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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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Designing high-strength steel stamped parts for formability

June 12, 2003 | By Art Hedrick

The use of high-strength steel to manufacture automobiles and other transportation vehicles has increased dramatically. The material's strength allows manufacturers to reduce vehicle weight substantially and increase fuel efficiency, without sacrificing performance.

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Reducing Die Changeover Time without Capital Expenditures

May 29, 2003 | By Gary Zunker

One of the cornerstones of an efficient stamping operation is its ability to perform die changes in less than 10 minutes. Retrofitting an entire stamping operation for quick die change can require a very costly investment. Justifying such a large amount of money in a short payback scenario can be impossible.

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Getting it Straight

May 29, 2003 | By Bruce Grant

Before coiled material can pass through a die to produce an acceptable part, it must be straightened. Coil straightening is accomplished by bending a strip of material around sets of rollers that alternately stretch and compress the upper and lower surfaces so that the material's yield point is exceeded.

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Handling the rush

May 29, 2003 | By Lincoln Brunner

Think delicate: an antique vase, velvet gloves, the sweet sound of string music. Then imagine a typical stamping operation: bam-bam, metal on metal, all day long.

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Examining slit coil handling and packaging

May 15, 2003 | By Ray Kuch

While it is common knowledge that slit coil handling and packaging often limit the productivity of even the most modern, high–speed coil slitting line, coil processors generally spend too little time examining the effectiveness of these operations.

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Finding the best splice for your light-duty conveyor

May 15, 2003 | By Beth Miller

One way to increase your stamping operation's productivity is to get all the uptime you can from the belt conveyors that carry materials, parts, and finished and packaged products throughout your plant. As moving, wearing equipment, conveyors naturally demand a certain amount of downtime for maintenance and parts replacement. However, keeping those events as infrequent and brief as possible is what uptime is all about.

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Truckin' along through a stamping plant

April 24, 2003 | By Tom Juric

International Truck and Engine Corporation's Springfield, Ohio, plant recently undertook the challenge of building a high-performance truck with the dimensional tolerances that meet today's quality standards within a cost structure that would allow it to remain competitive. This new product launch was the first of its kind for the company in more than 20 years.

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Applying and handling die lubricants

April 24, 2003 | By Stan Reinke

The two main reasons for applying die lubricant are to reduce friction and dissipate heat. Heat can build up between the tool surface and metal, causing the lubricant to break down. This results in metal-to-metal contact and galling.

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Hydraulic forming takes a front seat

April 24, 2003 | By Tom Paisley

For about 50 years roll forming was the process of choice for making seat track channels at Dura Automotive Seat Systems, Stockton, Ill. While the process was high-speed, low-maintenance, and flexible, it also caused channel end flare, twist, and bow.

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