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Advancements in furnace design improve hot stamping

February 16, 2017 | By Borek Dvorak, Jad Tawk

New roller furnaces for hot stamping have been designed using finite element method (FEM) analysis for numerical simulations of heating processes and heating power distribution. The advanced designs focus on optimal heating, modern roller drives, a new approach to the furnace’s input and output without movable parts, and other items with respect to the optimal technological and technical aspects to enhance the ability to perform nonuniform (Taylor) tempering and hardening.

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Achieving successful stamping of AHSS

January 16, 2017 | By Daniel J. Schaeffler

Forming products from advanced high-strength steels is a challenge. Understanding how these materials react during press feeding, straightening, blanking, and forming is necessary in designing production processes that run as efficiently as possible.

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R&D Update: Predicting springback when bending AHSS and aluminum alloys, Part II

January 12, 2017 | By Aanandita Katre, Ali Fallahiarezoodar, Taylan Altan, Ph.D.

Editor’s Note: This article is Part II of a two-part series. Part I, which appeared in the November/December 2016 issue, discussed the challenges of determining Young’s modulus, one of the most important parameters for springback prediction.

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Die Science: What makes a topnotch metal stamping plant?

January 11, 2017 | By Art Hedrick

Some stamping plants and die-building facilities are far more productive and efficient than others. Each shop typically has its own niche, as well as its own strengths and weaknesses. So what are the key decisions managers make that result in a successful stamping or die-building shop? Staffing...

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Ask the Expert: How do we fix our slug pulling problem?

January 11, 2017 | By Thomas Vacca

Q: We are developing what we thought would be a fairly straightforward stamping. We are blanking a rectangular shape, 2.15 by 2.35 inches and 0.004 in. thick, from 301 stainless steel. A simple, single punch blanks the part through the die chase in one shot. But as we brought up the stamping speed...

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Using key performance indicators to measure progress

January 4, 2017 | By Bill Frahm

To improve a process, you need to measure the results and compare them against expectations. In many instances, a metal former needs to define key performance indicators and keep track of them to determine just how its shop is performing.

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Colorado stamping manufacturer’s solar array sees 5-year ROI

December 15, 2016 | By Kate Bachman

Colorado stamping manufacturer Qualtek Manufacturing installed a solar array on its warehouse and office with a wind power purchase agreement, and replaced inefficient heat treatment furnaces.

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Connecting the toolroom with ERP software

December 15, 2016 | By Michael Sweet

Software integration that links toolroom data and processes with the rest of the company can uncover time savings, harmonize schedules, and unleash a wealth of information from which management can improve the business.

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R&D Update: Predicting springback when bending AHSS and aluminum alloys, Part 1

December 5, 2016 | By Aanandita Katre, Ali Fallahiarezoodar, Taylan Altan, Ph.D.

Editor’s Note: Part II of this article, which will appear in the January/February 2017 issue, will discuss the results and case studies of the newly introduced inverse analysis method for improving springback prediction. In the automotive industry, the use of advanced high-strength steels (AHSS)...

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Die Science: Estimating die cost

December 2, 2016 | By Art Hedrick

Before receiving a contract to design and build a die, the building shop must quote a price to the customer. Because every die usually is a one-of-a-kind tool, the process of quoting tooling cost is not always easy. The person estimating this cost must have a good understanding of sheet metal...

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Ask the Stamping Expert: The continuous improvement approach to die design

December 2, 2016 | By Thomas Vacca

The “10 Die Design Laws,” which appeared in the September/October 2016 issue, are most effective when used along with a continuous improvement approach. At the end of every tool build and final development cycle, the die design team should review what went well and build on those strengths, but...

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57-year veteran tool- and diemaker “started somewhere”

November 18, 2016 | By Kate Bachman

Of all of the roles 57-year veteran tool- and diemaker Paul Rettberg has had, the one he has enjoyed the most is the one he fills currently … as a teacher.

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6 Q&A about compact in-die transfer tooling

November 18, 2016 | By Bob Gunst

Compact in-die transfer tooling technology brings the flexibility of a press-mounted transfer system to small-press and small-part applications. The small transfer system mounts directly to the stamping die, becoming part of the die. The in-die transfer tool is set up and run in continuous mode, just like a progressive die.

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Xtreme MRO keeps heavyweight stamper on track (video enhanced)

November 18, 2016 | By Kate Bachman

If an ounce of prevention equals a pound of cure, what is it worth when you’re stamping thousands of tons? To Rockford Toolcraft, it’s priceless. The $100 million annual sales stamping manufacturer specializes in stamping heavy-gauge material up to ¾ inch thick. Its maintenance, repair, overhaul program must be topnotch to keep operations moving. The millwrights and electricians who maintain, repair, and overhaul the 60 massive, high-tonnage mechanical presses are highly skilled, very experienced, and ready at a moment’s notice to get the presses back on track ASAP. Here’s how the company keeps its fleet of presses humming.

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Using strengths and experiences to boost profitability

November 14, 2016 | By Bill Frahm

Metal formers are more than just suppliers of stamped parts. They understand how material reacts during the forming process and how downstream processes can be set up to handle stamped parts efficiently. This is valuable knowledge and should be shared with customers to solidify relationships and possibly boost revenue opportunities.

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