Company extends its capabilities to new parameters with the introduction of the Peak Performer part levelling machine from Kohler and a new large format DNE 15kW fiber laser with bevel cutting head and a 30 metre bed.
Levelling/flattening and destressing of metal components and blanks that have been processed on a fiber laser or plasma machine at TW Profile Services has jumped to a new level at the company with the introduction of the Part Performer machine that is manufactured by German company Kohler Maschinenbau.
Sheet metal and plate delivered to a metal fabrication company may appear perfectly flat, but looks can be deceiving—especially with metal. What seems flat at first often loses its shape during fabrication. This is due to the material’s journey before reaching the shop. Sheets and plates originate from slabs that is produced into coils and plates, Coils are uncoiled, straightened, and cut to length at metal service centers. Despite their flat appearance, these sheets retain internal stress, which is embedded in the material’s grain and the same is evident in Plates.
The new Kohler part levelling machine – the Kohler Peak Performer 130P.2500, which was supplied and installed by Retecon
“In addition to material arriving less than perfectly flat, one of the biggest challenges for any flat metal processor using heat-based cutting methods—whether laser, plasma, or oxy-fuel—is the distortion or warping that occurs. This deformation increases downstream processing requirements and labor costs,” explains Shaun Waring, Director at TW Profile Services.
“Take for example robotic welding. This process has increasingly established itself on the shop floors of many customers. So if our customers can fully profit from the advantages robotic welding offers, components and blanks need to feature the highest precision in terms of flatness and stress-relieving. That’s something we can only deliver with the introduction of our new Kohler part levelling machine – the Kohler Peak Performer 130P.2500, which was supplied and installed by Retecon.”
“We believe it is the first of its kind in South Africa and certainly the first that Kohler has had installed locally.”
The new Kohler part levelling machine will only be levelling cut parts initially
From decoiling to levelling
“Few companies in South Africa are levelling beyond the coil stage to meet growing demand for steel sheet that arrives flat and should stay flat after laser, plasma or waterjet cutting. When steel is produced in coils, it undergoes significant rolling and winding processes that introduce internal stresses into the material. To create flat sheets, these coils are unrolled, straightened, and cut to length at service centres. However, despite appearing flat, the material retains residual stress within its grain structure. When subjected to cutting processes like laser or plasma cutting, the heat input causes uneven expansion and contraction, which can release these internal stresses and lead to warping or distortion. Depending on the thickness and composition of the steel, parts may curl, bow, or develop a wavy shape, making downstream processing more difficult and increasing the need for additional levelling or rework.”
“Any advantage that is gained in this fashion is welcomed but many know that further downstream processing will still need to be done.”
Inside the new Kohler part levelling machine
“You can use a plate roll but with the plate roll, you basically chase the flatness deformations out of the components. It can takes several runs or more to get rid of them. This is time-consuming and labour-intensive. As orders grow, you can then have components begin to pile up in front of the plate roll.”
“You could also manually tweak the components to flatten them or use a press brake with custom-built tooling but generally it is a very expensive option that doesn’t necessarily have the desired result.”
Kohler levelling machine: Only processing cut material
It is still too early to assess the leveller’s performance at TW Profile Services as the machine was only installed in December 2024 and in future the company will closely monitor its output so it can talk about, for example, reduction in throughput times. However, the company thoroughly evaluated the options, always carefully weighing their potential to add value.
New large format DNE 15kW fiber laser with 30m by 3m bed that is equipped with a bevel cutting head
“We were looking for a machine that would really be an asset to our processes and this we have found in the Kohler. What we can talk about is the versatility of the machine including the processing of components of all shapes and sizes, without compromising on quality. Besides the levelling and destressing, a big advantage of this machine is that we only process the cut components. You don’t have to spend money on processing the de-nested material that is going to end up in a scrap yard,” explained Waring.
There is another factor that takes processing with the Kohler machine to the next level. With the plate roll, you could characterise material solely as being flat or non-flat. The leveller, however, makes it possible to adjust flatness tolerances, which has substantially boosted the company’s levelling precision. Now you can even ask customers, ‘How flat do you want it?’. Additionally, the simultaneous stress-relieving of parts, sheets, and plates makes downstream processing much more efficient.
“Our Kohler levelling machine is fitted with an advanced cleaning system allowing for quicker cleaning when swopping to a different material to avoid cross contamination. Tension-free and level sheets are a precondition of achieving the absolute best quality in downstream manufacturing processes when welding, bending, fabricating or assembling.”
Test components that were cut on the new large format DNE 15kW fiber laser
Actively looking for new clients
“Currently we are doing a number of time-saving tests with local clients and will talk about those once qualified. We will however be looking for new clients because we will have the capacity to accommodate them.”
New large format DNE 15kW fiber laser with 30m by 3m bed that is equipped with a bevel cutting head
“Making use of oversized lasers is not new to us. For many years we have had them in our production line. But technology has taken giant leaps forward and the demand for shorter lead times and more beneficiating processing options has also grown. We have always been able to offer the variable angle, bevelling, counter sinking and a number of other processes but not having them done on the same machine. Like a CNC lathe you need a machine that can offer multitasking processes or as many like to call it ‘Done-in-One’.”
“We needed to say goodbye to tedious setups and manual adjustments. Hence we have invested in a new large format DNE 15kW fiber laser with 30m by 3m bed that is equipped with a bevel cutting head. Whether we’re working on thick plates or intricate designs, we now have the full range covered.”
Bystronic 15kW fiber laser with 12m by 2.5m bed equipped with nitrogen
“Before acquiring the latest DNE fiber laser last year, we invested in a 15kW Bystronic fiber laser. with a bed size of 12m by 2.5m. Aside from its size, the key difference in this machine is that it is equipped with a nitrogen plant. A nitrogen laser operates using nitrogen gas as its active medium.”
“Before acquiring the latest DNE fiber laser last year, we invested in a 15kW Bystronic fiber laser with a bed size of 12m by 2.5m. Aside from its size, the key difference in this machine is that it is equipped with a nitrogen plant. A nitrogen laser operates using nitrogen gas as its active medium.”
“Besides costs there are many other advantages in using nitrogen. That laser is capable of cutting stainless steel up to 50mm. The plant produces enough nitrogen to efficiently power the 15kW laser.”
“Our vision is to continuously invest in cutting-edge technology to drive innovation and growth. But it is also our vision to take away those boilermaker hours away from our clients. We want to offer them a service that lightens their load, and saves them money, with having to do the least amount of downstream processing.”
For further details contact TW Profile Services on TEL: 011 894 3031 or visit www.twprofile.co.za
