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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Handling metal stamping wastes: Protecting the environment - - and your businessMetal stamping companies are required to comply with a number of regulations relating to the collection, transport, treatment, and disposal of the wastes they generate. As a result, each company must learn which materials are classfied as hazardous and how to comply with detailed regulations.
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Predicting the service life of galvanized steelZinc, which has been used to hot-dip-galvanize steel for 250 years, provides 50 to 75 years of corrosion protection in many environments. Empirical data collected about hot-dip galvanized (HDG) steel field performance from 1940 to 1980—in environments ranging from industrial to marine to suburban—indicates that zinc can prevent base steel corrosion more than other surface treatments. Because of zinc's long-lasting protection, projects require no maintenance and therefore no maintenance costs.
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Staying safe during HF welding: A common sense approach to personnel protectionProper clothing, training, procedures, troubleshooting, preparation, and equipment for HF welding are critical if you want to prevent workplace accidents.
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Employees value workplace health and wellness programsSixty percent of respondents to a recent survey consider health and wellness programs a viable incentive to stay at their current jobs. But it must be the right program, one that addresses the employees' concerns.
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Defibrillators—Should you have one in your workplace?This article explores the facts about AEDs, the legalities surrounding their use by laypersons, and guidelines for implementing an AED program in the workplace.
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Your best safety resource: The FMA/CNA Safety CommitteeDo you know the Fabricators & Manufacturers Association, International™ (FMA)/CNA Safety Committee? If not, you should. They're an excellent resource for guidance on workplace safety issues. And they're the force behind the safety focus on thefabricator.com.
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Making the workplace safe for Spanish-speaking employeesModifying your safety program to address the needs of your Spanish-speaking employees can create a much safer work environment. Here's how one company achieved that goal.
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Workplace stress—Part 1Stress is a fact of life. It's here to stay, and even if we could abolish it, we wouldn't want to. At its best, stress can be the catalyst that moves us to make changes and achieve great things in life. At its worst, it can create all kinds of emotional and physical problems. What determines whether stress is a friend or foe? Whether it precipitates changes that improve our lives or whether it greatly diminishes the quality of our lives? One determining factor is how we handle or manage stress. We can be our own best friend or our own worst enemy.
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Workplace stress—Part 2If you've visited a doctor recently and were told that stress is the cause of or a contributing factor to what ails you, you're not alone. Although you can't expect to eliminate all of the stress in your life, you can learn to manage it and reduce its negative effects.
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Safety pays |
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Take control of safetyWelders are among the millions of workers who face respiratory hazards every day in the workplace. Confined spaces, solvents, and gas emissions, as well as welding, grinding, and soldering, may expose workers to airborne hazards.
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Surviving an OSHA inspection: What to do if an investigator shows up on your doorstepWeathering an inspection by OSHA is a matter of knowing your operation from top to bottom and being prepared for a visit at all times.
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What price workers' compensation insurance?It's a Catch-22 for many manufacturers. Not having workers' compensation insurance can put them out of business. Paying for workers' compensation insurance can put them out of business. How is a company to survive?
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Workers' compensation—Managing the process |
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Metal formers: Keep an eye on monitoring program: Might Congress consider a change in SIMA? |
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10 questions to ask about equipment leasing: Inquire before you signEquipment leasing—an arrangement in which a business pays for the use of equipment but does not own it—is growing in popularity for many reasons. Benefits of leasing include flexibility, convenience, and protection from having to be responsible for equipment obsolescence.
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Do you see the light?In this article, The FABRICATOR® attempts to shine the light on opportunities for improvement in both the front office and on the shop floor. In this case, the light is on the lights—as well as the heating and ventilating system and other energy-sapping devices.
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Overcoming the skilled labor shortageThe labor force of tomorrow needs to embrace manufacturing today if the industry is going to attract and keep the workers it needs in the future.
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The future of vocational educationThe death knell is sounding for vocational programs throughout the U.S. Readers who responded "Yes, vocational programs have been cut" to thefabricator.com's recent question regarding the status of vocational programs where they live outnumbered those responding "No, vocational programs are intact" three to one.
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Budget cuts hit welding hard: Extraordinary effort is critical to welding programs’ survival |
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Installing and maintaining coil cradles and reelsThe installation procedures that can help to prolong the life of coil cradles and reels are outlined in this article. Specific steps to maintain cradles and reels are also included.
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Technology modernizes CMMs: Hardware, software progress to enhance these shop toolsCoordinate measuring machines have progressed since their inception in the 1970s.
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Bending tube with an all-electric machine: Characteristics and capabilitiesThis article discusses the ins and outs of all-electric tube bending machines, discussing the challenges, performance characteristics, and typical options of all-electric benders.
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Automating for the future: Tube bending tool manufacturer uses software to speed production timeIf you need to cut production time, you might glean a few tips from a little job shop in Ohio that has made the most of its software.
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The growing use of orbital tube welding: Quality, repeatability, and documentation drive the technologyAlthough orbital tube welding has been used in aerospace, semiconductor, and other high-purity applications for a long time, general industrial markets just now are beginning to view it as a viable and economical option for joining stainless steel tubing.
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Tooling, the key for mill productionThis article discusses three main criteria that govern tube mill tooling—design, materials used in their construction, and alignment of tooling on the mill. Discusses advancements in design due to CAD technology; experimental use of ceramic and plastic materials for making tooling; and the use of subplates and interchangeable components to ease tube mill alignment.
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Achieving faster, more efficient tube mill changeoversTube mill changeovers involve more than just tooling. Several variables
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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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Managing environmental risk in tube, pipe production: What you need to know about state and federal regulations |
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Automated welding for job shopsA robotic weldingsystem represents a significant capital investment for a job shop.
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How to Kill a Robotic Project in Five Easy StepsHow would you like to fail utterly in your quest to modernize your shop with robotic weldingequipment? Look no further—we've got all the bad advice you need right here.
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Programming multiple robots: Operating two or more robots from a single point of controlIn many applicatios -- such as large-component welding, press-tending lines, and multiprocess cells -- running multiple robots from a single point of control assists in preventing collisions, simplifying the programming structure, and reducing integration cost. This approach also meets the American National Standards Institute/Robotic Institute of America (ANSI/RIA) R15.06-1999 safety standard.
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Gas-shielded cored wires find their niche: Suitable applications for flux-cored and metal-cored electrodesGas-shielded flux-cored and metal-cored wires are growing in popularity because the wires are fabricated and can be applied to many applications.
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Supporting the defense: Manufacturer uses direct diode laser to weld missile canisters |
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The Brakes: Press Brakes and You -- Whose business is safety? Everybody'sWhat sort of safety measures needed in your shop depends somewhat on your equipment, but making your press brake a safe piece of equipment is largely a matter of old-fashioned common sense.
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New PC-based controls open path to better press brake utilization: Control improvements simplify operator usePress brake forming always has been a labor-intensive process. Shrinking lead-times and smaller lot sizes demand more frequent setups, which cut into productive output hours and put more pressure on manufacturing efficiencies. Fabricators need to find ways to reduce machine downtime for setup and operator adjustments.
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The future of structural welding |