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Establishing a die setup recipe for progressive dies

April 10, 2003

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Setting up a stamping die is one of the most critical steps in a successful stamping process. It's a fact: More damage is done to a die, especially a progressive die, in the first 10 hits than in the next 10,000 hits. Most die damage happens during initial setup, when the material is being fed into the die. Mistakes such as misfeeds, pilot piercing, double metal, sheared cutting sections, and stock hang-ups often occur.

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Superior Service—Why you need it

April 10, 2003

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Service can make or break a business. Of the top nine reasons consumers give for buying a specific product, eight pertain to the abilities of the customer service system, for example, responsiveness, technical skill, and professional attitude.1

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Aluminum Workshop: How to recognize, minimize weld smut

April 10, 2003

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Q: When I weld any aluminum alloy, I see a covering, light gray to black in color, over the weld. I see it when I gas tungsten arc weld (GTAW), but it's worse when I gas metal arc weld (GMAW). What is it? Does it affect the mechanical properties of the weld? How do I get rid of it?A: A common...

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Using narrow-gap GTAW for power-generation equipment

April 10, 2003

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Narrow-gap gas tungsten arc welding (GTAW) frequently is used to weld regular and multilayer high-chromium steel for power generation boilers, stainless steel for nuclear power generation equipment, INCONEL® alloy and other high-alloy steels, and thick-wall stationary pipes.

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Substance abuse in the workplace—Part 2

April 10, 2003

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The toll that substance abuse takes on the abuser, his or her family and friends, and those who become victims of substance abuse-induced accidents and crimes is well-documented.

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Drawing on the strength of people

April 10, 2003

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During the recent economic downturn, sheet metal stampers, die shops, and some job shops experienced layoffs and some closed their doors. However, a few stampers have remained profitable despite uncertain economic times.

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Improving perforating die performance

April 10, 2003

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Perforating is defined as a process of making a hole by removing a slug. During perforating in a stamping operation, a punch shears and breaks a slug out of the part material and then pushes the slug into a matrix (die bushing). The matrix hole is larger than the punch point. A clearance must be maintained constantly around the entire punch point.

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Sizing up pallet uncoilers

April 10, 2003

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Horizontal payoff of coiled materials on pallet uncoilers can help reduce downtime for coil changeover, increase coil handling efficiency, and improve operator safety.

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Solving the mysteries of the fin pass—Part 1

April 10, 2003

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The fin pass was not the first time your father gave you five bucks for your allowance. The fin passes are those forming passes that immediately follow the breakdown or initial forming stages on a tube mill. Their role is paramount in the successful final presentation of the formed tubular section to the welding process.

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Making the connection

April 10, 2003

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Hundreds of types of machined end connectors are used to transmit fluid in fabricated tube and hose assemblies. In recent years manufacturers and end users of these connectors have been developing new methods and processes that eliminate machined connectors and the associated joining operation. Eliminating connectors and joining operations can help save both money and time.

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Lifting the load

April 10, 2003

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Manufacturers face relentless challenges in their efforts to meet changing demand. In their materials handling operation, these challenges include moving materials in tight spaces, providing just-in-time (JIT) delivery to production areas, and ensuring that lift trucks are available when and where they are needed. Maintaining production efficiency requires sturdy, dependable lift trucks that are maneuverable, easy to operate, and easy to maintain.

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Mixed Metals Reactions

April 10, 2003

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Under controlled conditions, aluminum and steel powders can be mixed to create a chemical reaction to produce heat for welding. If you mix these materials under uncontrolled conditions, you will want to call the fire department.

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Making the cut

April 10, 2003

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Band sawing is the starting point for many tube and pipe fabricating operations, and it can help determine the throughput and profitability of your whole shop. Maximizing the productivity of tube or pipe cutoff requires a coordinated approach to saw blades, sawing machines, and your cutoff process.

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Gauging difficult parts at the press brake

March 27, 2003

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Gone are the days when engineers and draftsmen slaved for hours over drafting boards with a pencil and slide rule in hand (does anyone remember slide rules?). Today we've moved beyond slide rules and even beyond hand-held calculators to personal computers and mainframes to do much, if not all, of our design work. CAD and CAM software has made this possible.

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A different battlefield, the same strategy

March 27, 2003

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The war in Iraq is giving the world a firsthand look at modern warfare and its latest weapons. Embedded reporters and military experts give us blow-by-blow details and explain strategies, logistics, aircraft, weapons, and other tools of war. While war coverage and weapons have evolved since previous wars, the basic strategies remain the same, and these same strategies have found acceptance in business.

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