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.
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.
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.
As versatile as the Ironworker is, however, it is possible to purchase the wrong machine—or at least not the best machine—for your application. Important considerations for selecting a machine include its capacity, versatility, safety features, and quality.
The material thickness you process will indicate whether to use an Ironworker or a Turret Punch Press. An Ironworker punches plates up to 1 inch, and sometimes even thicker. Ironworkers usually are used for shorter production runs and applications for which tolerances are not as critical.
Determining capacity is extremely important. Ironworkers typically are rated by tonnage at the punch station. A 40-ton Ironworker should punch a 1-in. hole in 1/2-in. material; a 60-ton machine should punch a 1-in. hole in 3/4-in. material; and an 80-ton machine should punch a 1-in. hole in 1-in. The first step, therefore, is to determine the maximum material thickness so you can establish the tonnage range needed for your punching application. Examine the steel rack and the product that you are fabricating. Determine the maximum hole diameter to be punched, the maximum thickness of the material to be punched, and the maximum thickness and width of the channel, angle, and rod to be sheared or bent.
The material or part width plays a part in your Ironworker selection. The throat depth of an Ironworker punch station should be greater than half of the part or material width. Material length, however, really is not an issue. An Ironworker can process almost any material or part length.
Because many different types of steel and ranges of hardness in mild steel exist, it is advisable to get a machine that is at least 20 percent larger than you think your everyday use requires to avoid getting a machine that is too small. Most machines are rated for material with tensile strengths between 60,000 and 65,000 pounds. When punching hard steel, such as stainless steel, it is better to increase the estimated tonnage by 50 to 100 percent, depending on the grade of steel. Be sure to compare the rating of the machine not only in tons but also in the diameter of the hole and the thickness of the material it can punch. Ironworker tonnage ratings can vary from Ironworker to Ironworker.
All Ironworkers are equipped with flat bar shears. The main differences between flat bar shear stations are the length and the approach of the blade to the metal.
Keep your Ironworker clean 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.
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, 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.
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.
