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R&D Update: Flow stress data and FE simulation

November 30, 2015 | By Ali Fallahiarezoodar, Taylan Altan, Ph.D., Zeming Yin

Finite element (FE)-based computer software commonly is used in the sheet metal forming and stamping industry for die design and for predicting metal flow and thinning in the formed part. It is a useful tool for predicting and preventing forming defects such as fracture and wrinkling. However,...

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Ask the Stamping Expert: How do I calculate press tonnage for swaging?

November 30, 2015 | By Thomas Vacca

Q: We are in the process of quoting a new job for the swaging and stamping of copper rod. To do this job, we need to buy a hydraulic press. The goal is to deform copper rods into a flat form on one of the edges. How do we calculate how much press tonnage we need? A: Obviously I would need a...

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Die Science: Training new tool- and diemakers

November 27, 2015 | By Art Hedrick

I must get two or three calls a week from companies needing tool- and diemakers, die maintenance specialists, or die repair specialists. The demand for skilled labor has skyrocketed in the last year or so. Unfortunately, most of the time I can’t help them. The Dwindling Talent Pool...

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Profiles in stamping: John Boughton

November 11, 2015 | By Kate Bachman

When everything hangs on the frame, and you design the frame, everything hangs on you. Profile of Fiat Chrysler Automobiles frame designer John Boughton reveals insights into his 52-year career.

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3-D transfer die simulation eliminates transfer die headaches

November 11, 2015 | By Mark Hansen

Often, transfer dies are designed, built, and installed in a press, and then stamping manufacturers discover that they have crash interference problems. Then diemakers are sent to fix the problems, but the solutions slow down productivity. Running transfer dies through simulation software first can circumvent those problems.

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Manufacturer revives stamping department with overhaul, press rebuild

November 11, 2015 | By Kate Bachman

Quality Industries made a U-turn on its decision to let its stamping department stall and has reignited the department’s restart with a press retrofit, quick die change (QDC) equipment, and a new press.

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Servomechanical press makes foray into hot stamping

October 26, 2015 | By Aitor Ormaetxea, Gorka Ibañez

As corporate average fuel economy (CAFE) standards require increasingly lighter vehicles, stamping manufacturers look for innovative ways, such as hot stamping, to form increasingly harder metals. Hydraulic presses have been the default technology for hot-stamping presses. Now servo-mechanical presses have entered the arena that hydraulic presses previously soloed, offering improved energy efficiency, cycle time, and reliability.

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How lubricant roller application systems reduce friction without the oil slick

October 22, 2015 | By Kyle Billin

Applying the right amount blots waste, cost. Roller lubrication systems apply lubricants in a consistent film across the coil.

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Freeing space for metal fabrication

October 19, 2015 | By Tim Heston

In a few years Performance Stamping may well be a very different company. It recently cleared away inventory to free space not for more stamping, but for metal fabrication.

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Zigzagging your way to material savings

October 8, 2015 | By Robert Allred i

Zigzag feeds are being used increasingly for some applications. Stampers can achieve multi-out results using a one-out die.

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R&D Update: Determining flow stress data by combining uniaxial tensile and biaxial bulge tests

October 8, 2015 | By Ali Fallahiarezoodar, Taylan Altan, Ph.D.

In the sheet metal forming industry, finite element (FE) simulation is an important tool for fabricators predicting metal flow, optimizing geometry, and selecting process variables before developing new dies. The accuracy of the simulation results depends highly on the accuracy of the input...

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Die Science: The top 5 drawing die violations

October 6, 2015 | By Art Hedrick

Deep-drawing failures—from splitting to scoring to shock lines—often are a result of common engineering mistakes. These problems can occur whether you are using a single-station drawing die, multiple drawing stations, or drawing reductions. Let’s take a look at the five most common...

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Ask the Stamping Expert: What is the best method for selectively removing burrs from stamped holes?

October 5, 2015 | By Thomas Vacca

Q: We receive high-volume, high-precision, low-cost stamped parts from a vendor. The oval-shaped parts come with burrs that we need to remove from the inner holes, but we cannot round the outside part edges. The cold-rolled steel parts have two sets of holes with different diameters stamped through...

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Metal stamper takes to the lake

September 8, 2015 | By Dan Davis

Kenmode Precision Metal Stamping, Algonquin, Ill., displays strong design and manufacturing skills in the creation of a cardboard catamaran for the 31st America’s Cardboard Cup Regatta at Crystal Lake, Ill., earlier this summer.

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R&D Update: Forming aluminum alloys at elevated temperatures, Part II

July 1, 2015 | By Taylan Altan, Ph.D., Long Ju

Elevated-temperature (ET) forming of aluminum can be accomplished isothermally or nonisothermally. In isothermal warm forming, the die, blank holder, and punch are heated. In nonisothermal deep drawing, the die and blank holder are heated, and the punch may or may not be cooled. The die and punch...

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