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Applying and handling die lubricants

April 24, 2003

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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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Truckin' along through a stamping plant

April 24, 2003

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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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Improving the bottom line in automotive applications

April 24, 2003

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The automotive industry is under extreme pressure to improve the productivity and quality of its operations. Tier 1 suppliers especially are being squeezed by a combination of very competitive upfront bidding for contracts and yearly price reductions. One area ripe for savings in most automotive companies is the total cost associated with welding quality.

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Cutting exotic alloys

April 24, 2003

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Cutting tubing with a circular cutoff saw is a common metal fabrication operation. This type of saw can produce a smooth finish that requires little secondary finishing.

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Coating fabricating tooling

April 24, 2003

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Tube fabricators all over the country are starting to see some major benefits from new coating technology. Many coatings-both those that are time-proven and new ones just hitting the market-can provide many benefits for many tube fabrication processes, including extended tooling life, better finished parts, and less stress on machinery.

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Slash maintenance inventory costs

April 10, 2003

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The quickest boost for most organizations' bottom line is finding opportunities for decreasing costs without sacrificing quality. An area frequently overlooked is the inventory of parts kept for maintenance, repair, and operations (MRO).

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Establishing a die setup recipe for progressive dies

April 10, 2003

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Setting up a stamping die is one of the most critical steps in a successful stamping process. It's a fact: More damage is done to a die, especially a progressive die, in the first 10 hits than in the next 10,000 hits. Most die damage happens during initial setup, when the material is being fed into the die. Mistakes such as misfeeds, pilot piercing, double metal, sheared cutting sections, and stock hang-ups often occur.

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Superior Service—Why you need it

April 10, 2003

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Service can make or break a business. Of the top nine reasons consumers give for buying a specific product, eight pertain to the abilities of the customer service system, for example, responsiveness, technical skill, and professional attitude.1

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How to recognize, minimize weld smut

April 10, 2003

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When I weld any aluminum alloy, I see a covering, light gray to black in color, over the weld. I see it when I gas tungsten arc weld (GTAW), but it's worse when I gas metal arc weld (GMAW). What is it? Does it affect the mechanical properties of the weld? How do I get rid of it?A common occurrence...

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Using narrow-gap GTAW for power-generation equipment

April 10, 2003

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Narrow-gap gas tungsten arc welding (GTAW) frequently is used to weld regular and multilayer high-chromium steel for power generation boilers, stainless steel for nuclear power generation equipment, INCONEL® alloy and other high-alloy steels, and thick-wall stationary pipes.

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Substance abuse in the workplace—Part 2

April 10, 2003

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The toll that substance abuse takes on the abuser, his or her family and friends, and those who become victims of substance abuse-induced accidents and crimes is well-documented.

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Drawing on the strength of people

April 10, 2003

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During the recent economic downturn, sheet metal stampers, die shops, and some job shops experienced layoffs and some closed their doors. However, a few stampers have remained profitable despite uncertain economic times.

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Improving perforating die performance

April 10, 2003

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Perforating is defined as a process of making a hole by removing a slug. During perforating in a stamping operation, a punch shears and breaks a slug out of the part material and then pushes the slug into a matrix (die bushing). The matrix hole is larger than the punch point. A clearance must be maintained constantly around the entire punch point.

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Sizing up pallet uncoilers

April 10, 2003

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Horizontal payoff of coiled materials on pallet uncoilers can help reduce downtime for coil changeover, increase coil handling efficiency, and improve operator safety.

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Solving the mysteries of the fin pass—Part 1

April 10, 2003

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The fin pass was not the first time your father gave you five bucks for your allowance. The fin passes are those forming passes that immediately follow the breakdown or initial forming stages on a tube mill. Their role is paramount in the successful final presentation of the formed tubular section to the welding process.

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