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Load monitor

Controlling stamping processes with statistical logic

June 27, 2002

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The output from a load monitor can be expressed using statistical language, such as X-bar, sigma, and Pareto charts, and histograms, to help stampers make decisions regarding their stamping processes.

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Committing to consistent preventative maintenance

June 27, 2002

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Why do we pay lip service to preventative maintenance but seldom practice it?

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Gold earth image

Manufacturing in Mexico

June 27, 2002

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The recession in the U.S. was also felt by Mexico, the 2nd largest trading partner of the U.S. But, through the maquiladora program, which has been in effect for 37 years, the blow was softened.

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Welder, beware

June 27, 2002

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This article provides some statistical analysis, causes for, and tips to consider regarding welding and cutting fire and explosions. It includes a sidebar about governing codes and questions to ask regarding fires and explosions when welding or cutting is suspected in an incident.

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Komatsu Mechanical Press

Evolution of the beast

June 27, 2002

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This article outlines how mechanical presses are changing to meet a new marketplace. Stampers are adding extra stations to create a more complete part and stamping harder alloys. Servo-driven mechanical presses will make traditional flywheel presses obsolete because they use less energy and can be adjusted midstroke. Technological advances include real-time press monitoring, automatic die changes, and computerized troubleshooting.

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Electrode wear in air, oxygen plasma

June 27, 2002

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A trained plasma technician can tell a lot about the health of a plasma system if he learns how to inspect the electrode, understands normal wear patterns, and knows how to spot signs of trouble. This article shows the difference between good and bad wear in air and oxygen plasma systems.

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Good design, set-up, maintenance can keep dies out of repair shop

June 26, 2002

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Take this old maxim to heart: A stitch in time saves nine. The same goes for die maintenance and repair.

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Staying lean in a lean economy

June 18, 2002

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Slow times call for some desperate measures, but losing sight of a lean approach to manufacturing should not be one of them. Take an opportunity that slow times present to evaluate your business and take appropriate steps towards a lean operation.

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Mixing welds & bolts

June 13, 2002

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This article provides background on bolted connections and situations in which welds are added to mechanically fastened joints. It also offers information on AWS code provisions for mixing fasteners and welds.

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Automating reciprocating saw blade production

June 13, 2002

Milwaukee Electric Tool Corporation faced the problem of finding reciprocating saw blade production equipment that could withstand continuous on-demand operation, accommodate a variety of material thicknesses, and fit into its tight floor space parameters. This was solved, after a long search, by using an AIDA gap frame press, which limits frame deflection, has low overall bearing clearance, and a patented overload protection system.

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Anatomy of an abrasive cutting machine

June 13, 2002

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This article discusses the components that make up a modern abrasive cutting machine. Many of the design considerations are based on the characteristics of the cutting wheel. The author also discusses feeding systems, vises, ejection systems, and the electronics and software that control the machine. Also included is some safety information.

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Exploring dry cutting technologies

June 13, 2002

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The evolution of high power dry plasma technology and other cutting methods, such as conventional dual gas PAC, water injection PAC, high precision PAC, and laser for metal fabrication. Variables such as, process speed, cut quality, productivity, and cost per foot are discussed in detail.

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Achieving success with rotary draw bending

June 13, 2002

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This article discusses several aspects of rotary draw tube bending, including machine specifications; tooling and lubrication; tube material; and machine controls. It discusses advantages and disadvantages of single-level and multilevel machines; selecting lubricants and coatings to reduce tool wear; consistency of tube dimensions and the material's characteristics; and how machine controls are programmed or manually set by the operator.

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Forge welding process diagram

Electric resistance welding at a glance

June 13, 2002

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This article provides an overview of electric resistance welding (ERW). It dicusses high-frequency ERW (contact and induction) and rotary wheel contact welding (AC, DC, and square wave). It describes the differences among the processes, as well as the power supplies and weld rolls.

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Examining roll forming machinery, tooling, and lubrication

June 13, 2002

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Given the problems in your roll forming operation aren't attributable to material, you may want to look into machinery setup and especially your lubrication situation to uncover the real culprit.

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