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Die Science: 7 ways that part material affects die design and the forming process

March 16, 2017 | By Art Hedrick

I recently had an opportunity to train some young product designers. During this training session, one of the product designers brought me a print of a project he was working on. It was a contoured, deep-drawn part with many intricate features, and he had a lot of questions about the...

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R&D Update: Practical use of servo hydraulic cushions in stamping operations

March 15, 2017 | By Ali Fallahiarezoodar, Darrell Quander Jr., Pratik Mehta, Taylan Altan, Ph.D.

In deep drawing, with or without draw beads, the sheet metal blank is restrained at the periphery of the die by the blank holder force (BHF). The relative motion between the punch and the die forces the metal to flow into the die cavity (see Figure 1). The quality of the formed part is determined...

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Ask the Expert: Which equation adds up to smooth strip feeding in progressive dies?

March 14, 2017 | By Thomas Vacca

Q: Many people believe that the feed height = passline height. But the way I learned it, feed height + lift height = passline height. If feed height + lift height = passline height and you feed the material, when the die closes, with the stock check open, the material will be pushed down by the...

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Die Science: Finding the true cause of poor-quality parts

March 13, 2017 | By Art Hedrick

As a professional consultant, I find it both amusing and frustrating how many times dies are accused of being “bad.” Certainly, poor-quality dies exist. In my career I’ve seen dies that are well-engineered, precision tools, and I’ve seen dies that might as well have been made from sawdust...

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Die Science: Open wall angles versus vertical walls

March 10, 2017 | By Art Hedrick

All too often designers employ open wall angles simply because they’ve been told that they are easier to form than vertical walls. Although this statement may be true for many part geometries, it is certainly not true for all. Sometimes a draft angle can be desirable; other times it can be...

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Die Science: Maximizing tool steel life

March 9, 2017 | By Art Hedrick

One of the questions I get asked most frequently is “What is the best tool steel?”To me, that’s like asking, “How long is a piece of string?”There is no “best” tool steel. To choose the appropriate tool steel for a given application, you need to consider all of the situations and...

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Advancements in furnace design improve hot stamping

March 9, 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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Die Science: Fitting the drawing pad for optimal metal flow

March 9, 2017 | By Art Hedrick

Production stampers and die builders understand that the process of designing, building, troubleshooting, and maintaining a drawing die can be very difficult. Unlike metal cutting tools, drawing dies can take a great deal of time to develop, especially if the final part will be very deep and...

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Die Science: Choosing the right blank type for your stamping application

March 7, 2017 | By Art Hedrick

Selecting the proper blank size and profile often is critical to achieving a successful stamping process. Attempting to form a part’s geometry with the incorrect blank size or shape can result in splitting or excessive thinning. The blank shape also affects the consistency of the trim line...

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Die Science: Finding the right method for die shoe guidance

March 7, 2017 | By Art Hedrick

Choosing the proper guidance and heeling method is critical to the success of any stamping operation. Improperly guided and heeled die shoes may result in cutting and forming sections interfacing with the wrong clearances, severe deflection, and die damage. Guide Pin and Bushing BasicsGuide pins,...

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Die Science: Under pressure to find the best pressure pad

March 7, 2017 | By Art Hedrick

Pressure pads are critical to the success of a stamping operation. These pressure-loaded plates, either contoured or flat, perform the function of holding, stripping, or controlling metal during cutting or forming. Three Basic TypesAlthough there are many specialty pressure pads, they can be broken...

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Die Science: The time and place for die polishing

March 7, 2017 | By Art Hedrick

As a young apprentice tool- and diemaker, I was taught that when building a forming die for a drawing, stretching, or bending operation, all forming sections had to be polished to a mirror-like surface finish in the direction of metal flow. Not doing so would result in poor material flow, premature...

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Die Science: 4 causes of poor strip feeding in progressive dies

March 6, 2017 | By Art Hedrick

Most stamping plants have experienced poor strip feeding in a progressive die. Not only can this problem cause great frustration, but it also can lead to die and press damage, poor quality, scrap, safety hazards, and downtime. Four potential causes usually are to blame. 1. Die Alignment The...

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Die Science: Drawing pad basics

March 6, 2017 | By Art Hedrick

The drawing pad, otherwise known as the binder, blank holder, or pressure ring, is one of the most important components of a drawing and stretching operation. Its shape, thickness, deflection, and surface quality are critical features. In addition, the material it’s made from is crucial....

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Die Science: Choosing between pressure pads and stripper plates

March 6, 2017 | By Art Hedrick

Many problems result from a poorly designed or completely absent pressure pad. In the May/June 2013 issue of STAMPING Journal, I discussed the characteristics of the three kinds of pressure pads. Now it’s time to review the pressure pad styles and see how they compare to stripper plates. Stripper...

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