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thefabricator.com is the digital home of The FABRICATOR magazine, the metal fabricating industry’s foremost authority on manufacturing technology. Technical articles, case studies, and company profiles from The FABRICATOR and its sister publications, Practical Welding Today, The Tube & Pipe Journal, and STAMPING Journal can be found on this site. Additionally, thefabricator.com has a team of subject matter experts that write exclusively for the website, covering topics such as welding skills and metal forming basics.

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The reality of waterjet abrasive recycling

June 1, 2016 | By Dan Davis

Because shipping spent waterjet abrasive off to the landfill usually is easy, not too much thought is given to attempting to recycle it. However, in today's manufacturing world, all aspects of the operation are scrutinized for possible cost savings. That includes looking at abrasive recycling.

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Ask the Stamping Expert: Is it necessary to balance a die in a press?

May 31, 2016 | By Dennis Cattell

Q: I always try to balance my single-stage and progressive dies in our presses. However, with some new dies coming in, I have no room to move them in the press to a balanced condition. Is it necessary to balance a die in a press? A: To give you a better understanding of the subject, we should...

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Ask the Stamping Expert: How can I increase press speed without constant production stoppage

May 31, 2016 | By Dennis Cattell

Dennis Cattell advises that the centerlines of the press, bolster, feed, straightener, and reel might not be in line and the coil material guide settings might not be correct.

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Ask the Stamping Expert: How can we form holes smaller than the material thickness?

May 31, 2016 | By Thomas Vacca

Q: We are using a progressive die to make a part that is 3.770 inch in diameter with 45 holes, each 0.172 in. in dimeter, on a 3.514-in. bcd [basic center diameter]. Our customer has asked us to change the material from 0.080-in. half-hard copper to 0.240-in. half-hard copper. Now the hole is...

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Ask the Stamping Expert: How can I avoid die crashes?

May 31, 2016 | By Dennis Cattell

Q: I am a die setter and press operator who works with progressive dies that run up to 120 SPM. For die and press protection, we have: Strip material location with pilots. Pilot protection with limit switches. Four double-material-thickness stripper sensors in case of slug pull-up. Sensor on...

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Ask the Stamping Expert: How can I prevent slivers in blanking operations?

May 27, 2016 | By Thomas Vacca

Q: We are making shallow drawn cuts from 0.007-inch-thick aluminum base material with a thin polymer coating. The cups are assorted sizes from 0.375 to 0.75 in. and equal depths. We pierce the blank and use a balentine to carry it in the strip web through the draw operations, and finally we...

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Growth strategies for fabricators

May 26, 2016 | By Eric Lundin

Many small businesses grow quickly in the early years, but eventually growth hits a plateau. Big gains in additional growth come from gaining new customers or acquiring another company. In Going to Market, a presentation at The FABRICATOR®’s Leadership Summit, Lisa Wertzbaugher, sales and marketing manager for fabricator Superior Tube Products, discussed a four-part strategy for expanding the company’s sales, revenue, and profitability.

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What’s new in the tube and pipe industry?

May 26, 2016 | By Eric Lundin

Eric Lundin provides an overview of many of the technologies displayed at the 2016 Tube Düsseldorf expo.

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Advanced GMAW processes help in welding P91

May 26, 2016 | By Dan Hernandez, David Benson

Alloy P91 has excellent high-temperature strength and creep resistance, making it a favored alloy for piping systems for power boilers and other applications that work at elevated temperatures and pressures. The conventional welding processes, gas tungsten arc welding and shielded metal arc welding, do a good job on P91, but modified gas metal arc welding (GMAW) processes and flux-cored arc welding (FCAW) have deposition rates three to four times faster.

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Manufacturer uses servo press to hasten safety part production safely

May 25, 2016 | By Kate Bachman

Ultraform Industries sought ways to increase output of the safety seat belt and air bag assemblies the company manufactures, but speed could not come at the expense of quality. The company installed a servo press to slow the stroke before the draw, perform restrikes.

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Optimizing hydraulic presses for deep drawing

May 25, 2016 | By Greenerd Press & Machine Co.

Optimizing a hydraulic press requires choosing the best press frame, hydraulic circuit, auxiliary function, electrical controls, and hmi for your deep drawing application and parts drawn.

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Lockset manufacturer gets handle on scrap to boost productivity

May 25, 2016 | By Kate Bachman

When you stamp 2.2 million pieces a day in the manufacture of lockset and doorset assemblies— 550 million stampings a year—smooth, speedy operation is your goal and bottlenecks and obstructions to productivity are your targets. Kwikset developed a unique way to handle scrap that removed a bottleneck and increased output.

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Getting to know more about the metal you are forming

May 25, 2016 | By Daniel J. Schaeffler

An estimated 3,500 different grades of steel currently exist, with about 75 percent of them developed in the past 20 years. And more than 500 sheet aluminum alloys are registered with the Aluminum Association. Each of these materials grades has a different chemistry and different tensile properties...

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Industrial dust collection goes modular

May 24, 2016 | By Tim Heston

Large-scale dust and fume collection can be somewhat inflexible. A fabricator moving, adding, or removing a few work centers can throw off the airflow balance and make the entire system less effective. A new technology aims to change this.

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