1. Lower power consumption: a typical blanking press or turret punch consumes 50kW of power in total. A 4kW laser system uses 10kW of power total typically.
2. Safety: A blanking press has a large blade that moves rapidly up and down, and doesn't necessarily have safety features to prevent a hand getting caught in it. A fiber laser is required to be enclosed by a light tight box which means they are designed to run without human intervention during cutting.
3. Material Scrap savings : Due to a cutting tool requiring material on either side of the cut, a border of at least 1/2 inch is required. For a laser, if parts share a common outline, they may be cut with a single cut, with no scrap. A minimal scrap skeleton may also be cut, as small as 1/16 of an inch or even less for some materials.
4. Cutting properties: a blanking die can only cut materials up to a maximum tensile strength. A laser can cut any strength of material, as long as the material can be melted.
5. Low maintenance: A blanking press or turret punch has expensive tools that must be sharpened and stored regularly as different parts are cut. A laser can change parts by changing programs, and requires relatively inexpensive replacement parts like lenses and nozzles.
6. Flexible operation: A traditional blanking line has a tool for each part that is a fixed design that is very high investment, typically costing somewhere on the order of $50,000 per tool, depending on the shape. A turret punch is somewhat better in that you can program any shape that can use that set of smaller shapes to make something, but if you want to change a dimension on a hole or something of that nature, design change is limited to the tools available, or a new tool must be purchased and it must replace an available slot on the turret. These tools are less pricey, but still require regular maintenance, which is a somewhat specialized task, so the labor costs will be higher. A laser can change the cutting profile on the fly, and typically takes less than an hour to reprogram, costing approximately $60 to apply a change, and that is a high estimate of the cost.
7.Improved edge quality: Since presses and punches are shearing through the material, which literally stretches the edge until it breaks, the top side of a part typically has a rounded over edge, while the bottom has a bunch of stretched ribbons that are very sharp. These are sometimes required to be cleaned off with an abrasive, which is a secondary process that adds to price. A laser, when properly focussed and set for a material, cuts a part with an edge with a mirror-like surface, the top edge remains square, and the bottom edge is smooth to the touch.
8. Faster changeover: A blanking press requires 30 minutes to change between cutting different parts, as the dies must be swapped out. A laser can change programs instantaneously, leading to time savings and allowing for smaller production runs to have a decreased price.
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Advantage: Optical comparators provide high magnification for accurate measurements, facilitate quick and easy inspection of parts, and are non-contact systems that prevent damage to sensitive components. Disadvantage: They may have limited accuracy compared to other metrology tools such as CMMs, may require skilled operators for precise measurements, and can be less effective for measuring complex or 3D features.
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