est Central Steel Inc.’s customers lamented having to send parts away to be processed. WCS saw an opportunity to fulfill a growing need for its customers, enabling it to produce parts and supplement supply chains, offering a local solution.
“We create parts our customers need and it helps them grow their businesses faster as well as reduce costs,” says Bill Pattison, WCS director of business development. “Rather than selling the stock steel, we realized there was an opportunity to help our customers and [help] our business grow by producing the parts they need.”
Willmar, Minnesota-based WCS expanded its facilities and purchased additional bending machines from Ursviken, including 13-ft., 350-ton and 30-ft., 1,100-ton custom-built press brakes. “With the additional machines, West Central Steel is able to provide new services. This includes up to 30-ft.-long parts at 1 in. thick,” says Marten Weidgraaf, general manager for Ursviken Inc., Elgin, Illinois.
In order to run the new units, WCS hired multiple press brake operators. “The biggest selling point for us was Ursviken’s hands-on service,” says Brian Kath, operations manager. “When we installed the machines, they were here to provide extensive training.
Customers wanted WCS to process larger pieces and eliminate or reduce the need for splice welds. “Customers no longer need to perform additional processing since we are able to run [more sizes] on our 30-ft. press brake,” Kath says. “That’s important when it’s already difficult to find experienced welders. If we make the part to fit and eliminate any additional welds, that allows our customers’ engineers to include longer parts into their designs with less welding.”
“It is commonly used for most of our production, and we have a large variety of different slip-on nose radius tips ranging from 1/4 in. up to 1.5 in. that can easily be changed,” Weidgraaf says.
In a job shop environment, especially when forming a single large plate, it’s common to let the press beam stop at the bottom dead center (BDC). The operator can bring the ram up and not worry about whether the plate is held stationary at a targeted/programmed angle.
Proper tool storage for upper segmented punches is another example of tool changeover efficiency. Ursviken tooling design is based on short segmented upper radius tools that can be slid from the tool rack onto the upper tool adapter, on which only tools for the upcoming job are loaded. The press beam can be lowered and aligned with the tool rack at different levels, so the tool rack can be moved to the correct position, storing the tools that are no longer required and advancing the tool rack to the new tools to be loaded.
The Ursviken Toolrack design can be adapted for any radius tools required and keeps the tools safe, clean and close to the machine.
Adds Weidgraaf, “It is also used to better understand how to manipulate the plate in the shop on the press brake and to better understand all tooling requirements.” Once the solid model is imported, unfolded and the tools available by the press brake have been selected, “you can create an actual bend simulation. The program will automatically recalculate and compensate for the correct stretch and springback based on the tools selected so that the blank to be laser or plasma cut is the correct unfolded length.”
In order to bend a U-shape model with two 90-degree bends with different flange lengths as well as unsymmetrical features throughout the plate, the press brake operator imports the part from the network onto the Cybelec Control system. The operator selects the upper tooling the program calls for and loads this in the press brake. The lower CNC variable die will automatically position to the programmed V-opening and the rear gauges will position according to the programmed position for the first sequence; front support is also activated.
“The operator will get a true 3D representation on the HMI display of the Cybelec controller from the program that was created offline,” Weidgraaf says. “[He]can see how to position the material based on the displayed simulation.”
Operators must still understand the overall process but they have a much better chance of success than if they had to figure it out themselves, he says. “A more skilled operator may prefer to program the machine, but a less skilled operator will have one less thing to worry about.”
There is a face mask mandate in Minnesota. For workers managing tasks in 90 degree heat, “wearing a mask isn’t comfortable but we’re doing our best to maintain safety,” Kath says.
WCS serves several industries. Although some customer sectors have seen demand declines, others have increased business. “I can’t predict too far into the future but where we’ve seen some customers slow down we are seeing others pick up,” Pattison says.
Over the years, WCS has worked to expand its capabilities, including the installation of a 1,100-ton press brake that arrived via barge from Ursviken’s headquarters in Sweden. “Our customers that used to have to send material to Chicago to be bent are able to turn to us to have it processed here in Minnesota,” Kath says. “It’s opening up opportunities for them and for us as we work toward helping our customers become more profitable.”