Kzell Metals – A Variety of Capabilities

 

Laser

  • Bystronic Bystar 4020
    • 4400 watt solid state CO2 laser cutting system.
    • Equipped with 2 meter by 4 meter shuttle tables
    • Automatic load and unload material handling system.
    • 1” mild steel maximum thickness
    • 3/4” Stainless Steel maximum thickness
    • 3/8” Aluminum maximum thickness
    • 80” x 157” maximum sheet size
    • +/- 0.004” machine cutting accuracy in 1 meter area.
    • Rotary 4th axis for tube and pipe cutting
    • ½” diameter to 10” diameter
    • 12 foot maximum part length
    • Controlled pulse pierce for small hole cutting
    • Cut tap drill size holes ready for tapping
    • Pulse cutting for detailed features in heavy mild steel plate
    • Equipped with high volume high purity nitrogen assist gas supply to produce oxide free (non discolored) cut surfaces on Stainless Steel cuts through 3/4”

     

CNC Press Brakes

  • Bystronic Byler PR250 IPC
    • 250 metric tons
    • 13.3’  (4m) bending length
    • Deep Throat
    • Extra ram travel
    • Wila new standard segmented precision tooling
    • 6 axis CNC back gauging
    • 2 axis ram programming
    • Automatic pressure control produces same angle with different lengths of material
    • Automatic sheet spring back compensation and high-precision sheet thickness measurement
    • Hydraulic dynamic crowning producing accurate bends the full length of the bend
    • +/- ½ degree repeatability
    • Offline programming
    • Fast setups
  • Bystronic Byler PR150 IPC
    • 150 metric tons
    • 10’  (3m) bending length
    • Deep Throat
    • Wila new standard segmented precision tooling
    • 6 axis CNC back gaging
    • 2 axis ram programming
    • Automatic pressure control produces same angle with different lengths of material
    • Automatic sheet spring back compensation and high-precision sheet thickness measurement
    • Hydraulic dynamic crowning producing accurate bends the full length of the bend
    • +/- ½ degree repeatability
    • Offline programming
    • Fast setups

     

Robotic Welding Cells

  • Panasonic Performarc 360S
    • 1.9 meter reach 6 axis articulated arm robot with 6kg payload
    • 3AC servo axes: 2 Head / Tailstocks, 1 sweep rotation
    • Max length 120” x 43” width 1100 lb payload capacity
    • WG350 built in Artificially Intelligent Inverter Pulsed and CV Power Supply (350) Amp
    • Water cooled GMAW torch with setups for Steel, Stainless Steel and Aluminum
  • Panasonic Perfomarc  122s
    •  1.6 meter reach 6 axis articulated arm robot with 6kg payload
    • 2AC servo axes: 2 Head / Tailstocks
    • 1 sweep rotation turntable
    • Max length 60” x 40” width 1100 lb payload capacity
    • WG350 built in Artificially Intelligent Inverter Pulsed and CV Power Supply (350) Amp
    • Air cooled GMAW torch with setups for Steel and Stainless Steel

     

Tube Bending

  • 65 MM Horn Metric CNC Tube Bender
    • CNC control of bend angle, distance between bends and angle of rotation between bends
    •  push roll capable
    • 2 stack tooling
    • 20 foot mandrel
    • Automatic mandrel extraction
    • Mandrel lubrication system
    • Well tooled
  • 3" Tube and Pipe bender with numerical controls for up to 2" sch 80 pipe

 

Welding Capabilities

  • 7' Jetline Longitudinal Seam Welder 7" to 48" diam GTAW
  • Jetline Circumferential Welding Lathe 20" Swing X 96" Long GTAW or GMAW Capable
  • (13) GTAW Welding Machines to 350 amp
  • (6) GMAW Welding Machines to 400 amp
  • (8) Pulsed GMAW Welding Machines 300 amp
  • (2) Miller Aluma Pro micro processor controlled Aluminum Pulsed GMAW machines 300 amp
  • (2) 30 KVA Spotwelder with Electronic Controls
  • (2) capacitance discharge stud welders to 3/8” diameter studs

 

Rolling Capabilities

  • 10' x 3/16" Initial Pinch Plate Rolls (6 inch top roll)
  • 4' x 1/4" Initial Pinch Plate Rolls (6 inch top roll) with 1 1/2 x 1 1/2 x 3/16" Angle Roll
  • 6' x 16 Gage Initial Pinch Sheet Rolls (4 inch top roll)
  • 8' x 1/2" Pyramid Rolls (9 1/4 inch top roll) with Pipe Rolls
  • 1 1/2 x 1 1/2 x 3/16" vertical angle rolls with pipe rolls
  • 3 x 3 x 1/4" Horizontal angle rolls - leg in/leg out

 

Cutting Capabilities

  • 10' x 3/16" Mechanical Shear
  • 12' x ½" Hydraulic Shear
  • 14" Semi-automatic Cold Saw with NC back gage
  • (2) 15" Horizontal Band Saws one with 20’ NC back gage
  • 10" Abrasive Saw
  • 10” compound miter saw
  • 10” vertical band saw
  • 8" Horizontal Band Saw
  • 8" x 8" Amada Corner Notcher
  • 36” vertical band saw
  • 10” vertical band saw
  • 30 amp and 50 amp Hand Plasma

 

Polishing Capabilities

  • 24" Timesaver dry graining machine
  • 9" Timesaver dry graining machine
  • Full range of air sanders, grinders, and polishing equipment

Other Equipment

  • Haeger 824plus hardware insertion press
  • Strippit  1250 Turret punch 60” throat
  • Strippit super 30-30 single hole punch with duplicator
  • Burgemaster turret drill
  • 20” disk sander
  • 4 drill presses
  • 40 ton Rouselle OBI punch press
  • 60 ton Rouselle OBI punch press
  • 80 ton Hydraulic press
  • ALMI abrasive Notcher
  • Burr King #760 belt sander
  • Portable welding fume extractor
  • Bridgeport style vertical manual mill
  • Geka 110 ton hydraulic ironworker
  • (2) pressure pot style blast cabinets.
  • (2) 500lb powered welding positioners
  • 50 lb powered welding positioner
  • 250 lb  manual welding positioner

 

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Inspection Equipment

  • 48 x 72” granite inspection table
  • 24 x 36” granite inspection table
  • Height gages
  • Bore gages
  • Ultrasonic thickness gages
  • Coating thickness gages
  • Calipers and Micrometers

 

Material Handling Equipment

  • Forklifts (2) 8000 lb, (1) 6000 lb, (1) 4000 lb and (3) 2500lb Capacity
  • (2) 3 Ton 16' Flatbed Truck

 

Engineering Software

  • Solidworks 2010 3D Cadd
  • Solidedge 2010 3D Cadd
  • Autocadd 2010
  • Bystronic Bysoft Laser and press brake software
  • Panasonic software for offline programming of Robotic welding
  • Bend Pro software for offline programming of tube bending
  • Glancy Engineering Gendr Layout software
  • Teksoft CNC programming software
  • Visual Cadd 2D