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Precision Metal Fabrication

Metal Forming

The predictability of the computer combined with the empirical experience, has caused Weldmac to be very unique in the draw forming process.
Weldmac has developed finite elements that allow us to simulate the metal forming process to fully develop and compensate for the stress concentrations and thus localized thinning; this Metal Forming Productmodeling process allows us to develop a customized sized and shaped blank. This modeling coupled with the vast experience of the forming operators has made Weldmac capable of successfully forming parts not possible by other processes. Our unique experience in this arena that calls for customization of forming blanks shapes can only be obtained through 40 years in the industry.

 

The solid modeling approach allows for cross sectioning of the components thus design and build of form tooling that is right the first time.
The model serves to assist in press settings, identifies clearance issues, depth of draw, the rate of curvature on the surfaces and provides excellent insight to the process allowing for repeatable success. In compensating for material grain direction, individual heat lots of raw material and thickness variance, Weldmac plans for forming accomplish repeatability within .002” with a high degree of consistency. Tooling can then be designed in a way that the critical dimensionsMetal Press Fabrication can be controlled.

Weldmac's largest press has 450 tons of force and we also operate a 150 ton press.

 

 

Laser Cutting and Welding

Weldmac utilizes four lasers in its operations; a Y.A.G. pulsed laser and the three continuous wave CO2 lasers.Laser Drill
All four lasers have a 5-axis capability, whether it is interpolating holes, percussion drilling or trimming on a contour. Automatic focus control allows the laser head to track the surface of the part providing a close tolerance and repeatable component. Each laser is fitted with a rotary table providing greater accuracy and faster processing for circular parts.

Using the Y.A.G laser we can produce percussion drilled holes in the .020” diameter range while maintaining a +-.001” tolerance as a standard.
This can be accomplished while drilling as many as 13 holes per second, as the part rotates through the laser. Quality of the holes can then be improved as the laser is refocused with two additional laser firings taking place on the same holes. The Y.A.G. laser can run in a weld, trimming or drilling mode up to 400 watts. The huge benefit of laser welding is a highly localized heat zone, ideal for thin wall or thru welding applications.

Laser Welding

CO2 lasers with up to 900” per minute travel, coupled with 2500 watts of power, allows Weldmac to trim the most complicated parts in very short succession .
We utilize the CO2 lasers for contoured cutting. The C02 lasers operate utilizing 2500 watts of power and can cut up to ½” thick stainless steel material. The close tolerance achieved through the laser cutting process provides for a perfect fit going into welding or assembly. The laser cutting also produces an edge with less than .0002” recast, which is easily removed in a deburing process.

Metal Fabrication Parts In The YardMetal Fabricated Components

Metal Fabricated Parts