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Ask the Stamping Expert: When is a WEDM purchase justifiable?

March 11, 2016

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A stamper is getting pressure from customers to add WEDM to reduce costs. Thomas Vacca advises him on how to justify the purchase.

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Ask the Stamping Expert: How can we maximize our tooling’s hits per service?

March 10, 2016

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Q: We are running high-strength, low-alloy (HSLA) brackets for a large aerospace firm. We cannot get the hits per service we need from our tooling and are struggling to meet production requirements. Any advice? A: Regardless of how many hits per service you get off a tool, you always want to...

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Ask the Stamping Expert: Why does tooling fail during coining and forming operations?

March 10, 2016

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Q: In our stamping division, we do a lot of coining and forming of 300 and 400 series stainless steels from 0.030 to 0.090 in. thick. We coin up to a 30 percent reduction in thickness and form multiple bends with very tight radii. Our punches and form die inserts fail. They break, crack, chip, or...

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Ask the Stamping Expert: How do I calculate shear pressure when figuring stamping die tonnage?

March 9, 2016

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Q: I read the article “How can I reduce snap-through condition effects?” in the September/October 2012 STAMPING Journal®. If I understand the article correctly, you do not want to stagger the punches too much to prevent the stored energy from releasing before the next set of punches hit. If...

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R&D Update: Lightweighting in the automotive industry using sheet metal forming, Part 2

March 9, 2016

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Editor’s Note: Part I of this article appeared in the January/February 2016 issue.

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Ask the Stamping Expert: Why does my tooling yield such big variation?

March 9, 2016

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Q: My company stamps right-side and left-side links for conveyor belts. The peanut-shaped parts, made in a changeover tool, are about 0.1 in. thick, 1.5 in. wide, and 3 in. long. Half of the part (lengthwise) is coined offset, one material thickness in depth. This is in addition to a number of...

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Troubleshooting sheet metal defects: Part II

March 8, 2016

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Part II of this series about sheet metal defects focuses on the common problems that can be caused during various stages of the material's production.

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Ask the Stamping Expert: What's the best-in-class process for developing a progressive-stamping die?

March 8, 2016

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Q: What is the best-in-class process for developing a new progressive-stamping die? A: Many tool builders think the process of progressive-die development is undefined and difficult to predict, and therefore takes way too long. Development is costly. It ties up engineering, design, toolroom...

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Ask the Stamping Expert: What type of hydraulic clamps are best for quick-change setups?

March 8, 2016

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Q: What type of hydraulic clamps do you use in your stamping presses for quick-change setups? A: The type of clamp is insignificant; there are many suitable brands. How you use the clamp is the important thing. Before you get into a true lean die-change system, you need to do some homework....

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Ask the Stamping Expert: How do we solve problems with die springs in hinge stamping?

March 7, 2016

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Q: We stamp low-carbon steel hinges, anywhere from 0.045 in. thick low-carbon steel about 0.5 in. square with a 1/16-in.-dia. roll form on the end, up to 1/8-in. thick and 5 in. square with a 3/4 roll form on the end for the assembly pin. Our stampings have a lot of dimensional problems, which we...

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Die Science: Understanding deep-drawing and stretching variables for best results

March 4, 2016

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Numerous variables affect the success of a deep-drawing or stretching process. Some are major and some minor, but you’ll need to take all into consideration when designing, building, and troubleshooting a drawing or stretching operation. Sheet and Coil Material Material is a major...

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Sheet metal fabrication basics: 7 strategies for punching success

March 2, 2016

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One of the most mature technologies in metal fabrication, punching is also one of the most misunderstood, perhaps because the process can ccomplish so much—punch myriad shapes, form, even bend flanges. Regardless, if a shop follows some basic strategies, it will be well on its way to better parts and greater throughput.

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The case for kaizen activities

March 2, 2016

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Continuous improvement activities don't always have to involve classroom time dedicated to training and excessive resources. They can be brief, direct, and have immediate impacts. That's where kaizen activities come in.

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Hot tubbin' and grillin'

March 2, 2016

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Omaha, Neb., man with the need to create found two unique uses for a couple of old '57 Chevy cars. The first, a working grill. The second, a hot tub and tabletop bar.

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Plasma cutting maintenance: Are you throwing money away?

March 2, 2016

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It's not unusual to see shops replace at least some plasma cutting consumables at the start of every shift, but some of these consumables should last 50 shifts or more. Getting the most out of your consumables goes back to the basics: proper inspection and preventive maintenance.

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