Not your father's abrasive jet: Technological advances, attention to common woes give fabricators options for precision cuttingThe advances made in abrasive jet cutting in recent years have negated much of the downside formerly associated with the technology.
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Successful tube hydroforming: Watching parameters, accurately simulating the process yield good resultsA typical tube hydroforming system is shown in Figure 1. Within this system, a host of factors must be taken into account, from starting tube geometry and material properties to the quality of the final part (such as thickness distribution and dimensional accuracy).
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Hydroforming of tubes, extrusions, and sheetRecent advances at the University of Stuttgart and acfross the industry have opened doors for hydroforming all kinds of materials and shapes.
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Effective simulation of hydroforming: Current capabilities and requirements for the futureSimulation is used in the hydroforming process to replace the experimental investigation and tests required in a real tryout process.
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Occupational injury and illness statistics: Where does your manufacturing job rank?In December 2003 the U.S. Department of Labor's Bureau of Labor Statistics (BLS) released its 2002 occupational injuries and illnesses data. A total of 4.7 million nonfatal injuries and illnesses were reported in private-industry workplaces during 2002, resulting in a rate of 5.3 cases per 100 equivalent full-time workers. Among goods-producing categories, incidence rates ranged from 4.0 cases per 100 workers in mining to 7.2 cases per 100 workers in manufacturing. These numbers are overall averages of subsets in each major category.
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Inline Process auditing: Moving beyond random samplingImagine this: The line is running smoothly, delivery is tight but on schedule, it is 10 minutes to shift change, and suddenly Art the quality control inspector runs by the office window shouting, "We've got bad parts coming out!" You shut the line down, your production supervisor comes running, Art is grabbing as many parts as he can to start checking, and the operator is thinking, "I should run now and let the second shift deal with it."
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Steel industry anything but status quo: Next generation of distributors set to lead wave of changeAs the market demands change, the steel distribution industry will take up the gauntlet and change with the times. Contrary to some speculation, the steel manufacturing industry is neither going away nor reluctant to embrace the innovations necessary to survive.
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Looking to the future: Steel supplier designs facility based on regional current, future needsA growing manufacturing base in the Southeast spurred Thompson Steel in the mid-1990s to research what type of equipment to purchase for its new facility in Fountain Inn, S.C. The steel supplier had been shipping coils of slit steel from its plants in Baltimore; Franklin Park, Ill.; and Rome, Ga., almost daily to several customers in the area.
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Metal stamping and electromagnetic forming: New process improves material formability, reduces wrinklingThis article describes the development of electromagnetic forming (EMF) and how EMF works.
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Designing high-strength steel stamped parts for formabilityThe use of high-strength steel to manufacture automobiles and other transportation vehicles has increased dramatically. The material's strength allows manufacturers to reduce vehicle weight substantially and increase fuel efficiency, without sacrificing performance.
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Do you use checking jigs and fixtures?: An ounce of prevention is worth a pound of cureHow do you check tube fabrications to ensure they meet quality standards? Do you ship parts without checking them and hope that the next time the phone rings it isn't a prelude to a tirade from a disgruntled customer? Or do you check finished parts only to realize that your scrap rate is too high and wish you had checked them at earlier stages of the manufacturing process?
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Die Design for flat parts: Achieving perfection in a difficult taskFlatness is one of the most difficult part characteristics to achieve in a conventional stamping die.
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Rising expectations spark new approach to draw die development: Reconciling demands for increased quality at lower costsA recently formulated approach to draw die development incorporates simultaneous engineering to identify and address potential problems before dies are built.
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Controlling bend anglesBend angles are among the most frustrating geometric features to control in metal stamping. This is due primarily to two factors – the inconsistency of the mechanical properties in the metal being bent and the die design.
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Selecting a pressure system for a stamping dieAuthor's Note: Before I begin, I would like to take this opportunity to express my sincere thanks to thefabricator.com's readers. I hope you have enjoyed the stamping articles, and I am excited about writing for 2004. I also would like to wish all of you a great holiday season as well as a prosperous and successful year. Best holiday wishes!Art
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Selecting a stamping die pressure system, Part II |
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Die basics 101 starts with eight basic components: Getting to know stamping diesA stamping die is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a desired shape or profile. Most dies are constructed of several basic components, including die plates, shoes, die sets, guide pins, bushings, heel blocks, heel plates, screws, dowels, and keys. Dies also need stripper, pressure, and drawing pads, as well as the devices used to secure them—spools, shoulder bolts, keepers, and retainers; and gas, coil, or urethane springs.
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Structural tube on campus: Aluminum bridge spans science departmentsCentral Washington University in Ellensburg, Wash., is known for its strong science programs. "Flying Bridge," a structure designed by artist and sculptor Ed Carpenter, physically and metaphorically spans the biology and chemistry departments in the university's new Dean Science Building. Carpenter, who designed the bridge with engineering consultation from Peterson Structural Engineers Inc., teamed up with Albina Pipe Bending Co. Inc. to tackle the project's material bending and fabrication requirements.
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Low-tech system mechanizes pipe welding: Backing device allows GMAW on open rootWelding technology has changed dramatically over the last few decades. Although skilled welders always will be needed in manufacturing, mechanical welding devices can provide improvements over manual welding in terms of repeatability and throughput.
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Plotting for success: Using edge thickness measurements to aid troubleshootingThe butler slipped through the pantry area with the warm milk and, after adding some arsenic, served the beverage to his master. The butler had been gradually increasing the amount of arsenic over many months, so the change in the milk's taste wasn't noticeable. Soon the mistress and her nefarious servant would be rid of the one thing stopping their affair.
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The history of welding according to MartyThis is a welding history synopsis, as seen by me. If you are a history or English professor, you might want to stop reading at this point; it ain't gonna be pretty.
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Building a business: Minnesota couple learns how to market residential, custom iron artDel and Sally Halling started a business together, selling the custom residential iron art they create. Through their process, they found that much marketing and research was needed before they could be successful.
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Whale watching: A doctor's love of whales leads to a complex welding projectMetal artist James Berry constructed a large whale display by making healthy use of Gas Metal Arc Welding. Here's how he did it, and why.
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It happens 'under the hood': Chicago-area builder of water gardens becomes sculptorRick Walsh isn't your typical artisan, nor are his works typical welding pieces. But his personal evolution as both an artist and a welder illustrate the innovation and persistence of any successful welding operation.
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Terrorist attacks inspire Washington welder: Nonprofit organization, memorials aimed at rallying American spiritJohn Jackson is a welder in Lacey, Wash. who has started The Spirit of America Foundation with a group of people. He established the foundation so that memorials to honor those who were killed in the Sept. 11, 2001 terrorist attacks.
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A dream come true: Vermont artist finds way to create architectural sculpturersBy the time he was 12, John Rubino was on a quest: He wanted to weld sculptures.
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Riding on the cusp of something great: When Colorado artist's career hits plateaus, he climbs themKevin Robb's sculptures seem to defy gravity, arrest time, encroach space. Each sculpture is a moment freeze-framed; each element seems to be impossibly suspended.
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Art From the Forge: Finding new sources for inspirationThose of you who are busy fulfilling commissions for gates, fences, staircases, and the myriad items that keep food on the table might want to look at artwork created by people whose backgrounds are based in the arts. Metalworkers often are so tuned to traditional designs that they are unaware of a swelling modern movement that could generate new ideas, new visions, and new clients.
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Found art: Welding artist finds inspiration in industrial, natural formsWatching the sparks fly as his dad welded a temperamental posthole digger mesmerized Derek Arnold. "I found the immediacy of something so permanent absolutely fascinating," he said. "I knew I wanted to weld."A hands-on welding education on the family farm drove Arnold to take his skills and creativity to the next level. In 1993 he graduated from the Maryland Institute College of Art in Baltimore. "I've been welding regularly since my freshman sculpture class," he said.
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Unique fireplace items can fire up your incomeFireplace screens don't have to be boring. Fireplace tools don't have to be ordinary. Re-thinking the function of fireplace screens and tools can add a new dimension to these items and attract customers like moths to a flame.
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Metal Art Takes on the Fireplace: Jim Truett’s custom fireplace screens are both functional and beautifulMetal art takes on many forms, from wall hangings to picture frames to fireplace screens. Just ask Jim Truett, a district sales manager for Miller Electric Mfg. Co. by day and artist in his spare time from his Huntsville, Utah, home.
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A recycled dream: Tennessee welder finds success one scrap at a timeA Tennessee artist and welder uses scrap metal parts to create one-of-a-kind metal sculptures.
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In search of the perfect bend: Advancements in press brake angle measurement and bend springback systemsPress brake manufacturers have made tremendous advances in the art of machine design and manufacturing.
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