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Articles tagged with "automotive industry"
Results: 53
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Hydroforming gains ground in Germany: Growth seen in high-volume automotive structural partsThis article examines hydroforming in Germany, focusing on the advancement of the technology. It specifically discusses growing automotive uses, a new type of hydroforming press, material quality requirements, cost factors, new testing methods, and simulation software.
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Liquid curves: Sheet hydroforming helps the sporty Solstice stand outSheet hydroforming has fewer restrictions when forming complicated parts, which gives styling designers and manufacturing engineersmore flexibility during the design process. To provide a stylish body shape for the Pontiac Solstice®, GM chose sheet hydroforming to manufacture its hood, door, deck lid, and body side assemblies.
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Forming a new approach: Hydroforming is no longer a brand new technology, but it may be the solution for new applicationsAttendees of the fifth Hydroforming Conference and Exhibition, organized by the Tube & Pipe Association, International, and the Society of Manufacturing Engineers, learned that hydroforming technology is not dead yet.
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Baled out: Stamper's autoloading scrap conveyor system maximizes ROI, productivityWith growth coming fast and future expansions likely, this Tier 1 auto supplier replaced its capacity-limited scrap baling system with an autoloading conveyor system to maximize ROI and productivity.
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New forms for modern autobody stamping: High-strength, low-weight requirements spur new developmentsWith the introduction of stronger safety legislation and increased fuel prices, auto 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 together to achieve autobody weight reduction with improved crash characteristics.
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Protecting magnesium alloys from corrosion: The cold spray alternativeFinding cost-effective solutions for protecting magnesium alloys from corrosion has become paramount in automotive design. Corrosion protection through cold spray might be the answer.
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Improve HSS part quality before die tryout: Calculating springback compensation with simulation softwareThe use of high-strength steels (HSS) and aluminum in automotive and other stamping manufacturing is creating forming challenges for tool and die engineers. Forming simulation software, formerly used to predict conventional failure causes, now also enables the stamping tool and die engineer to simulate secondary operations, including springback to avoid expensive and time-consuming die tryouts.
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Taking one step at a time: Automotive parts manufacturer takes modular approach to growthAutomotive parts manufacturer Pridgeon & Clay was looking for a way to manage the growth it was forecasting. The company decided to buy several robotic welding workcells and modular air filtration systems so it could rearrange the facility's layout and give the company the opportunity to buy one piece of equipment at a time.
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Selling to GM – A tough customer gets tougherThe 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.
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Automotive toolmaking tricknology : Applying NUMMI's concepts to tool and diemaking: Cut diemaking costs in halfIn 1984 the Fremont, Calif. GM assembly plant shuttered under the strain of horrible management-labor relationships. Toyota offered to reopen the plant in a joint venture with GM implementing its Toyota Production System. Tool and diemaking shops can apply the same NUMMI concepts to revitalize their companies and reinvent themselves.
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Handling engineering changes in automotive parts: A discussion of the process from start to finishControl of engineering changes for automotive components and assemblies requires cooperation and communication among groups within a company, as well as with outside suppliers. Changes must be initiated, communicated, implemented, and verified enterprisewide.
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The right trace at the right time: Laser marking is the answer to Ford's traceability needs |
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Ridin' the storm out: ArrayArray
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Trouble in Motown: Despite record sales, near future registers a sour note for auto industryDetroit's Big Three have big problems ahead if they can't figure out a way to profit in a time of booming sales, let alone downturns such as the one looming this year.
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Auto show lessonsThe North American International Auto Show held in Detroit is a stage for automakers to display their latest and greatest; it also serves as a harbinger of what's coming at suppliers over the next few years.
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The Midwest automotive exodus—fact or myth?While the Midwest has not lagged as far behind in international investment as many believe, the financial struggles of the Big Three have been a substantial economic burden for the region over the last three decades.
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The U.S. sedan — an endangered species?: Future cars may be built overseasSoaring fuel prices caused by Hurricane Katrina and turmoil in the Middle East have turned U.S. tastes toward passenger cars. Rather than trying to catch up with the competition, the Big Three are using global partners to speed their response to international automakers' passenger car success.
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Detroit's reality check: Production cuts, restructuring threaten supply chain viabilityAs the Big Three try to return to profitability, most of their suppliers, many with a negative cash flow, are starting to crack under the pressure. Declining OEM unit volume and mix issues, pricing pressures, and high sustained raw material costs continue to constrain cash flows and limit balance sheet improvements that, in some cases suffered significant deterioration in 2006.
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Will tube and pipe industry have energy to continue expanding?: Despite some trouble spots, prospects overall are goodThe current expansion in the tube and pipe industry isn't new, but it bears a close look nonetheless. Understanding the factors that are causing it and how manufacturers are reacting to it provide some guidance to the future of this trend.
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Implementing a coil-end joiner: Automotive stamper reduces downtime on its heavy-gauge linesAfter adding a coil-end joiner, automotive stamper Pax Machine Works increased its productivity approximately 33 percent, reduced its scrap, and created a safer working environment.
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For flawless cosmetic finish, start at the head: A clean straightening head prevents debris damage during coil feedingStamping 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.
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Pressing through power failures:: Transfer press energy overcomes voltage fluctuations at BMWWhen BMW Dingolfing (Germany) decided to modernize one of its transfer presses, the desired benefits included increased line availability, increased production through the use of an electronic transfer system, and reduced maintenance. However, one of its highest priorities was to minimize or eliminate the risk of production loss caused by interruptions to the power supply.
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Collaboration in the stamping industry: More than a buzz wordWhat is the best way to determine the optimum combination of application, design, and costs? An effective collaborative process makes the difference. Teamwork and open communication throughout the process — from prototyping to production — ensure the best design and most efficient manufacturing process, which can save millions of dollars in large projects.
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Total transfer knowledge: The evolution of transfer pressesTransfer systems can deliver flexibility to perform a variety of tasks for current requirements, yet deliver the capability to carry the company at a competitive level over the long haul.
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A need for speed: Dana Corp. increases capacity with three automated hydraulic press linesCurrently, Dana's Chatham, Ontario division produces several heat shields for fluid-management systems including heat exchangers, valves, and coolers. With higher demand yields and new orders, the stamper needed an automated press line that could improve uptime, quality, and reliability.
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Stamping complex parts: Hydraulic presses expand deep-draw capabilitiesBy adding sophisticated hydraulic deep-draw press technology, Tools Inc. was able to greatly enhance its in-house forming and production capabilities.
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Hot forming: Strong meets light: Caught between NHTSA and CAFECosma International applies its own hot-forming technique to stamping automotive metal components such as A and B pillars, roof headers, roof rails, rockers, door intrusion beams, and bumpers, to meet new CAFE standards for weight, NHTSA requirements for strength, and to counter problems with springback in UHSS components.
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Transfer technology: Servo-based press transfer system maximizes productivity, flexibility for automotive supplierVenest Industries, an automotive parts supplier based in St. Catharines, Ontario, Canada, needed an automated transfer system that could be parked away from the machine bed during progressive operations and die changes, so that new dies could be delivered to the press via an overhead crane.
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Automotive blanker presses on: Production software helps Kasle Metal Processing weather slowdown, prepare for the futureAmidst the bad news associated with Ford Motor Co., good news is surfacing in Jeffersonville, Ind., home of Kasle Metal Processing. The company is using a software tool to ensure it is operating as efficiently as possible as it heads into one of its busiest months ever.
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Servo press forming applications: ArrayArray
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Ridin' the storm out: ArrayArray
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Sensors clear the way for high-speed stamping: Safely navigating the press autobahnWhen you stamp 100 million automotive parts annually, as does Tennessee Stampings LLC, Portland, Tenn., you might accept die collisions as just part of the "traffic statistics." Not so. Before the dies ever hit the high-speed presses, they are properly sensored to prevent downtime, accelerate production.
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Driven to integrate: Automotive component stamper branches out, adapts to industry changesChanges come often in the steel industry--a business that sticks around long enough might eventually bear little resemblance to the version established at its inception. This is the case for Parkview Metal Products, Lake Zurich, Ill. The company opened in 1950 as a tool and die shop in Chicago, later moving and shifting its focus to automotive, electronic, and grill components. The company believes its culture is changing for the better and plans to continue developing its 5S initiatives, increasing its on-time delivery, and reducing its scrap rate.
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Servo press forming applications Part I: Part I: An introductionA servomotor gives a press slide motion flexibility in terms of accurate speed, motion, and position control. This flexibility produces infinite slide motion variations that may improve part quality and operations such as painting and assembly during one press stroke.
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Servo press forming applications Part II: Part II: Drive systemsServo presses are classified into two main types based on their drive systems: direct drives with high-torque, low-speed servomotors, or low-torque, high- speed servomotors.
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Ridin' the storm out Part II: Part II: Sensors prevent crashes, clear way for growthAutomotive Tier II supplier of ride control parts Tennessee Stampings makes extensive use of sensors to mistake-proof its stamping, and clear the way for its 23 percent annual growth. Before the dies ever hit the presses, they are properly sensored so you don't incur downtime associated with troubleshooting the sensor in the press.
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Ridin' the storm out Part III: Part III. Transfer press, expansion, underground conveyorAutomotive Tier II supplier of ride control components Tennessee Stampings installed an 800-ton transfer press to get to get new business from European customers, and expanded its facility to accommodate the new press, as well as a new underground conveyor system.
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Evaluating dry film lubricants for automotive applications: ArrayArray
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Lubricant developments for forming high-strength steel: Upgrades help meet special challenges of this materialForming lubricants always have been a critical component in the metal forming process, but the performance characteristics of these products are even more essential when working with HSS.
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Developing forming dies: ArrayArray
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Seeking tooling longevity: TD coating extends punch life, reduces downtime in transmission staking operationBorgWarner Inc., a drive-train developer and manufacturer of four-wheel-drive and traction control parts for the automotive industry, was having a problem with punches used to deform the ends of shafts (axles) in the reduction carrier and differential carrier.
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Evaluating dry film lubricants for automotive applications Part III: Testing through deep drawing: Part III: Testing through deep drawingIn recent studies, dry-film lubricants have been shown to give better lubrication conditions when compared to oil-based liquid lubricants. This factor, as well as savings in the amount of lubricant used, has helped increase the use of dry-film lubricants in the automotive industry for forming of aluminum and high-strength steel stamped parts
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Evaluating dry film lubricants for automotive applications Part I: A general review: Part I: A general reviewIn stamping operations, wet (oil-based) or dry film lubricants are used to protect the surfaces of the sheet blanks, reduce friction during deep drawing, and minimize required surface treatments before assembly.
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Evaluating dry film lubricants for automotive applications Part II: The ironing test: Part II: The ironing testThe Ironing test developed at the ERC/NSM reproduces production conditions of contact pressure up to 94 kilo pounds per square inch (KSI) and temperatures up to 300 degrees F to quantitatively evaluate lubricant performance.
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Developing forming dies Part II: Part II: Die geometryDetermining the best die geometry to produce multicontoured formed parts can be difficult. A full understanding of the drawing and stretching process is necessary, as well as a good understanding of all tooling factors related to complex geometries.
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Developing forming dies Part III: Part III: Creating effective die geometryThis is the final article in a series of columns taking the reader step-by-step through the development of forming dies and processes. This final installment covers unfolding a part, developing the blank holder shape, adding addendum features, and simulating forming and die tryout.
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Replacing rivets: Vehicle body manufacturer switches to adhesivesSupreme Corp. prides itself on producing general-purpose and custom vehicle bodies for its customers, which include contractors. Appearance was an issue - one that led it to replace rivets with structural adhesives in its manufacturing.
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Don't get stuck wondering about composites: If you have questions about joining composites and their relationship with metal, we have answersAutomakers and other manufacturers are interested in utilizing composites more in their manufacturing operations. Composites come with their own set of challenges, and one of the most important challenges is how to join the engineered material to a metal correctly using an adhesive. When joining materials, adhesives evenly distribute loads and reduce labor time.
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Getting autobody welding down cold: Cold metal transfer helps Volkswagen meet customer demandsVolkswagen's automobile manufacturing facility in Saxony, Germany, was spending more time and effort on post-weld finishing operations than it wanted to, but because of the requirements the company was dedicated to meeting, not much automation was possible. Through its research, Volkswagen decided to invest in cold metal transfer welding, which helped the company save time and effort while keeping up its product quality.
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Joining GMAW and GTAW: Hybrid welding takes on a whole new meaning with new technology developmentsOne form of hybrid welding combines both GMAW with a GTAW process in a welding torch. An electronic interface unit containing a plasma power supply controls the hybrid process. Research has indicated that such an approach to welding leads to faster welding times, deep penetration, and cleaner welds when compared with conventional GMAW technology.
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New lube gives the slip to stamper's slips, trips, and falls: Lubricant change improves auto supplier’s safety, savings, greenKI 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.
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Advanced materials require advanced knowledge: Understanding resistance spot weld performance on AHSSGiven the range of advanced high-strength steels to be introduced into automotive bodies over the next decade, automakers must recognize the implication of non-traditional resistance spot weld failure modes.
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Getting close to remote laser welding: Research reveals that the technology is a reasonable alternative to resistance spot weldingRemote laser welding is a fairly new kid on the block in terms of joining metal in North America. But it makes complete sense for those high-volume applications where resistance spot welding is used commonly.
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