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How to gild your safety record

July 13, 2016

Talan Products has consistently reduced its safety incident rate since 2006. That it has manufactured for 1,600 days without a lost-time accident is no accident. It is the result of a deliberate development of an omnipresent safety culture. Other manufacturers often ask, “How do you do it?” The manufacturer shares its safety secrets, including establishing a safety culture, learning from near-misses, using sensors, and tracking safety metrics.

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High-speed stamping quenches thirst for beverage cans

July 13, 2016

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All of the components of a beverage can are stamped in a high-speed press. The process of producing two-piece beverage cans starts with the blanking and forming of a cup from a large aluminum coil. Today’s most advanced cupping presses can run a 14-out die up to 350 strokes per minute (SPM), producing up to 4,900 cans per minute. Would soda beverages be as popular if they could not be packaged in a portable, singular, recyclable can made inexpensively by a high-speed stamping process? Some unique challenges and critical factors for press work in high-speed can stamping include high operating speeds, dynamic balancing, and off-center loading. Here are some ways to handle stamping at (almost) the speed of light--and takeaways for slower operations.

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Stamper powers up to do the heavy lifting

July 12, 2016

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Stamping manufacturer StampSource brought in more than $3 million worth of work—a 25 percent revenue increase—with a capital investment of two heavy-duty feeders and three high-tonnage presses. It was the largest expansion in the company’s 66-year history.

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R&D Update: Practical methods for estimating formability of sheet materials

July 7, 2016

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Formability is the ability of a sheet material to deform without failure or fracture. Information on formability helps process and tool design engineers predict failure during analysis of sheet metal forming processes for tool design. Formability information also is used to evaluate...

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Die Science: How many hits does it take to get to the end of a tool’s life?

July 7, 2016

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Recently I was asked at a training session to state the average life of a stamping die. The person asking was from the costing department of a large automotive firm. He said he needed to know because he was getting different answers from different individuals in the organization—anywhere from...

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Ask the Stamping Expert: How do we prevent buckling in thin material during strip feeding?

July 6, 2016

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Q: We are trying to stamp a drawn cup from 0.002-inch-thick by 0.500-in.-wide fully annealed stainless steel on a Bruderer BSTA 22e high-speed press with an aluminum ball bearing die set and a Bruderer 198/85 roll feed. There are six draws, and all of the draw die bushings are carbide with steel...

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R&D Update: Controlling material flow in drawing operations

June 17, 2016

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The researchers at The Ohio State University's Center for Precision forming perform research on controlling material flow in drawing operation using CNC hydraulic cushions to help improve drawability.

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Reading progressive die strip — Part II

June 16, 2016

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Editor's Note: This is the second part of a two-part article about reading progressive-die strips. Part I, which appeared in the May issue, covered the causes of pilot hole distortion and mismatched cuts. Hard marks, otherwise known as coin marks, occur when metal is severely squeezed between two...

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Die Science: Developing forming dies - Part III

June 16, 2016

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Editor's Note: This is third installment of a three-part series that discusses die development for producing nonuniform, contoured parts by breaking the process down into eight steps. Part I covers the part material, its form, and its function. Part II discusses length-of-line analysis and tip...

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Die Science: Developing forming dies - Part II

June 16, 2016

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Editor's Note: This is first installment of a three-part series that discusses die development for producing nonuniform, contoured parts by breaking the process down into eight steps. Part I covers the part material, its form, and its function. Part II discusses length-of-line analysis and tip...

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Die Science: Solving punch breakage problems - Part III

June 16, 2016

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Numerous factors contribute to the premature failure of piercing and cutting punches. In addition to problems with the punches, such as tool steel or problems caused by EDM and grinding, the press can cause problems through deflection, and bridge strippers also can cause punch breakage.

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Die Science: Designing dies 2-D or 3-D?

June 16, 2016

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Both 2-D and 3-D die design packages have advantages and disadvantages, which are discussed here, but true success lies in the designer's ability, not the software's.

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Die Science: Fundamentals of drawing

June 8, 2016

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Columnist Art Hedrick goes back to basics about drawing, offering a comparison of drawing and casting, an explanation of flow and control.

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Ask the Stamping Expert: Five essential stamping rules for component designers

June 7, 2016

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Over the years I have received many requests from readers asking for suggestions and advice for particularly challenging stamping applications. Some of the issues can be addressed through creative tool design; some can’t. Some stampings by design make it virtually impossible to satisfy all the...

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

May 31, 2016

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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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