An automotive OEM's 4,000-ton transfer press produces parts with difficult draws, such as pickup door panels, in the 1,600-ton first station. Facing problems finding obsolete parts for repair and also considering crucial performance requirements in that first drawing operation, the automaker had Schuler Inc. upgrade the press with a modular hydraulic bed cushion.

There is no best tool steel type, coating, or way of keeping the punches from breaking. The best solution for each of these problems can be found by collecting specific data with respect to why each of the problems occurs

Stamping cosmetic parts in coil feed lines can be challenging. Cleaning the coil feeding head properly can eliminate waste or scrapped parts caused by debris and contamination.

Red Rock Stamping, Chandler, AZ, airbag and seatbelt components manufacturer, looked for ways to improve its die change processes to handle the anticipated business volume increases. A lot of cleanup had been required around the machines as a result of the lubrication system. By installing a new fluid application system by UNIST, the stamper gained more control over the spray volumes and locations and reduced die change times. Fluid disposal was eliminated as well.

KI USA, a division of KI Japan, stamps and produces sub-assembly parts for Toyota, Honda, Nissan, and other "transplant" automotive OEMs. The stamper wanted to improve plant safety by reducing incidents of slips and falls. Petroleum-based stamping lubricants that had been used created a slippery environment at the press and other sites. Changing the stamping lubricant system to a synthetic lubricant from MS Fluid Technologies not only improved plant safety and appearance, it produced cost savings and reduced the plant's impact upon the environment.

A third-generation dry-film lubricants consist primarily of blends of various polar and low- to nonpolar plymers with different molecular weights. They are designed to form extremey thin, highly cohesive bonds to the metal surface. This article explains how they differ from previous generations of dry-film lubricants and presents several application examples.

Material is the largest cost component for stamping companies, but does not receive much management attention. An annual material buy program can help stamping plant managers make substantial cuts in their material costs and other costs associated with the purchasing department.

Editor's Note: This article is part of a three-part series. Part I categorizes defect types and discusses the factors that affect formed part quality; Part II covers various destructive and nondestructive tests for evaluating incoming material; and Part III is an introduction to process monitoring systems.