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Positioning your welds

January 10, 2006 | By Geoff Lipnevicius

Robotic welding can improve your productivity, but only if your fixturing design lets you. When you're designing fixtures for your welding application, consider your fixture's material; welding circuit optimization; orientation and deposition rates; accessibility, repeatability, simplicity, and dependability; and alternatives to fixture design when design costs are prohibitive.

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How to prevent press brake ram upset

January 10, 2006 | By Bob Butchart

Every press brake is subject to normal deflection under load. This deflection is corrected by shimming. If you deflect behond design limits, you will put a permanent bend in the ram and this is known as ram upset. You cannot adjust to compensate for ram upset. Remachining of the ram is the only solution. To avoid causing ram upset be careful about bending loads above your tons per inch limit and only air bend if possible.

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Cutting to the chase - integrating secondary operations

January 10, 2006 | By William Holyoak

Tube cut-off machines have evolved to integrate end forming and bending capabilities that normally are considered secondary operations. The suitability of a cutting method to be integrated inline with end forming and bending depends on each cutting method’s characteristics and the bending and end forming requirements.

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Creating an efficient offline band sawing system Part II

December 13, 2005 | By Doug Harris

Planning an offline band sawing system can be complicated because it can affect, and is affected by, many interrelated factors. Breaking it down to infeed, sawing, and outfeed helps to frame the planning by breaking it down to three subprocesses. Furthermore, answering 15 pertinent questions can help you tailor an efficient sawing operation to your specific facility and sawing applications.

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Die basics 101: Part V

December 13, 2005 | By Art Hedrick

Many specialty components can be used in dies, but the most commonly used are die plates, shoes, die sets, guide pins, bushings, heel blocks, heel plates, screws, dowels, and keys—all of which were explained in Part IV of this series. This article focuses on other common components—pads,...

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Cutoff die setup for dimple-free rounds

December 13, 2005 | By John J. Pavelec

With the right equipment and proper setup, tube mills can produce dimple-free round tubing efficiently. A multistep process using a two shear blade makes a dimple-free cut, and an inline brush end finisher can be used to remove the ever-present clearance burrs, if needed

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The shocking truth about welding

December 13, 2005 | By Marty Rice

Welding instructor Marty Rice explains how welding power current works and how failing to follow safety practices can have shocking results. He also expands upon the information contained in "TIG welding—An overview"and discusses TIG qualities, applications, hazards, and the best way to learn TIG.

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Achieving consistent stock lubrication with less oil

December 13, 2005 | By Ron Hawkins

Low-volume, low-pressure (LVLP) lubrication systems can offer stampers a way to maintain the most appropriate lubrication level for each job while reducing oil consumption.

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Bulletproof processes

December 13, 2005 | By Kathleen McLaughlin

While some stampers are filing for bankruptcy, Alpha's lean manufacturing initiatives have propelled the Detroit-based stamper to a $50 million-dollar company and growing

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A need for speed

December 13, 2005

Currently, Dana's Chatham, Ontario division produces several heat shields for fluid-management systems including heat exchangers, valves, and coolers. With higher demand yields and new orders, the stamper needed an automated press line that could improve uptime, quality, and reliability.

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Straight to the point

December 13, 2005 | By Brian Landry

The straightener, when set properly, removes the coil set, or curvature of the rolled material. If the machine is used or set incorrectly, the coil set can remain in the material, even after being struck in presses with capacities to hundreds of tons. This can cause a variety of problems: out-of-tolerance parts, difficult feed operations that can disrupt and slow performance, and, to some extent, additional wear and tear on feed line components and tooling.

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Meeting the challenges of modern architecture

December 13, 2005 | By Mark King

Today's architects develop designs and concepts that push past the boundaries of yesterday. Fabricators are faced with a sometimes daunting challenge to make unusual components to assist architects in completing unusual buildings, to the extent that they sometimes have to rely on themselves to develop new equipment and processes.

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Relief ahead in 2006?

December 13, 2005 | By W.B. "Bud" Graham

An overview of the pressures faced by the tube and pipe producing industry in 2005 and the author's views on how 2006 will be similar, but with a greater emphasis on energy costs, conservation, and availability. Ends with a few reminders about tube mill maintenance and efficiency.

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Ergonomic injuries and the workplace

December 13, 2005 | By Ron Wood

Work-related ergonomic injuries can exact a high price from employers and employees in both factory and office environments. Even a few incidents can deal a severe financial blow to small and medium-sized companies. Identifying potential risks and developing and implementing an effective ergonomics program can help reduce injuries and costs.

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End distortion on roll formed parts

December 13, 2005 | By Hanhui Li

Roll-formed parts are subject to end distortion when the parts are cut at the end of the roll-forming line. Understanding the forces that contribute to end distortion is the first step to balancing the forces and eliminating end distortion.

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