Interface Solutions for Common Challenges of Metal Manufacturing

The metal industry is integral to global industry, encompassing the extraction, production, and processing of ferrous metals like steel and iron, as well as non-ferrous and specialty alloys such as aluminum, copper, titanium, and high-strength nickel. From the massive structural beams used in infrastructure to the microscopic components found in advanced electronics, the quality of every metal product depends on the precise control of force.

In metals manufacturing, specifically production and processing, high-accuracy force, torque, and weighing solutions are essential in managing metals’ inherent resistance to change. Transforming raw ore into a finished part requires immense energy, whether through high-pressure stamping, thermal molding, or high-speed cutting.

Without accurate measurement, the line between successful formation and material failure is impossible to maintain. Force sensors provide the feedback loop necessary to ensure that hydraulic presses apply the exact tonnage required for molding, that drive shafts deliver the necessary torque for rolling, and that alloying ingredients are weighed to the gram for consistent material properties.

Meeting the Challenges in Metal Processing and Production

Metal production occurs in punishing environments that require hardware capable of withstanding high heat, vibration, and immense physical stress. Interface is well-positioned to meet the challenges of metal manufacturing with an array of load cells and instrumentation devices.

Processes such as stamping, forging, and rolling involve forces that can reach hundreds of tons, requiring sensors with high capacity and overload protection. Molten metal processing and hot-rolling expose sensors to high ambient temperatures, necessitating specialized thermal compensation.

In automated cutting and milling, undetected tool breakage can result in scrapped batches and costly damage to machinery. It is important to find reliable solutions that help prevent damage and identify maintenance opportunities.

Interface sensors are frequently used in cutting and grinding operations, which generate metallic dust and debris that can compromise the integrity of standard electronic components. Using ATEX-approved devices and those with higher IP ratings is a good approach for this type of metal production.

Here are some of our products used to meet the challenges of metals processing and production.

• High-Capacity LowProfile™ Load Cells are engineered for massive compression forces in hydraulic presses and forging hammers.
• Stainless Steel and Sealed Sensors are built to withstand the corrosive fluids and high-pressure washdowns common in metal processing facilities.
• Rotary Torque Transducers are used to monitor the efficiency and rotational force of motors used in rolling mills, extruders, and heavy-duty mixers.
• Multi-Axis Sensors are essential for measuring simultaneous forces and moments during complex machining and multi-point forming operations. As more data is required for industrial automation, these advanced load cells are valuable assets for improving processing and production.
• Wireless Telemetry Systems (WTS) enable real-time data collection from moving machinery or high-temperature zones without the risk of cable failure.
• Weigh-Check™ Load Cells are specifically designed for large tank and hopper weighing, where material expansion and contraction occur.

 Metal Manufacturing Application Use Cases

 

Roboform Cutting

Roboforming is a new manufacturing term where robotic systems form different materials. For instance, roboforming sheet metal, or robotic incremental sheet forming (RISF), is a process in which a robot uses a forming tool to shape a sheet of metal into its desired form gradually. A force measurement system can monitor and control the amount of force exerted on the roboforming tool. Interface’s 6A40-6 Axis Load Cell measures forces and torques (Fx, Fʏ, Fz, Mx, Mʏ, Mz) and the BXB-HD44 Data Acquisition log, display, and graph these measurements while sending scaled analog output signals for these axes to the robot’s control system. Learn more here.

Hydraulic Metal Press Machinery 

Hydraulic presses are common in metal-forming processes such as stamping, punching, and bending. It is crucial to test the press to verify that it can exert the needed force and that the produced parts meet the required specifications. For press machines that cut metal, Interface recommends installing a 3-Axis Force Load Cell beneath the plate where metal pieces are to be cut or punched. When connected to the BXB-HD44 Data Acquisition, the force results of different metals cut will be displayed, graphed, and recorded on the customer’s PC. It also has an analog output that can connect to the machine’s PLC in the event of an overload. In high-volume metal stamping, a LowProfile™ Load Cell is integrated into the press to monitor the force applied during each stroke. The sensor helps to ensure the die is fully engaged and that the metal is formed correctly without tearing or wrinkling. If the force deviates from the set parameters, the system triggers an immediate stop to prevent the production of defective parts.

Milling Tool Force and Wear Monitoring

Interface Multi-Axis Sensors in the development and monitoring of CNC cutting tools provide valuable measurements. By measuring the forces exerted in three directions during a cut, engineers can identify the exact moment a tool begins to dull or chatter. The sensor data enables predictive maintenance, ensuring tools are updated or replaced when necessary and maintaining the metal part’s surface quality. Learn more about our Laser Machine Cutting Force App Note.

Foundry Ladle and Silo Weighing

Precise ingredient ratios are vital when creating specialized metal alloys. We recommend an A4200 WeighCheck Load Cells and 1280 Programmable Weight Indicator and Controller Weighing System, in which the load cells are placed beneath silos containing alloying elements such as chromium or nickel. These sensors provide continuous inventory data, allowing for automated batching by weight, which is significantly more accurate than volumetric measurement in high-heat environments. Check out our Silo Monitoring and Weighing App Note.

Rolling Mill Torque Analysis

To produce a uniform sheet of metal, the motors driving the rollers must maintain consistent torque. Rotary torque transducers are installed on the drive shafts to provide real-time data on the resistance of the metal in processing. This information helps operators adjust the rolling speed and pressure to ensure the final product meets thickness specifications across the entire run.

Why Interface for Metal Manufacturing

Interface is the trusted partner for metal producers and OEMs of equipment and machinery. We provide force measurement solutions that require structural stiffness and fatigue-rated longevity for millions of cycles in the most grueling industrial environments.

Our application engineers specialize in matching sensors to the specific thermal and physical demands of metal production, ensuring that your facility operates with maximum efficiency, safety, and product consistency.