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Roll forming basics

January 11, 2005

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Roll forming, often called open-section forming, uses successive sets of roller dies to bend a strip of steel progressively until the desired shape is achieved. This process is very similar to traditional tube- and pipemaking, but differs in that it can form more complicated sections.

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Balancing work and life

January 11, 2005

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To remain competitive in today's cutthroat economic environment, companies are doing more with fewer people. The tight job market can make even those employees whose work loads haven't increased feel they have to expend more effort—or even create an illusion of having to expend more effort—simply to keep their jobs. No longer is it just the workaholics among us who are working harder and putting in longer hours.

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More about MIG welding

January 11, 2005

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Editor's Note: This article is a companion piece to Marty Rice's article MIG welding—The basics and then some. My first time using MIG (also called gas metal arc welding, GMAW) in the field was working on four stainless steel hoppers (tanks) at an Owens Corning plant. X-rays of the hoppers'...

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Leadership lessons from the forge

January 11, 2005

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One of the benefits of coaching individuals and teams across the country is that I have the opportunity to meet bright, insightful, and creative people. The inspiration and much of the content of this article come from one of those people—Bob Nichols.

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Listening to your parts

January 11, 2005

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Figure 1Even if the scoring is the reason for the split, that doesn't mean that resolving the galling issue will ensure a robust process.I recently had the chance to engage in some very interesting conversation with the head of the sheet metal formability lab for a very large automotive stamper....

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Simplifying shielding gas selection

January 11, 2005

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Have you ever asked yourself any of the following questions: Why is welding affected by the shielding gases used? Why are so many blends available for carbon steel? Why can I use some gases for some materials and not others? Answering these questions will help you take the mystery...

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Optimize your plasma performance

January 11, 2005

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Plasma arc welding (PAW) uses plasma, a gas that has been heated to a high temperature and ionized. The plasma becomes electrically conductive, transferring an electric arc to the workpiece through a small orifice.

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Welding zirconium and zirconium alloys Part III

January 10, 2005

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Editor's Note: This is the third installment of a three-part series on welding zirconium. Part I addresses metallurgy, weld preparation, and shielding techniques. Part II covers welding technique. Part III discusses additional methods of joining refractory metals.

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Welding zirconium and zirconium alloys

January 10, 2005

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Editor's Note: This is the first installment of a three-part series on welding zirconium. Part I addresses metallurgy, weld preparation, and shielding techniques. Part II, which will appear in the October/November issue, will cover welding technique. Part III, which will appear in the December issue, will discuss additional methods of joining refractory metals.

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Pipelines to China

December 7, 2004

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Joe Shooshani was smoking a cigarette outside Hall 4 at the Shanghai New International Expo Center (SNIEC). He had traveled from Los Angeles where he owns Bobco Metals, a metals service center offering a range of services, including forming, bending, welding, and fabricating. Shooshani was in...

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Forming advanced metals

December 7, 2004

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The demand for lightweight components continues to be a primary driver in the automotive industry.

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Cams, cams, and more cams

December 7, 2004

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How do you choose a store-bought cam for your stamping operation? Hundreds of cam designs are available today from numerous suppliers. Choosing the one that best fits your needs, as well as your budget, sometimes can be very confusing.

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Finding simplicity and efficiency in servo press feeds

December 7, 2004

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Upon their debut in the 1960s, servo press feed systems were hailed as the technology for the future. They were recognized for their productivity advantages, a result of digital setups that quickly dialed in feed length and speed parameters, with controlled acceleration and deceleration rates, job...

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ME Four-Twelve concept car

The evolution of automotive stamping

December 7, 2004

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Magna International is an excellent example of a supplier adapting to OEMs' demands for suppliers to increase their capabilities. Magna not only provides parts, but also currently assembles the Jeep Grand Cherokee® in Graz, Austria.In August Magna announced plans to open a facility to assemble...

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Regaining flatness in stamped parts

December 7, 2004

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Of all the geometric tolerances that are difficult to achieve, flatness is one of the hardest. Most stampers probably would much rather try to make a complex-shaped, thin, high-strength steel deep-drawn part than hold a small-tolerance part requiring a tight flatness.Achieving part flatness is a...

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