Content tagged with "automotive-industry"
Results: 93
Article
June 26, 2009
Getting close to remote laser welding
Figure 1
A remote laser welding cell doesn't take up too much room on a shop floor and holds the promise of being more productive than traditional spot welding setups. Photo courtesy of Rofin-Sinar Inc.
In an RLW system (see Figure 1 ), the laser beam is focused over the workpiece... Read more...
Article
November 25, 2008
Don't get stuck wondering about composites
Adhesives distribute stress
evenly along the bond line.
Photo courtesy of Henkel Technologies.
With the price of metals increasing, manufacturers are modifying their designs to offset their rising costs. At the same time, more consumers want to purchase vehicles based on gas... Read more...
Article
June 17, 2008
Article
May 13, 2008
Driven to integrate
A Parkview Metal Products worker operates a stamping press at the company's facility in Lake Zurich, IL. Parkview produces components for the automotive industry, consumer electronics, and barbecue grills. Changes come often in the steel industry. An item manufactured in the U.S. today can... Read more...
Article
April 15, 2008
Improve HSS part quality before die tryout
This C-pillar reinforcement is manufactured by deep drawing, cutting, and flanging (on left). Die faces for the deep-drawing stage, including the binder, addendum, filled surfaces, and part, can be developed using simulation software (on right). The use of high-strength steels (HSS) and... Read more...
Article
April 15, 2008
Will tube and pipe industry have energy to continue expanding?
If you have been involved in the tube and pipe industry for more than a few months, you're well aware that this industry is in the midst of an unprecedented global expansion. It has undergone periods of active investment and rapid growth in the past, but never before has an expansion of this... Read more...
Article
April 15, 2008
Sensors clear the way for high-speed stamping
Tennessee Stampings (Portland) LLC stamps 100 million ride control components (struts and shocks) annually. To sustain high-speed stamping, the company puts sensors on all of its dies to prevent collisions and the production of defective parts that would bring its presses to a screeching... Read more...
Article
April 15, 2008
The right trace at the right time
Whenever a laser is used in an industrial setting, a safety enclosure is usually required. To eliminate the expense of setting up an expensive enclosure room for use of its MeccoMark 20-W, fiber-delivered ytterbium laser marking system, Ford and MECCO engineers developed a safety snorkel on... Read more...
Article
February 12, 2008
Projection welding for nut and bolt attachment
Figure 1 Weld Nuts Studied A modern car body contains some 300 welded and punched fasteners, such as bolts, nuts, and studs. The quality of the attachment of these fasteners to the stamped body components is critical for the final product's safety and reliability. Crucial components such... Read more...
Article
November 6, 2007
Protecting magnesium alloys from corrosion
Magnesium is the lightest of all structural metals, weighing 35 percent less than aluminum and 78 percent less than steel.
Lightweight characteristics and wide availability make magnesium alloys suitable for mass production of components in cars and light trucks. However, the percentage... Read more...
Article
November 6, 2007
Forming a new approach
An engine cradle is a good example of a large, tubular part that can be altered greatly with the hydroforming process. Eagle Precision Technologies, Brantford, Ont., Canada, displayed this automotive component at the 5th annual North American Hydroforming Conference and Exhibition in... Read more...
Article
November 6, 2007
Seeking tooling longevity
BorgWarner Inc. is a drive-train developer and manufacturer that specializes in blanking and finishing of shafts, gear and spline rolling, grinding operations, and assembly. The Muncie, Ind., manufacturer of four-wheel-drive and traction control parts for the automotive industry was having a... Read more...
Article
October 9, 2007
Ridin' the storm out
Editor's Note: This is the third article in a three-part series on Tennessee Stampings LLC. Part I in August explored the company's lean practices. Part II in
September discussed how the company's use of sensors and mistakeproofing led to its growth. Part III examines the company's... Read more...
Article
October 9, 2007
For flawless cosmetic finish, start at the head
To remain competitive and profitable in the face of rising energy and material costs and low-cost overseas labor, North American stampers are offsetting these higher costs by increasing pressroom efficiency. Stampers are investing in automation to reduce labor costs and to expand the use of... Read more...
Article
October 9, 2007
New lube gives the slip to stamper's slips, trips, and falls
KI (USA), Berea, Ky., a division of Keiaisha Co. Ltd. (Japan), stamps and produces subassembly parts for Toyota, Honda, Nissan, and other automotive OEMs (see lead image). Company President Gary Robinson requested that a team from the stamping department improve plant safety by reducing... Read more...
Article
October 9, 2007
Ridin' the storm out Part III
Editor's Note: This is the third article in a three-part series on Tennessee Stampings LLC. Part I in August explored the company's lean practices. Part II in September discussed how the company's use of sensors and mistakeproofing led to its growth. Part III examines the company's facility... Read more...
Article
September 11, 2007
Ridin' the storm out Part II
Editor's Note: This is the second article in a three-part series on Tennessee Stampings LLC. Part I explored the company's lean practices. Part II discusses how the company's use of sensors and mistakeproofing led to its growth. Part III, which will appear in the October issue, examines the... Read more...
Article
August 8, 2007
Implementing a coil-end joiner
Almost all metal stampers have downtime at the end of a steel coil. The amount of time a line is nonproductive between coils can vary. It's not uncommon for downtime to exceed 20 minutes. On heavy-gauge lines, where a coil's linear footage is low, the amount of downtime can be excessive. Pax... Read more...
Article
June 12, 2007
Don't underestimate India
Photo courtesy of Nancy Olson If you pay much attention to international economics, you know that during the past few years much of the press has focused on the BRIC countries—Brazil, Russia, India, and China. The term BRIC was first used in 2003 in a report written by the Goldman... Read more...
Article
June 12, 2007
Developing forming dies Part III
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... Read more...
Article
June 12, 2007
Article
May 8, 2007
Developing forming dies Part II
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... Read more...
Article
May 8, 2007
Servo press forming applications
Editor's Note: This is Part III of a three-part series on servo presses. Part I, which appeared in the March 2007 issue, provided an introduction to servo presses. Part II, which appeared in the April 2007 issue, focused on servo press drive systems. This column was prepared by Serhat Kaya,... Read more...
Article
May 8, 2007
Liquid curves
North American automakers are producing more specialty vehicles in limited quantities for niche markets. The vehicles are stylish and sporty and lure customers into showrooms. The most economical way to put a variety of specialty cars on the road is with a common platform or chassis with... Read more...
Article
April 10, 2007
Servo press forming applications Part II
Figure 1
In a screw-type servo press, motor rotation is converted to linear movement via the ball screw.1 Press ram tilt is detected by linear sensors and corrected by adjusting the motion of each individual motor accordingly.
This column was prepared by Ajay Yadav, staff member... Read more...
Article
March 13, 2007
Servo press forming applications Part I
This column was prepared by Serhat Kaya and Ajay Yadav, staff of the Center for Precision Forming (CPF, formerly ERC for Net Shape Manufacturing), The Ohio State University, Taylan Altan, professor and director.
Numerous press manufacturers have developed mechanical servomotor gap and... Read more...
Article
March 13, 2007
Automotive blanker presses on
The two consoles that control the two blanking lines at Kasle Metal Processing have three monitors with access to the enterprise resources planning system, die performance, and maintenance information. Increasingly supervisors are using the maintenance computer module to go online and access... Read more...
Article
February 13, 2007
Detroit's reality check
Detroit had one heck of a wake up call in 2006. The days of rampant excess capacity are over as General Motors, Ford, and DaimlerChrysler's Chrysler Group are desperately trying to slim down bloated cost structures as quickly as possible. The result? GM is on track, Ford needs more work,... Read more...
Article
December 12, 2006
Lubricant developments for forming high-strength steel
The features of high-strength steels (HSS) can help improve the fuel efficiency and safety of vehicle structures. However, this developing steel technology has created new challenges for the metal forming industry and, as a result, has spawned a frontier of techniques and supporting... Read more...
Article
November 7, 2006
Joining GMAW and GTAW
The American Welding Society has defined "hybrid welding" as the combination of two distinct welding energy sources within a single welding process.
Figure 1
A new hybrid welding approach combines a plasma arc and a GMAW arc into one process. These elements detail the process: (1)... Read more...
Article
October 10, 2006
Replacing rivets
Supreme Corp. used to manufacture its vehicles with rivets (top), but now uses structural adhesives to join components (bottom). It isn't enough that a truck or bus runs well—its appearance also counts. That's the sales strategy of Supreme Corp., a manufacturer of general-purpose... Read more...
Article
October 10, 2006
Transfer technology
As with profit margins, the margin for error in the metal forming industry is becoming tighter and tighter—choosing the wrong equipment or delaying new technology investments can quickly make a pressroom uncompetitive. And these days, once you get behind, it's almost impossible to... Read more...
Article
September 12, 2006
New forms for modern autobody stamping
With the introduction of stronger safety legislation and increased fuel prices, automotive manufacturers must respond with higher car body stiffness for safety and lower body weight for fuel efficiency. The fields of materials development, engineering, and manufacturing are working... Read more...
Article
August 8, 2006
The U.S. sedan — an endangered species?
Over the last decade the U.S. market has become a global anomaly. Vehicle buyers in Europe and Asia have embraced fuel-efficient vehicles and shunned SUVs and pickups popular in the U.S. Even their minivans are smaller and more efficient. The hatchback (popular overseas) combines the fuel... Read more...
Article
July 11, 2006
The Midwest automotive exodus—fact or myth?
Newspapers are filled with articles chronicling the growing automotive investment in the South and companies leaving the Midwest. Automakers from Asia and Europe have located many of their new facilities in Southern rural locations. They often move into small towns where they become the... Read more...
Article
July 11, 2006
Baled out
Figure 1 The stationary incline conveyor located in the load-out center discharges its load into a shuttle conveyor that automatically fills one of the two truck trailers located in the bays below. Jefferson Industries Corporation (JIC) in West Jefferson, Ohio, broke ground for its... Read more...
Article
June 13, 2006
Evaluating dry film lubricants for automotive applications
This column was prepared by Hyunok Kim, a staff member of the Engineering Research Center for Net Shape Manufacturing (ERC/NSM), The Ohio State University, Professor Taylan Altan, director.
In stamping operations, wet (oil-based) or dry film lubricants are used to protect the surfaces of the... Read more...
Article
June 13, 2006
Article
June 13, 2006
Article
May 9, 2006
Handling engineering changes in automotive parts
Changes in design, material, manufacturing methods, performance requirements, or even packaging are facts of life for all manufactured products. Coordinating these changes to ensure smooth implementation is an important function for most manufacturing companies; it becomes even... Read more...
Article
May 9, 2006
Hot forming: Strong meets light
One of the challenges of meeting the NHTSA requirements for increased part strength while also meeting the CAFE requirements for decreased weight is that cold-stamped UHSS parts have a tendency to spring back. To meet this challenge, Cosma experimented with hot forming complex parts. The... Read more...
Article
May 9, 2006
Race to be green
Automakers are scrambling to introduce environmentally friendly and fuel-efficient cars. From hybrids, diesels, and ethanol-capable engines to fuel cell-powered cars of the future, the race is on to be green. The Green Reality Toyota has dominated hybrid sales since its Prius® sedan hit... Read more...
Article
April 11, 2006
Auto show lessons
According to an old industry adage, you can judge the financial health of automakers by the food they serve at their parties—the bigger the shrimp, the fatter the wallet. By that measure, Toyota should have served lobster tails and champagne at its Camry® introduction, and GM... Read more...
Article
April 11, 2006
Getting autobody welding down cold
Figure 1 Metalworkers perform finishing work on the weld seam of an A-pillar. The bodywork for the Phaeton® and Bentley Continental GT® limousines is built at Volkswagen Sachsen's Mosel facility in Saxony, Germany. The purchasers of these models expect perfection in terms of... Read more...
Article
March 7, 2006
Stamping complex parts
Wisconsin-based Tools Inc. is proud of its deep-drawing expertise for highly complex parts. In the past, however, producing highly stylized shapes posed a continual challenge. "Our in-house stamping capabilities consisted entirely of mechanical presses," said Chris Snyder, general... Read more...
Article
December 13, 2005
A need for speed
Located in 28 countries, Dana Corporation, Toledo, Ohio, is a supplier of axles, driveshafts, engines, frames, chassis, and transmissions. The automotive supplier, which delivers to major car manufacturers around the world, reported 2004 sales of $9.1 billion. Currently Dana's Chatham,... Read more...
Article
November 8, 2005
Advanced materials require advanced knowledge
Mode 1 failure (left) shows that separation occurs through the opposing sheet around the base of the weld, resulting in a full- button pull. In Figures 1-8, nugget size is nominally 6 mm in diameter. Mode 2 failure (middle), also known as a partial-thickness fracture and partial-button... Read more...
Article
November 8, 2005
Article
November 8, 2005
Taking one step at a time
RoboVent Floor Saver, a self-contained filtration system that mounts on top of a robotic welding workcell, helped Pridgeon & Clay execute its plan for equipment versatility throughout its Franklin, Ind., facility. If the company wants to reconfigure the manufacturing floor, it can move... Read more...
Article
October 11, 2005
Total transfer knowledge
Figure 1 A transfer press can produce large, complex parts or support JIT manufacturing. Historically when a stamping job shop required an automated press system, its choices were limited to progressive-die operations equipped with coil feeders or transfer-die operations with... Read more...
Article
October 11, 2005
Collaboration in the stamping industry
This scenario is familiar to many metal stamping manufacturers: The customer's new product, designed to be an entry-level model, is struggling even before it enters the market. Tooling is completed, but costs have spiraled out of control, and the projected profit margins look... Read more...
Article
October 11, 2005
Selling to GM – A tough customer gets tougher
It's no secret that automotive suppliers regard General Motors as one tough customer. The automaker's relentless focus on cost-cutting has made few friends in the supplier community. GM recently made several announcements that may signal an even greater focus on price. Over the last several... Read more...
Article
September 13, 2005
Pressing through power failures:
Transfer presses are used in the automobile industry primarily to produce sheet steel body panels. In traditional transfer presses, the press slide and the part transport mechanics are coupled using mechanical transfer. As a result, the vertical motion of the press ram must be coordinated... Read more...
Article
December 7, 2004
Racing against the clock
Time is a nonrenewable resource, and to be competitive, manufacturers must use each second to their best advantage. No manufacturer knows this better than Prince Industries Inc., a contract manufacturer that supplies precision-machined and fabricated sheet metal components. The company... Read more...
Article
August 10, 2004
Lean on it
Mike Wriglesworth of W.W. Metal Fab, Milwaukie, Ore., is a convert. Lean manufacturing is his new religion. At least, that's what he and the 85 employees practice at work. With the encouragement and financial backing of one of its largest customers, truckmaker Freightliner LLC, and the... Read more...
Article
August 10, 2004
Article
June 8, 2004
Dangerous curves
Provocative lines and innovative materials are the hallmarks of luxury car manufacturer Jaguar Cars Ltd. Jaguar has reaped the benefits of aluminum since 1922, when the company, then known as the Swallow Sidecar Co., designed sidecars out of lightweight aluminum panels. Since then the... Read more...
Article
June 8, 2004
Selecting a shielding gas for joining stainless steel
The use of stainless steel has grown significantly over the past decade in North America. As its use has grown, so has the number of different consumables required to join it. Because stainless steels are used in applications that are different from carbon steels, it follows that their... Read more...
Article
March 25, 2004
Part feature developments in hydroforming products
Tube hydroforming technology continues to develop in ways that improve part utility, economy, and process robustness. Each advancement broadens the applicability of tube hydroforming by making designers aware of what is possible and of the economic and performance benefits to be... Read more...
Article
March 11, 2004
Venturing Into the World of 3-D Die Design
This question has been plaguing the tool and die industry ever since major advances in technology and software yielded this powerful potential. It is nothing today for central processing units (CPUs) to have gigahertz speeds and gigabyte memories. With prices stable or dropping on... Read more...
Article
January 13, 2004
Producing side-impact profiles
Euro-NCAP, which stands for European New Car Assessment Program, was introduced in 1997 by five European governments, together with the European Commission. The results of this program are followed closely by the general public, so much so that hardly any automobile producer would risk... Read more...
Article
January 13, 2004
Hydroforming heats up
Hydroforming at Higher Temperatures The majority of hydroforming knowledge is based on steel. Steel's characteristics make it a favorable choice for many products, and steel has been the dominant material in many industries, especially automotive, for decades. Lately, though, hydroformers are... Read more...
Article
October 23, 2003
Pinpointing future laser welding markets
While some laser welding equipment manufacturers are thriving right now, others still fight a battle as old as the technology itself—gaining acceptance for equipment that carries a hefty initial price tag (albeit one that can save money over time). Consequently laser welding... Read more...
Article
October 23, 2003
Using a gel-type tube lube
As one manufacturer of automotive exhaust assemblies recently discovered, selecting the most appropriate lubricant for a tube bending operation can have a dramatic impact on part quality, workplace cleanliness, and economic efficiency. Although the liquid lubricant it was using was reliable and... Read more...
Article
October 9, 2003
Investing in lubricants
Raw materials and overhead account for 75 percent (see Figure 1) of an average metal forming company's total operating cost. Improving these two areas can make the biggest impact on your bottom line. But what if you've optimized your material costs by paying the lowest price for your... Read more...
Article
October 9, 2003
Predicting springback in air bending, straight flanging
Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University, Professor Taylan Altan, director. Air bending and straight flanging are the most prevalent types of bending in sheet metal forming.... Read more...
Article
September 25, 2003
Making the most of hydroforming
Figure 1 To help ensure successful part development, it is necessary to establish a multitask project team. Designers, hydroforming technologists, and material specialists should be involved in the component stage. To achieve possible economic benefits from this process, it is... Read more...
Article
July 24, 2003
Tier 1 supplier builds four-stage competitive strategy
F & P Manufacturing Inc., a Tier 1 automotive supplier, is no stranger to competitive and financial pressures. Unrelenting competitive pressures come from the many other Tier 1 suppliers looking for opportunities to increase their slice of the automotive pie. Financial pressures come from... Read more...
Article
July 24, 2003
Advancements in waterjet technology
Stream Lag Caused Taper, Corner Problems Budd said he courted the gear processing market, but prospective customers wanted parts with a perpendicular edge, which he was not able to achieve with the 2-D abrasive waterjet equipment he was using. In 2-D abrasive waterjet cutting, the... Read more...
Article
July 10, 2003
Article
July 10, 2003
The problem with quality
The companywide scores, which represent the number of problems per 100 vehicles, are as follows: Considerable variation exists among individual divisions of some OEMs. At GM, for example, Cadillac's results prove to be the second best in the survey (103), while Hummer's are the lowest (225).... Read more...
Article
June 26, 2003
Taking an integrated build approach to stamping tool tryout
North American tool buyers are pushing to lower tool costs by: Seeking foreign suppliers with low-cost structures resulting from low labor costs and government subsidies. Aggressively advancing math-based tools, particularly in engineering, to improve design quality and reduce die rework.... Read more...
Article
June 12, 2003
Stretching metal's forming limits with HSP lubricants
The trend in metal stamping is to use more and more aluminum and other lightweight materials, such as advanced high strength steel (AHSS). The need for technology to help improve metal flow of these materials in deep-drawing applications also is increasing. In many cases, a stamper's original... Read more...
Article
May 29, 2003
Article
April 10, 2003
How to recognize, minimize weld smut
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... Read more...
Article
April 10, 2003
Drawing on the strength of people
When faced with a financial crunch, many companies react by immediately cutting employees and nixing training programs. While these cutbacks may fix the problems in the short term, they may create even bigger problems in the long term, such as employee turnover, decreased efficiency, and... Read more...
Article
December 12, 2002
Testing new waters Down Under
The Australian auto industry appears to have shrugged off global economic uncertainty to boost sales of new cars and trucks to 772,681 units in 2001, a 1.8 percent jump from 2000, according to the Federal Chamber of Automotive Industries (FCAI). The Australian Bureau of Statistics (ABS,... Read more...
Article
August 29, 2002
Car Corner: OEMs sock it to suppliers
Traverse City, Mich., may be a laid-back resort town, but there was more than a little tension in the air recently as automotive suppliers aired their grievances to the North American industry's heaviest hitters. The 2002 Management Briefing Seminars (MBS) hosted such industry titans as Ford... Read more...
Article
February 28, 2002
Steering toward aluminum Trends in the automotive industry
Exciting ideas, new applications, and experimental joining processes for welding automotive aluminum drove conversations and presentations at the 22nd annual Automotive Aluminum Design and Fabrication Seminar in October. Sponsored by The Aluminum Association's Automotive & Light Truck... Read more...
Article
February 14, 2002
Trouble in Motown
Despite its second-best U.S. sales year ever in 2001, many of the auto industry's key players find themselves in financial trouble. It seems that sales of 17.2 million units doesn't go as far as it used to. Ford Motor Co., once the darling of the industry, has become the poster child for this... Read more...
Article
January 24, 2002
Hydroforming gains ground in Germany
Object "We started to use the hydroforming process for the production of structural parts in 1999, and our current timetable schedules an annual production volume of 2.5 million hydroformed parts by 2005," explained Dipl.-Ing. Matthias Schroeder, calculation specialist in the hydroforming... Read more...
Article
November 29, 2001
Fabricating precision parts for automobiles
In September the Association of Southeast Asian Nations (ASEAN) trade ministers agreed with Australia and New Zealand to move ahead with a closer economic partnership initiative in the wake of a global economic slowdown. All 12 countries agreed on a need for an initiative to reduce trade... Read more...
Article
November 15, 2001
Article
November 15, 2001
Contract stamper increases die life and draw die productivity
Object Jancox Stampings has remained competitive by investing in link drive mechanical presses from PTC, offering value-added assembly services, and encouraging employee initiatives. The article discusses how the presses work and how reduced speed reduces springback (which allows the company... Read more...
Article
November 15, 2001
Using hydroforming aluminum components versus steel stampings
As the name implies, hydroforming is a metal forming process that uses water as a forming medium. In the case of tube hydroforming, a tubular workpiece is placed between two mating die halves. The tube is sealed, normally by metal mandrels inserted under pressure in each end of the tube. Water... Read more...
Article
October 25, 2001
To e, or not to e?
To e, or not to e? And the answer is complex. Electronic commerce was heavily hyped in the past half decade. The auto industry, it was proclaimed, was headed for a transformation. Everything from procurement to vehicle and component design was going online. OEMs were aglow at the prospect of... Read more...
Article
October 25, 2001
Article
October 25, 2001
Comparing single-cut and dimple-free tube mill cutoffs
This article covers the application of single-cut and dimple-free cutoff shear technologies as they are applied to contemporary high-speed tube mills. A single-cut die set is a unit composed of an upper shoe and a lower shoe in which a single severing blade and tube supporting jaws are... Read more...
Article
October 11, 2001
Article
September 17, 2001
Welding exhaust system components
In 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. Today, large numbers of these components are welded with a laser.... Read more...
Article
May 15, 2001
Ironworkers and contractors adapt to FCAW trends
In September the Association of Southeast Asian Nations (ASEAN) trade ministers agreed with Australia and New Zealand to move ahead with a closer economic partnership initiative in the wake of a global economic slowdown. All 12 countries agreed on a need for an initiative to reduce trade... Read more...
Article
February 19, 2001
Article
February 19, 2001
Auto industry demands shape the future of stamping
Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University, Professor Taylan Altan, Director. As we face the 21st century, the stamping business continues to be driven primarily by the automotive... Read more...
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