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Stamping 101

September 25, 2003 | By Daniel Kiraly

To promote real-world stamping training, the Tooling & Manufacturing Association (TMA) wanted to create a resource whereby stampers could receive a consistent, recognized, hands-on education on the industry's most current equipment.

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R&D Update: Using binder force control, force modulation, to improve part quality, stamping efficiency

August 28, 2003 | By Taylan Altan, Ph.D.

Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University, Professor Taylan Altan, director.Binder, or blank holder, force control is an important variable in the stamping process. Constant blank holder...

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Die geometry for embossing and stretching

August 28, 2003 | By Art Hedrick

Stretching or embossing, not to be confused with drawing, is the process in which the part's geometry is obtained by stretching the metal into a forming cavity.

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Protecting surface-sensitive materials in coil processing

August 28, 2003 | By Jim Russell

As manufacturers worldwide strive to reduce costs and streamline their production processes, the market for surface-sensitive materials continues to expand. Surface-sensitive materials include all prepainted steel products and nonferrous decorative materials, such as copper, brass, and stainless steel.

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Virtual tryout

August 14, 2003 | By Terry Swan

In this era of global warp speed and virtual reality, calculating the deep draws of progressive dies or the springback of metal is performed by simulation software instead of the earlier trial-and-error method. These software programs essentially replace the artistic methods of diemaking with...

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What's driving your press?

August 14, 2003 | By Errol Neider

Mechanical presses are challenged to provide high-speed production with a greater number of hits per minute, smaller batch runs, and quicker die changes.

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Stamping out bad parts

August 14, 2003 | By Tim Schmidt

Sheet metal manufacturers are under constant pressure to improve and document quality while reducing costs. Furthermore, original equipment manufacturers are shifting responsibility for quality inspections to suppliers, adding extra burdens. New, complex product designs and rigorous processes, such as deep drawing and the growing use of exotic materials, are placing greater demands on both quality assurance and development departments.

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Toolmaker tricks

August 14, 2003 | By Art Hedrick

It is not unusual for me to perform a few magic tricks when holding a conference on stamping die drawing, troubleshooting, or processing. Later on, I may disclose the magicbehind the trick. I do this for a couple of reasons: first, to entertain the conference attendees, and second, to show them that there is no such thing as magic, only physics.

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Maximizing a coil fed press

July 24, 2003 | By Ted Sberna

Coil-fed stamping presses are nothing new, but coil feeding processes have changed a lot since the days when press feeders were driven mechanically by crank motion. Influencing these processes are differences between transfer and progressive tooling.

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Taking the heat, keeping the current

July 24, 2003 | By Ken Wesseln

A DaimlerChrysler powertrain control module cover/heat sink assembly needed to be thermally conductive yet electrically isolated. The populated circuit board—one with all components in place—had to be bonded to the heat sink and postcured in a vacuum laminating press. The entire module...

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Improving blank edge conditions

July 24, 2003 | By Young Seo

A blank, stamped in the first station of a progressive stamping operation, usually is subject to subsequent forming processes to form a designated part. If the blank is subject to straining, deformation, bending, stretching, or lateral expansion in later stations, its edge condition should be carefully examined.

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Die width selection

July 24, 2003 | By Steve Benson

Most designers and engineers usually place very little importance on achieving the correct inside radius of a formed part. Why? Because the functionality of the part is unaffected if the specified inside radius is 0.062 in. and actual measured inside radius is 0.078 in. So why do we care about...

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Tooling tricks of the trade

June 26, 2003 | By Rodney Hewitt

Just make it work!" they scream. "I don't care how Just make it work!"As a tooling professional (whether you are a tool- and diemaker, engineer, press operator, or any other member of the team responsible for operating and maintaining that die), you quickly find that "making it work" is...

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Taking an integrated build approach to stamping tool tryout

June 26, 2003 | By Jay Baron

Market pressures to reduce tooling costs are pressing the tool and die industry to seek lower-cost tooling solutions. This column discusses different build approaches and the merits of an integrated build for trying out stamping dies (and molds) as part of the manufacturing validation process.

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R&D Update: Dieless NC forming

June 12, 2003 | By Taylan Altan, Ph.D.

Dieless NC forming or incremental sheet forming is a numerically controlled incremental process that can produce complex shapes from various materials. The process is based on localized plastic deformation in the sheet metal blank. It was developed as an alternative manufacturing method to prototype sheet metal stampings and produce panels in small lot sizes.

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