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New handling instructions

May 9, 2006

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In 2005 precision stamper Weiss-Aug of East Hanover, N.J., achieved a reject rate of less than 1 part per million. The company credits the success to meticulous planning and almost flawless execution. Such an approach applies for Weiss-Aug even when it comes to uncoiling metal.

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Handling engineering changes in automotive parts

May 9, 2006

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Control of engineering changes for automotive components and assemblies requires cooperation and communication among groups within a company, as well as with outside suppliers. Changes must be initiated, communicated, implemented, and verified enterprisewide.

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When a good tube bends bad - Part II

April 11, 2006

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Editor's note: This is the second part of a two-part article that examines tube bending defects, possible causes, and suggested remedies. Part I discusses surface defects; Part II covers other defects, such as wall thinning, ovality, buckling, and fractures. When the stress on the...

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10 steps to winning a government contract - Step 8

April 11, 2006

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Now that you've written your proposal, it's time to submit it to the government. Before you send it off, make sure, one last time, that everything necessary in your bid proposal is there.

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Modern flying shear tube cutoff systems - Part I

April 11, 2006

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Modern flying shear tube cutoff systems comprise state-of-the-art mainframes, tools, and controllers. This article, Part I of a two-part series, discusses the different types of mainframes, their capabilities, and construction. It describes and includes images of the construction process from start to finish.

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The regrind process for tube mill tooling - Part I

April 11, 2006

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Although most tube and pipe producers don't get too involved in the regrind process, it is crucial—reconditioning roll tooling can extend its useful life by 15 or 20 times. The regrind process reduces the producer's overall out-of-pocket tooling expenses, while helping to ensure the tooling continues to produce a consistent-quality product at the required speeds. A better understanding of the process, especially familiarity with the types of flaws that reconditioning can and cannot resolve, can go a long way toward a better working relationship between a tube and pipe producer and its regrind contractor.

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Intelligent Robotic Welding

April 11, 2006

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Planning a productive intelligent robotic welding workcell requires many phases. These include preplanning with a computer simulation, getting the virtual results to translate into real-world operation, using multiple robots within the workcell for material handling as well as welding, and utilizing vision systems to help compensate for part variations.

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Eliminating problems that cause flaws

April 11, 2006

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Problematic material? Yes, bad coil is out there. It could be mislabeled; the yield strength could vary from one part of the coil to another; it might have damaged edges; and so on. In the second part of this two-part series, columnist Bud Graham discusses steel coil, how its characteristics can vary, and how these variations can result in substandard tube.

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Processes for hydroforming sheet metal

April 11, 2006

Part three of a three-part series on sheet hydroforming, this article reviews the SHF-P and SHF-D processes.

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Die Science: Guidelines for forming high-strength material

April 11, 2006

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High-strength materials are becoming more common in stamping, especially for the aircraft and space industries. Although they all have their own specific features, they have some common characteristics and typical reactions to stretching and drawing.

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Management matters

April 11, 2006

Creating a sound workplace is good not only for your business and your employees, but for society. When it comes to labor costs, the U.S. cannot compete with China and India. Our only chance of remaining competitive is to work more effectively and efficiently and to develop new innovations continually.

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auto show picture

Auto show lessons

April 11, 2006

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The North American International Auto Show held in Detroit is a stage for automakers to display their latest and greatest; it also serves as a harbinger of what's coming at suppliers over the next few years.

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Getting autobody welding down cold

April 11, 2006

Volkswagen's automobile manufacturing facility in Saxony, Germany, was spending more time and effort on post-weld finishing operations than it wanted to, but because of the requirements the company was dedicated to meeting, not much automation was possible. Through its research, Volkswagen decided to invest in cold metal transfer welding, which helped the company save time and effort while keeping up its product quality.

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Home-court advantage

April 11, 2006

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A company bid and won a contract from a company who was previously sending its work to Mexico. The company bought a computer-controlled pipe cutting machine to automate the process and cut lead times.

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Stamper, prototyper, assembler, or fabricator

April 11, 2006

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Newspapers and business magazines are filled with stories about offshoring, layoffs, and plant closings. Quasar Industries, a prototyping and low-volume production shop near Detroit, has bucked this trend and recently increased its manufacturing capability when it purchased a new building. A diverse fabricator, the company provides tooling development and also does stamping, laser cutting and welding, robotic welding, tube fabrication, and machining. The company's client base includes the automotive, appliance, and aerospace industries, among others. But all the equipment it has and processes it performs don't make it successful. Its success is a result of its employees' expertise and its corporate culture.

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