Ironworkers
Edwards and Baileigh Hydraulic and Manual Ironworkers
Introducing Ironworkers
A Hydraulic Ironworker is a machine that can punch a variety of differently shaped holes onto any material, shear flat bar, stock material and angle bar/angle iron, notch corners, and also bend materials in steel plates and profiles.
The name is now used to refer to the machines themselves, made by at least a dozen brands, in many countries, including Edwards manufacturing in Albert Lea, MN. Ironworkers generate force using hydraulic systems.
An Ironworker is made of heavy steel metal to handle the stresses generated during use. Ironworkers are rated according to tonnage; ratings usually start at 25 tons and go as high as 220 tons. High-strength carbon steel blades and dies of various shapes are used to work the metal.
An Ironworker machine is a fabrication unit used in metal workshops to process metal in various ways. A typical Ironworker can shear, punch, notch or even bend metal products without requiring extensive setup times or complicated jig setups.
This makes these machines incredibly versatile and a useful addition to any metal workshop.
How Ironworkers Operate
There are several different Ironworkers on the market, ranging from manual home hobbyist machines to large, hydraulic production units that allow for more detailed fabrication of metal products.
A typical Ironworker consists of a fixed frame, motor, safety shields, metal working pieces as well as a control panel/foot pedal. Most machines are electronically and/or hydraulically controlled, and some typical working principles include:
- A sliding plate with a cutting edge to shear metal materials against a fixed edge
- A movable punch to produce customizable holes in a variety of metal materials
- A ram or sliding arm to force metal products around a fixed point or into a die
- A single operator can complete most actions using a foot pedal or button, with many actions often repeated in quick succession for a steady production flow
Productivity Tips for Ironworkers
Most Ironworkers have three or four workstations. Some models come with interchangeable stations that can receive attachments available to tailor the Ironworker to your needs. Think of it this way, you can customize an Ironworker to your exact needs and specifications and the flexibility of these customizations makes an Ironworker the most versatile machine in your workshop.
Other things to consider about Ironworkers is that they are compact which allows for fast and easy transitions between fabrication operations: Punch, shear, notch, bend, or cope all in one machine. Electric foot pedals with integrated jog control and adjustable electric stroke control are only a few of the benefits of today’s Ironworkers.
Safety and Maintenance of Ironworkers
Ironworkers are built with safety in mind, but they still present hazards that must be addressed and thoroughly thought out before they are operated:
- Proper Power Source: An Ironworker should never be operated from any power source that does not match the voltage rating stamped on the equipment.
- Lock Out Power Before Servicing: Immediately replace guards after adjustment, repair or service.
- Shear/Crush Hazard: Moving parts can cut and crush. Keep hands clear while operating.
- Wear Personal Protection: To avoid physical hazards, always wear personal protective equipment. Wear protective eyewear, clothing, gloves, footwear, head-gear and hearing protection while operating or servicing this machinery.
- Hydraulic Hoses and Cylinders Are Under Pressure: Pressurized fluid can pierce the skin and cause severe injury.
- Do Not Operate With Guard Removed: Physical barriers and guards have been designed and installed to protect the operator from moving parts that can pinch, cut and crush. Keep hands clear while operating.
General Maintenance To Be Done to Your Ironworker
- Daily:
- Clean your Ironworker daily with a brush and soft cloth lightly moistened with a mild, water-based detergent solution. Remove filings, dirt, dust, grime, and excess lubricant from working surfaces. All clean surfaces must be fully dry before powering up the machine. Grease all machine guides and pins supplied with a GREASE DAILY designation with NLGI Grade 2 (NLGI Service GC-LB) or equivalent premium, heavy-duty lubricant.
- Weekly:
- Check blade tolerance. Maintain 0.010 clearance between fixed and movable shear blades on 40, 50, 55, 60 and 65 Ton models at all times. Maintain 0.015 clearance between fixed and movable shear blades on 75, 100, 100D, and 120 Ton, 110 Elite, and 110/65 DO Elite models at all times. Insert a feeler gauge between fixed and movable blades to verify proper blade clearance and shear tolerance. Adjust the tolerance of shear blades by relieving the locking nuts that secure the gib-pins to the Ironworker frame. Once loose, rotate gib-pins to push the operating center against the frame. Gap the angle and bar shear blades with the specified clearance and tighten the gib-pin lock nuts. Failure to maintain proper clearance will result in lower quality cuts, damage to the blade, and blade pockets and the potential to damage the Ironworker frame.
- Monthly:
- Check gib-pins for lubrication and snugness to the operating center. Tighten gib-pins and locking nuts to maintain blade clearance as indicated above. Gib-pins are wearing parts so order replacement gib-pins through your Edwards Distributor or Edwards Mfg. Co.
- Check the ISO Viscosity 46 hydraulic fluid level monthly. Maintain the correct volume of hydraulic fluid in the reservoir as indicated.
- Contaminated fluid will compromise your cutting operation.