nearly burr-free shear cut usually requires no end finishing operations, but the system can be easily integrated into secondary processes, such as chamfering.