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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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Die Science: Drawing and stretching

July 1, 2015 | By Art Hedrick

When I conduct training seminars on drawing and stretching, I usually bring with me a variety of unusual parts made using those processes. Often, attendees ask how to stretch the metal into a shape such as a deep can or deeply formed part without splitting the metal. I simply answer: “We don’t....

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Ask the Stamping Expert: How can I evaluate the performance of recycled lubricant in-house?

June 29, 2015 | By Thomas Vacca

Q: I have an issue regarding the consumption of stamping lubricant in our facility. The toolroom is requesting to use only new lubricant rather than recycled, as well as a richer lubricant mix in some tools. This is increasing our lubricant and disposal costs. Is there a test that I can perform...

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R&D Update: Forming aluminum alloys at elevated temperatures, Part 1

June 11, 2015 | By Taylan Altan, Ph.D., Long Ju

To reduce vehicle weight, automotive manufacturers are using advanced high-strength steels (AHSS) and aluminum alloys, formed at room temperature, as well as hot stamping of boron steels. A few OEMs and Tier 1 suppliers also have started warm forming aluminum alloys, usually 5000 and 6000 series,...

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Die Science: Slug pulling—Causes and solutions

June 11, 2015 | By Art Hedrick

Slug pulling in a stamping die can be costly and frustrating. One pulled slug can cripple production. What Is Slug Pulling? When a pierce punch creates a hole, it also produces scrap, called the slug. When the slug sticks to the face of the punch during withdrawal or comes out of the button...

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Ask the Stamping Expert: Upfront spending reaps long-term savings

June 10, 2015 | By Thomas Vacca

Q: The cost of building new progressive dies has gone up substantially in the past few years. I am struggling, and in many cases lose money, on my tool builds. How is the industry expected to cope? A: This is a common problem throughout the metal stamping arena. It’s not easy to remain...

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Flight of a complex progressive stamping--from customer print to finished part

June 1, 2015 | By Ross Weber

A complex stamped component begins its journey as a part print. Then a CAD layout drawing marks the progression; a 3-D model fleshes out the form and indicates any possible interference; and the die is put through a test run before the first part is produced.

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Stamper performs subassembly superbly

May 21, 2015 | By Kate Bachman

DieMasters Inc. grew from a small diemaker shop to a 100-employee stamping contractor. The company added value to its bottom by making assemblies, which now comprise 70% of its revenue. The assemblies are a metaphoric representation of the company itself, which makes products diverse in every way possible—size, type, market, materials, complexity. While Diemasters’ success is the result of a concerted effort, President and CEO Virgil DeLay pulls the company together and keeps the band on cue with a well-defined production system.

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Large-bed servo press line enhances auto supplier’s efficiency

May 12, 2015 | By Kate Bachman

Automotive supplier of seating components Paul Craemer GmbH of Herzebrock-Clarholz, Germany, replaced two presses lines requiring press-to-press automation with one 35-foot tall, 48- by 25-ft. servo transfer press.

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Ask the Stamping Expert: Increasing progressive-stamping tooling life with the right lubricant

April 15, 2015 | By Thomas Vacca

I get a lot of questions regarding how to maximize the life of progressive-stamping tooling, but no one response fits all. We talk a lot about tooling materials, heat treatment, and coatings. But time and again, stamping lubrication is treated as relatively insignificant. Stampers put little...

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