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Metal spinning versus flow forming

October 27, 2016 | By Dirk Palten, Josep Mont

Metal spinning and flow forming are similar processes. In some respects, flow forming can be considered a specialized kind of metal spinning. But the two processes are different, and each is designed to meet different application requirements.

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Stretch flanging and hole expansion with AHSS

October 25, 2016 | By Daniel J. Schaeffler

New, stronger steels have forced metal formers to rethink what they have always done in the pressroom. Traditional rules are no longer applicable across the board. The case of punching holes in these new steel alloys is a good example.

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R&D Update: Evaluating lubricant using the cup drawing test

October 10, 2016 | By Cliff Hoschouer, David Diaz Infante, Frank Kenny, Jeff Jeffery, Taylan Altan, Ph.D.

Lubrication plays an important role in sheet metal forming by affecting metal flow and reducing the possibility of fracture during forming. A number of tests are used to evaluate lubricant performance, including the strip draw test, the twist compression test, and the cup drawing test.The cup...

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Die Science: The basics of troubleshooting die problems

October 10, 2016 | By Art Hedrick

In my career as a consultant, I have experienced numerous die-related problems. Some were complex, and some were easy to solve. But most were solved by following basic die design and troubleshooting guidelines. For a stamping die to function properly, you have to follow three basic die design...

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Ask the Stamping Expert: The 10 laws of die design

October 10, 2016 | By Thomas Vacca

Q: Can you provide me with some guidelines for die design? A: When it comes to die design, I find there are two best practices to live by: Follow Tom Vacca’s 10 Die Design Laws. Use a die design continuous improvement check list. Following are my 10 Die Design Laws. Look to the...

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How 2016 Car of the Year Honda Civic maneuvered around AHSS obstructions

October 4, 2016

Honda used Gestamp’s in-die “softzone” hot stamping process to form strategic zones of the 2016 Civic sedan’s rear frame rails to 1,500-megapascal (MPa) (shown in red), while cooling other zones (shown in pink), at a different pace to render them to a lower tensile strength to satisfy crush mode and performance targets.

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Servo press trends

September 21, 2016 | By Kate Bachman

Vehicular weight reductions that automakers have made largely have been attributed to the use of advanced high-strength (AHS) materials—and the stamping manufacturers forming them. Stampers have muscled the Olympian feat via many approaches, including using servo-driven mechanical presses. Servo presses have evolved and moved from the fringe into the mainstream. Four servo press manufacturers weigh in on how servo press technology has advanced to spot stampers in helping them meet the challenges inherent in forming superstrong metals with low formability and high work hardening.

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How to gild your safety record

July 13, 2016

Talan Products has consistently reduced its safety incident rate since 2006. That it has manufactured for 1,600 days without a lost-time accident is no accident. It is the result of a deliberate development of an omnipresent safety culture. Other manufacturers often ask, “How do you do it?” The manufacturer shares its safety secrets, including establishing a safety culture, learning from near-misses, using sensors, and tracking safety metrics.

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High-speed stamping quenches thirst for beverage cans

July 13, 2016 | By Greg Stueve

All of the components of a beverage can are stamped in a high-speed press. The process of producing two-piece beverage cans starts with the blanking and forming of a cup from a large aluminum coil. Today’s most advanced cupping presses can run a 14-out die up to 350 strokes per minute (SPM), producing up to 4,900 cans per minute. Would soda beverages be as popular if they could not be packaged in a portable, singular, recyclable can made inexpensively by a high-speed stamping process? Some unique challenges and critical factors for press work in high-speed can stamping include high operating speeds, dynamic balancing, and off-center loading. Here are some ways to handle stamping at (almost) the speed of light--and takeaways for slower operations.

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Stamper powers up to do the heavy lifting

July 12, 2016 | By Kate Bachman

Stamping manufacturer StampSource brought in more than $3 million worth of work—a 25 percent revenue increase—with a capital investment of two heavy-duty feeders and three high-tonnage presses. It was the largest expansion in the company’s 66-year history.

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R&D Update: Practical methods for estimating formability of sheet materials

July 7, 2016 | By Ali Fallahiarezoodar, Berk Aykas, David Diaz Infante, Taylan Altan, Ph.D.

Formability is the ability of a sheet material to deform without failure or fracture. Information on formability helps process and tool design engineers predict failure during analysis of sheet metal forming processes for tool design. Formability information also is used to evaluate...

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Die Science: How many hits does it take to get to the end of a tool’s life?

July 7, 2016 | By Art Hedrick

Recently I was asked at a training session to state the average life of a stamping die. The person asking was from the costing department of a large automotive firm. He said he needed to know because he was getting different answers from different individuals in the organization—anywhere from...

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Building effective and agile sheet metal forming supply channels

July 6, 2016 | By Bill Frahm

Strong supply chains hold the promise of all partners being able to share innovation. This requires a commitment from the manufacturers in the chain to be open and communicative. Without that trust, supply chain partners can hurt product success and sabotage profitability goals.

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Ask the Stamping Expert: How do we prevent buckling in thin material during strip feeding?

July 6, 2016 | By Thomas Vacca

Q: We are trying to stamp a drawn cup from 0.002-inch-thick by 0.500-in.-wide fully annealed stainless steel on a Bruderer BSTA 22e high-speed press with an aluminum ball bearing die set and a Bruderer 198/85 roll feed. There are six draws, and all of the draw die bushings are carbide with steel...

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R&D Update: Controlling material flow in drawing operations

June 17, 2016 | By Ali Fallahiarezoodar, Taylan Altan, Ph.D., Zeming Yin

The researchers at The Ohio State University's Center for Precision forming perform research on controlling material flow in drawing operation using CNC hydraulic cushions to help improve drawability.

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