Advancements in waterjet technologyWhen Jack Budd, president of Precision Waterjet, Orange, Calif., purchased his first waterjet system seven years ago, he expected most of the company's work to come from the aerospace industry, which was robust at the time. When business from that industry tapered off, he searched for new customers in the architectural, signage, and automotive aftermarket industries.
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Using hydroforming aluminum components versus steel stampings: The contender gains points, but the champion is still in the fightThis article examines two transitions that are occurring in the automotive industry—the change from stamping to hydroforming, and the substitution of aluminum where steel was used previously.
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Examining the effects of push assist on the formability of aluminum tubesIt is well-known that tube has become an important material for hydroforming hollow components. The increasing complexity of product structures, particularly in the automotive industry, often requires one or more forming operations before a tube actually is hydroformed. Prebending is one of these forming processes used to prepare tubes for the so-called prebent tube hydroforming.
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Tier 1 supplier builds four-stage competitive strategyF & P Manufacturing Inc., a tier-one automotive components supplier, focused on four areas when it developed a hydroforming line for manufacturing Honda Accord engine cradles. These areas were eliminating end scrap, decoupling the bending machines from the manufacturing line, reducing cycle time, and palletizing parts.
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Making the most of hydroforming: Pursuing product potential and possibilitiesHydroforming has become a competitive metal forming method and has succeeded in many applications because of its weight- and cost-saving attributes, elimination of joining operations, and ability to offer part design for confined spaces.
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Hydroforming heats up: New techniques and equipment push industry forwardHydroforming was one of the fastest-growing metal forming technologies during the 1990s. Most of U.S. industry cooled down during and after the recession of 2001, but things have been heating up lately, and the world of hydroforming is no exception. The North American Hydroforming Conference and Exhibition (Sept. 29 – Oct. 1 in Dayton, Ohio), which was sponsored by the Tube & Pipe Association, International® (TPA), and the Society of Manufacturing Engineers (SME), showcased new techniques, equipment, and applications that are moving the industry forward.
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Part feature developments in hydroforming products: Hydroforming continues to make automotive inroadsTube hydroforming technology continues to develop in ways that improve part utility, economy, or process robustness. Auto parts that have recently been produced by hydroforming include roof rails, radiator enclosures, a front-end structural module, and roof rails.
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Steering toward aluminum Trends in the automotive industryAdvances in the use of aluminum for cars and trucks could pave the way for greater use of the metal in the future.
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Stretching metal's forming limits with HSP lubricants: Forming aluminum, high-strength steel without tooling upgrade |
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To e, or not to e?: Hamlet.com? Not quite, but automakers trying to save princely sums via InternetThe idea was to have e-commerce solve everything. Then the thud of a million dot-coms hitting bottom gave people a new perspective. Are automakers still hip on e-commerce? You'd better believe it.
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Building a better business model: Strategic planning basics for automotive stampers to improve profitJust what is a strategic business model, and how can it be developed and used by an automotive stamping supplier wanting to boost its bottom line?
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Car Corner: OEMs sock it to suppliers: Drive for profits runs parts manufacturers off the road, study showsThe businesses that supply the auto industry with its parts are doing more and more work for less and less of the pie.
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Fabricating precision parts for automobiles: Examples of Malaysian manufacturers stepping up to strong demandThe Association of Southeast Nations (ASEAN) trade ministers have agree to move ahead with a closer economic partnership with Australia and New Zealand as an initiative amid the global economic slowdown. This article describes how some Malaysian companies are addressing productivity and cost issues.
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Pinpointing future laser welding marketsAficionados of laser welding technology at times must feel a little like telephone vendors beamed back to 1603. They know almost everyone is going to use them in the future, but getting buy-in today can be like hawking loans at 25 percent-lots of interest and few takers.
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Four Canadian automotive fabricators and what drives their success: The fast, the lean, the fair, and the curious |
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Don't underestimate India: TPA tours the country that could overtake U.S. by 2050TPA recently hosted a tour of eight tube and pipe producers and fabricators throughout India. Although the country is not advanced, this tour and a recent report by Goldman Sachs reveal where it stands and where it is likely to go in the near future. Its capabilities are modernizing and Goldman Sachs expects its economy to overtake the U.S. economy by 2050.
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Lean on it: Despite roots in high-volume production, lean manufacturing can still help job shops |
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Drawing on the strength of people: How one stamper is breaking the rules, retaining quality employeesDuring 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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Contract stamper increases die life and draw die productivity: Link-drive presses, value-added services, and employee initiative keep the company competitive |
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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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Auto industry demands shape the future of stampingAs the stamping industry heads into a new century, it continues to be driven primarily by the automotive industry.
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Predicting springback in air bending, straight flangingAll businesses tied to the metal forming industry are scrambling to find areas in which they can lower costs without sacrificing quality. Adding to this burden are a tight cash flow and a lack of financial resources to invest in process improvement equipment. Therefore, the savings must come from doing more with less.
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Dangerous curves: Jaguar successfully mass-produces the industry’s first aluminum body structure |
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The problem with quality: A closer look at quality ratingsIn May, automotive quality gurus J.D. Power & Associates released the results of its 2003 Initial Quality Study (IQS). As is the case every year, the winners will trumpet their scores while the losers will promise improvement. A closer look at the numbers, however, reveals some interesting observations.
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Part nesting and die design tips for reducing and utilizing scrap in stamping operationsYou might be able to gain a competitive edge by learning how to reduce the amount of engineered scrap, or that material that was inteded to be scrap rather than scrap created because of defective piece parts.
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Taking an integrated build approach to stamping tool tryoutMarket pressures to reduce tooling costs are pressing the tool and die industry to seek lower-cost tooling solutions. This column discusses different build approaches and the merits of an integrated build for trying out stamping dies (and molds) as part of the manufacturing validation process.
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Investing in lubricants: Increasing your profits 7 percent by changing metalsAll businesses tied to the metal forming industry are scrambling to find areas in which they can lower costs without sacrificing quality. Adding to this burden are a tight cash flow and a lack of financial resources to invest in process improvement equipment. Therefore, the savings must come from doing more with less.
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Venturing Into the World of 3-D Die Design: 10 questions to ask to make an informed decision2-D, or not 2-D; that is the question. Whether 'tis nobler to venture out into a brisk, bold, new world of 3-D or to stick with old, reliable methods in 2-D.
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Automotive motives - Tips for cutting per-piece prices for automotive customersToday's automotive industry is more competitive than ever. To compete with the European, Mexican, and Asian markets, the U.S. market must become more aggressive in finding ways to cut costs.
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Using a gel-type tube lube: Manufacturer decreases waste, improves lubrication |
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Comparing single-cut and dimple-free tube mill cutoffs: When to employ each systemThis article covers the application of single-cut and dimple-free cutoff shear technologies as they are applied to contemporary high-speed tube mills.
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How to recognize, minimize weld smut |
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Advantages of plasma welding: Often-overlooked PAW offers speed and affordabilityPlasma arc welding sometimes offers greater welding speed than gas tungsten arc welding at lower cost than laser beam welding.
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Ironworkers and contractors adapt to FCAW trendsWelders who want to become proficient in a technology whose time has come should look into getting certified for flux-cored arc welding.
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Welding exhaust system components: Laser technology may aid this traditionally high-volume applicationIn the field of automobile exhaust systems, such components as manifolds, pipes, catalytic converters, and mufflers are joined either by the car manufacturer or by a subcontractor to form a subassembly ready for attachment.
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Racing against the clock: Contract manufacturer measures success one second at a timePrince Industries Inc., a contract manufacturer of CNC machined components, branched out into CNC fabricated components several years ago when it purchased two turret punch presses, a plasma machine, and a laser with manual loading and unloading. These machines were quickly overburdened with the growing workload, so the company sought a more modern laser with automated material handling.
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Selecting a shielding gas for joining stainless steel: The right choice is critical for success |
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Producing side-impact profiles: Automotive body part combines roll forming, punching, laser weldingThe ramming machine bores into the side of the new automobile at a speed of 50 kilometers (31 miles) per hour. Within a fraction of a second, sensors situated all over the test dummy signal details of the stress load. Shortly afterward the overall results of the Euro-NCAP crash test will appear in all the specialized automobile magazines.
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Projection welding for nut and bolt attachment: Competing or complementary joining methods?Projection welding, also known as resistance fastener welding, is the most common method for nut and M- or T-thread bolt welding. This article examines recent experiments with projection welding of those components to various high-strength steel components.
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Testing new waters Down Under: Australian auto industry looks to benefit from lasers, information sharingCapitalizing on the latest laser and information sharing technology, theAustralian auto industry is working to achieve critical mass within itsdomestic market and to take advantage of the opportunities offered bye-commerce.
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