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Articles tagged with "die"

Results: 78

	Tube Hydroforming Design Flexibility—Part I By: Gary Morphy, Contributing Writer Publish date: May 16, 2002 Tech cell: Hydroforming
	The basic elements of tubular hydroforming By: Mustafa Ahmetoglu, Contributing Writer Many factors come into play when attempting to execute a production hydroforming operation, among them material selection, friction and lubricants, tube bending and preforming, and equipment. Many companies in the automotive sector are experiencing great success with the process, which can reduce weight, overall costs, and the number of parts per vehicle. Publish date: March 5, 2001 Tech cell: Hydroforming
	Successful tube hydroforming: Watching parameters, accurately simulating the process yield good results By: Taylan Altan and Suwat Jirathearanat, Contributing Writer A 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). Publish date: June 15, 2001 Tech cell: Hydroforming
	Hydroforming of tubes, extrusions, and sheet By: Klaus Siegert, Markus Haeussermann, and Bruno Losch, Contributing Writer Recent advances at the University of Stuttgart and acfross the industry have opened doors for hydroforming all kinds of materials and shapes. Publish date: May 15, 2001 Tech cell: Hydroforming
	Tube Hydroforming Design Flexibility—Part II By: Gary Morphy, Contributing Writer Publish date: October 10, 2002 Tech cell: Hydroforming
	Using hydroforming aluminum components versus steel stampings: The contender gains points, but the champion is still in the fight By: Daniel Hunter, Contributing Writer This 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. Publish date: November 15, 2001 Tech cell: Hydroforming
	Pressure-sequence and high-pressure hydroforming: Knowing the processes can mean boosting profits By: Gary Morphy, Contributing Writer Pressure-sequence hydroforming can form complex parts as well as forming most ductile metals, including high-strength, low-alloy, and stainless steels with sharper corners, thick-walled tube, and other difficult features. Publish date: February 19, 2001 Tech cell: Hydroforming
	Tube Hydroforming Design Flexibility—Part III By: Gary Morphy, Contributing Writer Publish date: April 24, 2003 Tech cell: Hydroforming
	Eliminating final trim shearing of hydroformed tube By: Donald Godfrey, Scott Huth, and Murray Mason, Contributing Writers The most common way to establish tube length after hydroforming is by cutting or shearing the tube to a specified dimension; however, cutting out this step can reduce scrap. A new method designed to eliminate this step combines forming the end of a tube to resemble its final form with using a hydroform die to correct end position variations off the bender. While this approach eliminates the final shear trim operation, it also presents new challenges. Publish date: October 9, 2003 Tech cell: Hydroforming
	Tube Hydroforming Design Flexibility—Part V By: Gary Morphy, Contributing Writer Publish date: February 26, 2004 Tech cell: Hydroforming
	Roll out the shelving By: Don Dykstra, Contributing Writer Just as office managers look for the most efficient way to store files, shop managers must look for efficient ways to store heavy, expensive dies. Many offices have file cabinets with an index system for locating files quickly. The shop equivalent for storing and retrieving dies may be air-powered rollout shelf units. Publish date: August 28, 2003 Tech cell: Materials Handling
	Keeping pace with today's punching requirements: Advancements in tool design, metallurgy lead to more accurate holes, improved part quality By: Frank Baeumler, Contributing Writer This article provides the basics on how the punch, die, and stripper work; how to perform material thickness calculations on various materials; how different applications affect punching quality; how fully guided tooling counters lateral forces; and how metallurgy, coatings, and maintenance affect tooling. Publish date: December 13, 2001 Tech cell: Punching
	Punching tips: The easiest solution to slug management is to keep the tooling in good condition By: Gerald Davis, Contributing Writer The author discusses what not to do to manage slug ejection. He mentions several tooling maintenance errors that he has made over the years, as well as what machine operators can do if they want to experience slug ejection difficulties. He concludes by stating that the easiest solution to slug management is to keep the tooling in good condition and to use the correct die clearance for the material. Publish date: December 13, 2001 Tech cell: Punching
	See unitized tooling make a difference: Reusable, modular press tooling fits lean manufacturing approach By: Henry Llop From small custom job shops to large, multibillion-dollar companies, manufacturers are accommodating shorter product life cycles to meet the rapid innovation in today's marketplace. Publish date: April 11, 2005 Tech cell: Punching
	Working safety with metalworking fluids: How to protect workers from their harmful effects By: Scott R. Meyer and William S. Boslett, Contributing Writers This article examines the hazards associated with metalworking fluids. Health effects, including skin and respiratory disorders and cancer, are addressed. A look at engineering and administrative controls that can be implemented to ensure the safe use of metalworking fluids is included. Publish date: September 17, 2001 Tech cell: Safety
	Ridin' the storm out: Array By: Kate Bachman, STAMPING Journal® Editor Array Publish date: Array Tech cell: Array
	Ridin' the storm out Part I: Part I: Lean helps stamper squeeze out �automotive 5 percent� By: Kate Bachman, STAMPING Journal� Editor While other automotive suppliers are struggling or going under, Tier II supplier of ride control components Tennessee Stampings established a lean program that merited a regional manufacturs' award and helped them grow 23 percent per year. Publish date: August 8, 2007 Tech cell: Fab Stories
	Maximizing a coil fed press: Variables that influence production speed, setup By: Ted Sberna, Contributing Writer Coil-fed stamping presses are nothing new, but coil feeding processes have changed a lot since the days when press feeders were driven mechanically by crank motion. Influencing these processes are differences between transfer and progressive tooling. Publish date: July 24, 2003 Tech cell: Press Feeding
	Appliancemaker reduces downtime with stamping press feed system: Inconsistent feeds caused die jams, inconsistent parts By: Kate Bachman, STAMPING Journal® Editor The Whirlpool Co. builds refrigerators at its facility in Fort Smith, Ark. The company stamps the appliance parts—large and small, galvanized, cold-rolled, and aluminum—on approximately 35 presses. The majority of its stamping presses are straight-side machines, although some are open-back inclinable (OBI), and a few are hydraulic. Publish date: January 13, 2004 Tech cell: Press Feeding
	Exploring upgrades in stamping presses: The top 10 improvements in the past 50 years By: Bob Kotynski, Contributing Writer The years have brought a host of improvements to stamping presses as technology has made presses more efficient, safer, and easier to use. Publish date: April 24, 2001 Tech cell: Press Technology
	Robotic press tending: vailable equipment and its effects on press productivity By: Rob Vieth and Mary Kay Morel, Contributing Writers Robots offer an alternative to automatic transfer presses in applications in which parts must be reoriented (tilted, rotated, or flipped) as they are moved between operations. When selecting a robot for press tending, three of the many features to be considered are size, flexibility, and mountion options. Publish date: February 19, 2001 Tech cell: Press Technology
	Auto industry demands shape the future of stamping By: Ohio State University As the stamping industry heads into a new century, it continues to be driven primarily by the automotive industry. Publish date: February 19, 2001 Tech cell: Press Technology
	Equipping Your Press With the Right Tonnage Monitor By: Dan Falcone, Contributing Writer This article explains why it's useful to monitor press tonnage, the types of tonnage monitors available, the choices for mounting load sensors, calibrating a monitor, and options available for tonnage monitors. Publish date: November 15, 2002 Tech cell: Press Technology
	Standardizing finger tooling: Modular systems provide alternative to dedicated transfer tooling By: Sharon Patton, Contributing Writer Modular, adjustable, articulated finger tooling for transfer presses may provide the flexibility you need to increase productivity and efficiency in your stamping operation. Publish date: September 4, 2001 Tech cell: Press Technology
	Truckin' along through a stamping plant: Redesigned truck cab leads to new plant, processes By: Tom Juric, Contributing Writer International Truck and Engine Corporation's Springfield, Ohio, plant recently undertook the challenge of building a high-performance truck with the dimensional tolerances that meet today's quality standards within a cost structure that would allow it to remain competitive. This new product launch was the first of its kind for the company in more than 20 years. Publish date: April 24, 2003 Tech cell: Press Technology
	Hydraulic forming takes a front seat: How an automotive supplier improved quality characteristics on seat adjuster channels By: Tom Paisley, Contributing Writer For about 50 years roll forming was the process of choice for making seat track channels at Dura Automotive Seat Systems, Stockton, Ill. While the process was high-speed, low-maintenance, and flexible, it also caused channel end flare, twist, and bow. Publish date: April 24, 2003 Tech cell: Press Technology
	Taking the heat, keeping the current: Heat sinks provide thermal conductivity, electrical isolation By: Ken Wesseln, Contributing Writer Publish date: July 24, 2003 Tech cell: Press Technology
	Virtual tryout: Simulation software simplifies progressive die troubleshooting By: Terry Swan, Contributing Writer Publish date: August 14, 2003 Tech cell: Press Technology
	What's driving your press? By: Errol Neider, Contributing Writer Mechanical presses are challenged to provide high-speed production with a greater number of hits per minute, smaller batch runs, and quicker die changes. Publish date: August 14, 2003 Tech cell: Press Technology
	Stamping out bad parts By: Tim Schmidt, John Tyson and Konstantin Galanulis, Contributing Writers Sheet metal manufacturers are under constant pressure to improve and document quality while reducing costs. Furthermore, original equipment manufacturers are shifting responsibility for quality inspections to suppliers, adding extra burdens. New, complex product designs and rigorous processes, such as deep drawing and the growing use of exotic materials, are placing greater demands on both quality assurance and development departments. Publish date: August 14, 2003 Tech cell: Press Technology
	Using binder force control, force modulation, to improve part quality, stamping efficiency By: Taylan Altan, Contributing Writer Publish date: August 28, 2003 Tech cell: Press Technology
	Spraying it right: Containing and controlling lubricants By: Stan Reineke, Contributing Writer Publish date: June 8, 2004 Tech cell: Press Technology
	Advanced lubricant technology for high-strength steel By: Brad Jeffery, Contributing Writer Publish date: June 8, 2004 Tech cell: Press Technology
	Ridin' the storm out: Array By: Kate Bachman, STAMPING Journal® Editor Array Publish date: Array Tech cell: Array
	Know your bending basics—Part 1 By: Art Hedrick, Contributing Writer Knowing how metal bends and what factors come into play during bending -- especially wipe bending—can make a positive difference in your stamping operation. Publish date: May 15, 2001 Tech cell: Tool and Die
	Deep drawing irregular sheet components: How cushion systems and die stiffness affect the operation By: Prof. Dr.-Ing. H.c. Klaus Siegert, Contributing Writer Innovations in die technology are helping stampers adjust to the many variations that can occur during the stamping process. Publish date: April 24, 2001 Tech cell: Tool and Die
	Preventative maintenance as a way of life: Die shop sparks plantwide process control renaissance By: Tom Ulrich, Contributing Writer The author relates his experience as preventive maintenance (PM) coordinator at a Big 3 automaker. The purpose of preventative maintenance is to gain control of the processes. This begins with data collection on die sets, die failure and material handling damage that will identify weak areas in the stamping process. The author's team began with one set of dies and eventually its PM program was so successful that it was implemented throughout the entire plant. Publish date: November 29, 2001 Tech cell: Tool and Die
	Designing progressive dies: Reviewing the basics of progressive tooling By: Michael Korneli, Contributing Writer Decisions and compromises must be made when designing progressive dies to produce a part. Knowing ahead of time what this process entails just might help you. Publish date: September 17, 2001 Tech cell: Tool and Die
	Improving in-press transfer preformance with tooling: Plan ahead for optimum design By: Daniel R. Leighton, Contributing Writer Using finger tooling and planning ahead of time to minimize costs can benefit your operation ahead more than you think. Publish date: August 16, 2001 Tech cell: Tool and Die
	Transfer die design considerations: Questions to answer for successful design By: Edwin A. Stouten, Cmfg, P.E., and Daniel R. Leighton, Contributing Writers A list of basic requirements must be met to begin the design process for a transfer die. You'll probably want to know why transfer dies are used, methods for loading material, the sequence of operations in a transfer press, and the details of manufacturing process before you start. Publish date: June 13, 2001 Tech cell: Tool and Die
	Cryogenics—Putting the Freeze on Wear Answering Some Commonly Asked Questions By: Bill Bryson, Contributing Writer While cryogenics has been around for awhile, alot of shops don't know how to use the process to their advantage. Knowing a few basics may help your shop turn that around. Publish date: October 25, 2001 Tech cell: Tool and Die
	Know your bending basics—Part 2 By: Art Hedrick, Contributing Writer When trying to make a good 90 degree bend with sheet metal, there's more than on way home. Just make sure your method can accommodate improvisation. Publish date: July 26, 2001 Tech cell: Tool and Die
	Die Design for flat parts: Achieving perfection in a difficult task By: Art Hedrick, Contributing Writer Flatness is one of the most difficult part characteristics to achieve in a conventional stamping die. Publish date: February 19, 2001 Tech cell: Tool and Die
	Part nesting and die design tips for reducing and utilizing scrap in stamping operations By: Art Hedrick, Contributing Writer You 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. Publish date: November 15, 2001 Tech cell: Tool and Die
	Gettin' down with downtime: Reducing unprofitable die changeover time By: Patrice A. Kelly, Contributing Writer Reducing the time it takes to change dies it important to all stampers, especially for custom stampers that run small-quantity jobs. This article summarizes the ways in which automation has helped in this process and then covers two die change methods that are used in a quick change system: the standardized clamping system and the V-notch, or key, system. Publish date: November 29, 2001 Tech cell: Tool and Die
	Designing presses and dies with FEA: Press load information aids process analysis By: Gerry Nord and Kevin J. Coughlin, P.E., Contributing Writers Publish date: November 29, 2001 Tech cell: Tool and Die
	Designing large die sections with reparability in mind By: David A. Smith, Contributing Writer The article explains how EDM has been used to simplify die making as well as some design considerations for minimizing deflection during production. Publish date: September 17, 2001 Tech cell: Tool and Die
	Incorporating available technology into die design: Tools of the trade are evolving By: Robert W. Harper, Contributing Writer Designing progressive dies has increasingly become a high-tech process. The more able an operation is to use computer technology, the more able it is to use the latest advances in the field in its own designs. Publish date: September 17, 2001 Tech cell: Tool and Die
	Tool design tips for coated stampings: Making surface quality a priority By: John Kaikis, Contributing Writer Designers and manufacturers of progressive or stage tooling are faced with a project involving production of metal stampings that will be post-processed with painting, powder coating, or plating operations. Publish date: July 26, 2001 Tech cell: Tool and Die
	Protecting dies against press system faults By: Harry J. Walters, Contributing Writer The need for die protection has existed ever since the first die was produced. The most elementary form of protection has always been an alert, dependable operator. However, an operator cannot always react to a problem before it damages a die. Publish date: May 30, 2001 Tech cell: Tool and Die
	Cutting die-related costs: Where to look to save money By: Michael Korneli, Contributing Writer Demands for cheaper, better, and faster tooling for stampings and the pace of business continue to escalate. This trend is not going to reverse itself. Publish date: February 19, 2001 Tech cell: Tool and Die
	How to draw round cups deeper By: The Ohio State University ERC for Net Shape Manufacturing Draw depth is limited by the onset of wrinkling and fracture. Controlling blank holder force plays a major role in achieving the amount of draw you want from blank material. Publish date: January 15, 2001 Tech cell: Tool and Die
	Improving perforating die performance: The effects of stress, clearance, material By: Nick Tarkany, Contributing Writer Perforating is defined as a process of making a hole by removing a slug. During perforating in a stamping operation, a punch shears and breaks a slug out of the part material and then pushes the slug into a matrix (die bushing). The matrix hole is larger than the punch point. A clearance must be maintained constantly around the entire punch point. Publish date: April 10, 2003 Tech cell: Tool and Die
	Establishing a die setup recipe for progressive dies By: Art Hedrick, Contributing Writer Setting up a stamping die is one of the most critical steps in a successful stamping process. It's a fact: More damage is done to a die, especially a progressive die, in the first 10 hits than in the next 10,000 hits. Most die damage happens during initial setup, when the material is being fed into the die. Mistakes such as misfeeds, pilot piercing, double metal, sheared cutting sections, and stock hang-ups often occur. Publish date: April 10, 2003 Tech cell: Tool and Die
	Applying and handling die lubricants: How to control lubricants for better housekeeping By: Stan Reinke, Contributing Writer The two main reasons for applying die lubricant are to reduce friction and dissipate heat. Heat can build up between the tool surface and metal, causing the lubricant to break down. This results in metal-to-metal contact and galling. Publish date: April 24, 2003 Tech cell: Tool and Die
	Reducing Die Changeover Time without Capital Expenditures By: Gary Zunker, Contributing Writer One of the cornerstones of an efficient stamping operation is its ability to perform die changes in less than 10 minutes. Retrofitting an entire stamping operation for quick die change can require a very costly investment. Justifying such a large amount of money in a short payback scenario can be impossible. Publish date: May 29, 2003 Tech cell: Tool and Die
	Toolmaker tricks By: Art Hedrick, Contributing Writer It is not unusual for me to perform a few magic tricks when holding a conference on stamping die drawing, troubleshooting, or processing. Later on, I may disclose the magicbehind the trick. I do this for a couple of reasons: first, to entertain the conference attendees, and second, to show them that there is no such thing as magic, only physics. Publish date: August 14, 2003 Tech cell: Tool and Die
	Die geometry for embossing and stretching By: Art Hedrick, Contributing Writer Stretching or embossing, not to be confused with drawing, is the process in which the part's geometry is obtained by stretching the metal into a forming cavity. Publish date: August 28, 2003 Tech cell: Tool and Die
	Controlling bend angles By: Art Hedrick, Contributing Writer Bend 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. Publish date: October 9, 2003 Tech cell: Tool and Die
	Rolling bolsters bolster productivity By: Said Lounis, Contributing Writer To thrive and experience growth and healthy profits, a stamping company must have systems in place that allow flexible manufacturing and minimize press downtime. Changing from one job to the next in the least amount of time possible is one of the primary factors impacting productivity and a company's ability to adjust to the changing needs of customers quickly and efficiently. Publish date: January 13, 2004 Tech cell: Tool and Die
	Venturing Into the World of 3-D Die Design: 10 questions to ask to make an informed decision By: Robert W. Harper, Contributing Writer 2-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. Publish date: March 11, 2004 Tech cell: Tool and Die
	Stamping tools for UHSS get tougher: New automotive materials force tool material to shift into high gear By: Ed Severson and Brett Krause, Contributing Writers Publish date: April 6, 2004 Tech cell: Tool and Die
	Pitch notch or not? Factors to consider when designing progressive dies By: Art Hedrick, Contributing Writer Publish date: April 6, 2004 Tech cell: Tool and Die
	Eliminating slug pulling during piercing operations By: Art Hedrick, Contributing Writer Publish date: May 4, 2004 Tech cell: Tool and Die
	Saving time and reducing waste with quick die change: Why and how to justify the cost By: Herb Kamphausen, Contributing Writer Quick die change is not just a way of setting up dies; it's a mindset for the elimination of waste. Publish date: May 4, 2004 Tech cell: Tool and Die
	Sink-making secrets By: Art Hedrick, Contributing Writer Publish date: June 8, 2004 Tech cell: Tool and Die
	Acoustic emission monitoring for stamping presses: Optimizing production for better quality, longer tool life By: Ferdinand Oppel, Dr. Thomas Terzyk, and Chris Kane Contributing Writers Publish date: July 13, 2004 Tech cell: Tool and Die
	Implementing a stamping sensor program—uphill: Gaining cultural acceptance the most difficult part By: Kate Bachman, STAMPING Journal® Editor Publish date: January 11, 2005 Tech cell: Tool and Die
	Actualizando una prensa para un cambio r�pido de dados: Una mirada a lo b�sico y a las alternativas en equipos By: Ron Demonet Un programa efectivo de cambio rpido de dados para equipo existente requiere una cuidadosa evaluacin de las necesidades del cuarto de mquinas, para reducir costos y aumentar la productividad. Publish date: July 10, 2007 Tech cell: Tool and Die
	Bending tube with an all-electric machine: Characteristics and capabilities By: Jeff Tapper, Contributing Writer This article discusses the ins and outs of all-electric tube bending machines, discussing the challenges, performance characteristics, and typical options of all-electric benders. Publish date: December 13, 2001 Tech cell: Tube and Pipe Fabrication
	The wrinkle-wiper for tube bends: How to choose and use wiper dies By: Teresa Fisher, Contributing Writer A wiper die is a piece of tooling used in tube bending that helps keep the bend from wrinkling. While there are many reasons and ways to use a wiper die in a tube bending maching, you should also know what types are available, their differences, and how to choose the right one for your application. Publish date: September 25, 2003 Tech cell: Tube and Pipe Fabrication
	Troubleshooting compression bending By: Marsha Blasengame, Contributing Writer You can achieve nearly trouble-free bending by being aware of the causes of typical compression bending problems and by correctly operating and maintaining the compression bender. Publish date: January 13, 2004 Tech cell: Tube and Pipe Fabrication
	Comparing single-cut and dimple-free tube mill cutoffs: When to employ each system By: John J. Pavelec, Contributing Writer This article covers the application of single-cut and dimple-free cutoff shear technologies as they are applied to contemporary high-speed tube mills. Publish date: October 25, 2001 Tech cell: Tube and Pipe Production
	Minimizing wall thickness variation in seamless tubing By: Wynn H. Kearns, Contributing Writer All mechanical steel tubing has some amount of wall thickness variation. Wall variation in welded tubing results from the strip manufacturing and tube welding processes. Seamless tube, which is created from a hot billet of solid steel, has wall variation that results from tooling wear, bearing and shaft variation, and normal hot-process variation. The wall thickness in seamless tubing varies in the cross section and along the tube's length. Publish date: August 28, 2003 Tech cell: Tube and Pipe Production
	Gas-shielded cored wires find their niche: Suitable applications for flux-cored and metal-cored electrodes By: Dwight Myers, Contributing Writer Gas-shielded flux-cored and metal-cored wires are growing in popularity because the wires are fabricated and can be applied to many applications. Publish date: June 15, 2001 Tech cell: Consumables
	Selecting a new press brake By: Bob Butchart, Contributing Writer Prospective buyers of press brakes are advised to consider their purchase in terms of its end use, the amount of deflection likely to occur in a give machine, the inside radius of their parts, and several other factors before speding their money. Publish date: March 23, 2001 Tech cell: Bending
	The Brakes- Press Brakes and You -- How to get the most out of your press brake By: Bob Butchart, Contributing Writer Problems with your press brake imperil what could be the most valuable machine you have. Take pains to ensure the health of this valuable piece of equipment. Publish date: June 18, 2001 Tech cell: Bending
	Discovering the limits of press brake tooling By: Steve D. Benson, Contributing Writer One of the most important aspects of press brake forming is tooling selection. What are the tools capable of? What kinds of loads can they withstand? Publish date: May 30, 2001 Tech cell: Bending