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Articles tagged with "stamping"
Results: 304
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How one company organized its powder coating process: Tips from a job shopLearn how Gauthier Industries, a stamper and powder coater, organized its powder coating operation into control points to help regulate quality and efficiency as parts move through the finishing process. Areas discussed include pretreatment, the paint booth, inspection, and tips for efficiency.
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Hydroforming of passenger car fuel tanksPassenger car fuel tanks have for many years been made out of plastic. To reduce MTBE leaks in the groundwater, the Department of Energy, The State of California, and the Western States Petroleum Association are studying material alternatives such as high-strength steel, stainless steel and aluminum gas tanks.
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Processes for hydroforming sheet metal: Part III: SHF-P and SHF-D case studiesPart three of a three-part series on sheet hydroforming, this article reviews the SHF-P and SHF-D processes.
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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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Scrap the belt conveyors: High-volume stamper turns to shaker system for scrap removalThe traditional belt conveyors used to remove scrap from the stamping operations at American Trim's facility on Baxter Street in Lima, Ohio, just couldn't stand up to the gritty shop environment. The company found a successful alternative with a belt-less material movement solution from GSW Press Automation.
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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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Mission: Spectacular scrap handling operations: Possible: Smooth, speedy, stealthyStampers, precariously squeezed by tight margins, high material costs, and increasing pressure to be leaner, have issued a request: we want our scrap handling operations to be faster, trouble-free, and more productive. Fortunately, the latest generation of scrap handling equipment makes that mission possible. New machinery, trending toward a greater use of invisible forces and high-tech gadgetry befitting a spy thriller, is equipped with sensors, edge-guide systems, automation, and magnetic forces, equipment manufacturers say. In addition, significant improvements have been made to the scrap handling equipment itself to save space, minimize jams, and to keep it moving.
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Moving material efficiently: 4 questions to ask before purchasing a conveying systemIt's a challenge to select the most efficient conveyor for a particular application. To make the best choice, it's imperative that all operating parameters be considered.
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Packaging finished stampings: Protecting parts so they don't end up scrapProper packaging is an essential part of the manufacturing process that often is overlooked. For stampers who outsource final part finishing, it is an even greater concern. This article explains why proper packaging is so important and gives several options for keeping part quality intact during shipping.
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5 ways to leaner die handling: Vertical storage and retrieval systems help shops reach for leanUsing conventional rack and shelving systems to store and retrieve dies is inefficient and can cause damage to dies. Five critical areas of concern are space utilization, worker productivity, potential for die damage, ergonomics and cost justification. Shops can reach new lean levels by improvements in these areas.
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Extend conveyor life with maintenance, modification: Avoid line shutdownTo the naked eye, conveyor design doesn't look looks it has progressed much in 40 years. The conveyors of today are engineered with unique design elements and innovations that make them more versatile than ever for today's metal stamping applications. A conveyor with the latest technologies is good only if it is running properly. Simple preventive maintenance techniques can save stampers time, money, and a lot of headaches.
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Conveying flexibility: How to avoid building up a conveyor graveyardManufacturing companies must walk a fine line between choosing a conveyor system suited for the application, while maintaining flexibility so the system can handle future jobs.
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Introduction to advanced high-strength steels: ArrayArray
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The benefits of materials engineeringU.S. stampers are missing an opportunity to gain a competitive edge by offering materials engineering support, which often is lacking within OEMs and Tier 1 suppliers. Many stampers take the position that they "just build to a print"—but so do overseas shops.
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Guidelines for forming high-strength materialHigh-strength materials are becoming more common in stamping, especially for the aircraft and space industries. Although they all have their own specific features, they have some common characteristics and typical reactions to stretching and drawing.
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Defining material specificationsThe root cause of splitting problems in deep-drawn parts often is that the process is not designed and engineered to accept the full range of mechanical properties within the ASTM specifications.
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Structured sheet metal: ArrayArray
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Stamping 101: Material guidelines: Properties and characteristics that affect formabilityEach metals has its own blend of physical, chemical, and surface properties and characteristics. Knowing about the major work metals (not tool steels), their properties, grades, and characteristics helps to achieve the best results in stamping and forming best results.
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Introduction to advanced high-strength steels - Part I: Grade overviewAdvanced high-strength steels (AHSS) offer enhanced formability. This article discusses the properties and performance of various grades.
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Introduction to advanced high-strength steels - Part II: Processing considerationsUnderstanding and compensating for the challenges associated with processing advanced high-strength steels (AHSS) can help you minimize springback, edge cracking, trimming, wrinkling, and die wear.
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Structured sheet metal - Part I: Comparing processesIncreasing sheet metal component rigidity while reducing weight can be achieved by substituting steel with aluminum, magnesium, or titanium alloys; advanced high-strength steel (AHSS); or 3-D structured sheet metal.
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Structured sheet metal - Part II: ApplicationsVault-structured sheet metal undergoes very little strain hardening during structuring, so it can be deformed further into shapes such as cans, containers, washing machine drums, thin-walled detector tubes, heat exchangers, and light reflectors.
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Continuing the look at die materials and wear in stamping AHSS: Part II: Tests for evaluating galling, wear of tool materials and coatingsStampers use tests to evaluate tool materials and coatings for wear issues. The main tests are scratching tests, twist compression test, strip-reduction tests, and forming tests.
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Die materials and wear in stamping AHSS: Part I: Die wear and die coatingsStampers use tests to evaluate tool materials and coatings for wear issues. The main tests are scratching tests, twist compression test, strip-reduction tests, and forming tests.
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Solving pierce punch breaking and chipping problems |
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Tap into success: Planning ahead for good tapping resultsEven with all of the new advances in metal stamping technology, screws and threaded holes are still the trusted staples for metal fastening. Tapping the threaded holes has never been an easy task, however.
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Safety with press hydraulic systems: Preparing for and handling hydraulic fluid spillsWhat happens when a hydraulic system—pumps, hoses, and fittings—fails—Knowing how to avoid, cope with and clean up the mess to ensure personnel safety and minimize downtime could come in very handy one day.
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Machine safeguarding with optoelectronic sensors: How to choose the most appropriate equipmentOptoelectronic sensing devices safeguard machine access and prevent injuries related to hazardous machine motion. The ultimate goals are to prevent access to the hazard, eliminate the hazard before access is attained, and prevent the unintended operation of a machine.
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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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Live or die making tools: Tool and die shop scraps its business model to remain successfulA tool- and die-maker for 50 years, Leo Niemela started out successfully enough in the tool and die business. But as the industry started to decline, he and his family had to decide which direction to take: stay with tool and die or reposition the company.
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Stamping CEO hopes to strengthen U.S. manufacturingUsing his experience in the manufacturing industry, Don Wainwright plans to help improve the U.S. manufacturing industry through his position as chairman of the Department of Commerce's newly created Manufacturing Council.
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Bulletproof processes: Alpha Stamping is reinventing itself with lean manufacturingWhile some stampers are filing for bankruptcy, Alpha's lean manufacturing initiatives have propelled the Detroit-based stamper to a $50 million-dollar company and growing
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Stamper, prototyper, assembler, or fabricator: One company, many rolesNewspapers and business magazines are filled with stories about offshoring, layoffs, and plant closings. Quasar Industries, a prototyping and low-volume production shop near Detroit, has bucked this trend and recently increased its manufacturing capability when it purchased a new building. A diverse fabricator, the company provides tooling development and also does stamping, laser cutting and welding, robotic welding, tube fabrication, and machining. The company's client base includes the automotive, appliance, and aerospace industries, among others. But all the equipment it has and processes it performs don't make it successful. Its success is a result of its employees' expertise and its corporate culture.
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Ridin' the storm out: ArrayArray
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Silicon Valley stamper sizes up, down electronics: Builds on strengths, carves nicheCalifornia electronics stamper Scandic Springs Inc. faces challenges of stamping ever-shrinking electronics components as well as stamping larger parts, such as enclosures.
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FMA goes to ChinaTwo weeks after the first FMA China Tour group returned to the U.S., news broke that IBM had entered into talks to sell its PC business to China's largest PC manufacturer, Lenovo. That news came as no surprise to tour participants.
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The Big Three's 2005 cost challenges |
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The China-dominated manufacturing environment: What are you doing to compete?All manufacturers have to realize that what is going on in China will affect them in some way, no matter how small their business is. Protectionist policies from the U.S. government aren't on the horizon to help. Business owners and managers are negligent if they do not make an effort to understand the economic changes caused by China's movement to a market economy in some detail and then use that understanding to evaluate and likely modify their companies' business plans.
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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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Appliance demand flat: Industry undergoing major segment shifts2007 U.S. appliance shipments are forecast to grow only 1 percent because of a sluggish housing market. Shifts in channel preferences; successful market penetration by offshore brands; a strong demand for high-priced, innovative white goods; and the Maytag/Whirlpool merger are changing the industry's landscape.
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Competing with global sourcing in a 'knowledge economy': How Western attitudes can be a disadvantageWestern companies believe that although India and China are receiving a lot of manufacturing sourcing jobs, they cannot compete with Western skills. However, with developing "knowledge economies" and an openness to change and progress sometimes lacking in Western companies, these countries could easily become top world economies. This article explores how one Indian stamping company had great success implementing a knowledge management system.
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Creating a pressroom preventive maintenance program: A step-by-step guideA press maintenance program should be designed to minimize downtime, enhance machinery output, and establish a formal record keeping system for ongoing inspections.
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'It's the economy, stupid'The annual "Fabricating Update" survey of metal fabricators about their main business concerns revealed that the economy, which edged out steel prices as the industry's leading concern in 2008, now outranks all other concerns by a huge margin. This latest survey also polled readers of "Stamping News Brief" and "Tube Talk" for an even greater sampling of the metal manufacturing industry.
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Lean and Mean: How a $50 million stamper became more efficient, profitableThe metal stamping industry is facing many challenges, such as increased raw material prices, pressure from automotive industry OEM and Tier 1 and Tier 2 customers to cut costs, and increased competition from low-cost offshore stampers.
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How to get a handle on your inventory: ... and what not to doWell-managed companies have taken aggressive steps to reduce "at-rest" inventory by revamping their supply chains to support smaller, more frequent shipments. Industry sources have reported that some of the best performing stamping companies are turning inventory 28 times annually.
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Lean implementation failures: Why they happen, and how to avoid themThe most important parts of lean implementation are preparation—especially an objective assessment and development of the business and technical cases for lean—leadership that can get things done, appropriate training, resolution of people issues, and well-designed deployment methods.
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Strategic sourcing for stampers: Reducing material and purchasing costs through an annual buy programMaterial is the largest cost component for stamping companies, but does not receive much management attention. An annual material buy program can help stamping plant managers make substantial cuts in their material costs and other costs associated with the purchasing department.
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Survival—Are factors other than the economy dragging down your operation?Art Hedrick, longtime consultant to the sheet metal stamping industry, has observed three internal factors that can negatively affect an operation. In this economic climate in which so much is at stake, you want to make sure that your business does not suffer from these self-destructive characteristics.
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Older than Oscar: Century-old stamper seats thousands of movie-goersFamily-owned, fifth-generation manufacturer Irwin Seating Co., headquartered in Grand Rapids, Mich. has been thinking about the comfort and functionality of the public seating it has manufactured for more than 100 years. The company's 35 presses are used to stamp the components that support the seats, mount them to the floor, and attach them to the backs; as well as pivots, brackets, and other internal mechanisms. Irwin does all the stamping, welding painting, and upholstery work in its 470,000-sq.-ft. facility. Some of the seating company's recent projects include the stadium seating for the New Jersey Devils, Miami Heat, and the Indiana Colts.
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Psychology for the tool room: How to open the lines of communication with your employeesAs a consultant for the sheet metal stamping industry, I have had the opportunity to visit numerous stamping plants, die shops, and engineering facilities. One comment I often hear during these adventures is how arrogant or "know-it-all" some of the toolmakers or engineers are.
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Not Your Parents' WorkplaceEditor's Note: This column was prepared by the staff of Winning Workplaces, a not-for-profit organization that helps small and midsized businesses create better work environments.
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Improving stamping production end to end: Reducing scrap, tooling damage with coil end weldingExploring the benefits of welding coils in roll forming and progressive stamping operations. Welding coils can reduce scrap, downtime, and tooling damage. A variety of coil end joiners are described, such as portable, stationary, single-and double-cut, fully automatic, and semiautomatic.
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Sizing up pallet decoilers: Choosing the proper motor table sizes saves time, moneyThe primary reason for purchasing a decoiler is to increase production. By correctly sizing the machine for your needs, you can increase production and the bottom line.
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Keep on stamping: Correcting material-equipment induced process problems |
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Evaluating in-house coil slitting: Key areas to consider |
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Straight to the point: The importance of straighteners in stamping operationsThe straightener, when set properly, removes the coil set, or curvature of the rolled material. If the machine is used or set incorrectly, the coil set can remain in the material, even after being struck in presses with capacities to hundreds of tons. This can cause a variety of problems: out-of-tolerance parts, difficult feed operations that can disrupt and slow performance, and, to some extent, additional wear and tear on feed line components and tooling.
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Achieving consistent stock lubrication with less oil: How LVLP technology works in the stamping shopLow-volume, low-pressure (LVLP) lubrication systems can offer stampers a way to maintain the most appropriate lubrication level for each job while reducing oil consumption.
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Maintaining a slitting line: Tips for extending equipment lifeA slitting line can operate efficiently for 20 or more years if properly maintained. Modern slitting lines are high-performance machines that are intended to produce 24 hours a day, 365 days a year. As a result, stampers must be sure that all line elements are properly maintained, which represents a titanic effort if you don't understand what components are critical.
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Straightening mistakes: Clearing up 12 common misconceptionsAs a consultant to the industry, the author has had the opportunity to discuss coil straightening and leveling with many people. In this article, he reviews 12 common misconceptions he has heard from those people.
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Getting a handle on coil handling: One size doesn't fit all when selecting coil handling equipmentCoil handling equipment can take up a lot of space, so it's important to consider different equipment configurations and options that may deliver much-needed floor space.
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New handling instructions: Weiss-Aug. Co. Inc. reorganizes its stamping operations, takes on a new approach to coil handlingIn 2005 precision stamper Weiss-Aug of East Hanover, N.J., achieved a reject rate of less than 1 part per million. The company credits the success to meticulous planning and almost flawless execution. Such an approach applies for Weiss-Aug even when it comes to uncoiling metal.
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Feed to registration: A different way to process round, nested parts efficientlyFor applications such as clutch disks, oil seals, oil filters, and other round stampings, feed to registration with scroll-slit material can reduce scrap rates and, in some cases eliminate the need to retool the job.
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Doing its level best: Automotive blanker's leveler eliminates costly shape defectsA precision roller leveler, installed between the coil payoff reel and the press equipment, allows an operator to stretch the edges when necessary to compensate for loose centers or stretch the center to compensate for loose edges before the blanking operation.
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The big payoff: Pallet uncoilers help to reduce scrap, labor, and safety costsTraditional coil slinging and hoisting for vertical dereelers and positioning them in coil cradles requires extra personnel and is time consuming because production must be stopped. When a line isn't running—it's not making any money. To keep your line moving, consider a pallet uncoiler.
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Roller leveling 101: A review of the basicsEvery metal coil has unique characteristics. Leveling is achieved by precisely bending metal strip back and forth as it's passed through a series of small-diameter offset rolls.
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Technological quantum leap: Multiblanking line improves output, creates new opportunitiesArme S.A., a Colombian service center, was producing cut blanks for several local, small customers using a 48-year-old Stamco cut-to-length line purchased more than 20 years ago. It served them well over the years, but the company realized it needed to upgrade its technology to take advantage of the market opportunities it saw growing around them.
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Keeping stainless flawless for appliance stamping, fabrication: Processing stainless safely through 7 damage-danger zonesBefore stainless steel is stamped, bent or folded, and fabricated into an appliance, stampers, other fabricators and coil processors need to do damage control as they process stainless steel coil through 7 damage-danger zones.
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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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Leveling flat-rolled strip: How roller levelers handle the taskOperating a leveler requires training and skill, but computers are making the task much easier. A computer can quickly set the machine to a good starting point and allow very fine adjustment of the back-ups. Once the leveler is delivering good results on a particular coil, the settings can be saved and called up later. That saves setup time when coils are partially run and then sent back to stock.
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6 ways to focus on slitting lines: Improving efficiency ... one component at a timeBy improving entry coil storage, coil inside diameter (ID) changes, slitter tooling changeover, scrap handling, and strip tensioning, you can slitting line efficiency.
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Dissecting defects: ArrayArray
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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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Reducing lubricant waste: A proactive approach for stampersThe best strategy for waste reduction is to reduce waste generation. Stampers have several strategies available, such as switching to metalworking fluids formulated for long life and instituting a fluid management and maintenance program.
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What you should know about stamping coated coil: How to maximize prepainted metal’s advantagesMore than 4.5 million tons of coil-coated steel and aluminum are processed in North America each year by manufacturers in the appliance, auto, machinery, heating and cooling, metal roofing, and beverage industries. Gaining insights into stamping, handling, tooling, and storage can help optimize results
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Die shop transitions to production stamper: Servo feeds help facilitate transformation, adaptationThird-generation die maker company, Die-Tech Industries needed automated press feeding equipment to help handle its transition from a die shop using tryout presses to one running full production.
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Controlling flat-rolled shape: What’s the problem? What’s the fix?What processes do you need to make sure your coil is flat? What is flat enough? You need to determine where you are at the start, where you want to end up, and how to get there. Once you have determined which shape problem you have you can determine which type of equipment is effective in controlling it.
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Dissecting defects Part I: Examining process variables to find stamped part quality flaws: Part I: Examining process variables to find stamped part quality flawsTwo main types of defects are typically observed in stamped automotive body components: Surface defects, such as cracks and necking, and form defects, such as fall-in, wrinkling, and marking lines. These static defects, such as surface imprints, are not process-related but instead are caused by contaminated die or tool faces. These defects are corrected by simply cleaning the die or tool surface before stamping. Dynamic defects are process-related and are caused by the forming process.
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Adding flexibility to stamping operations: The roles of material handling and group technology analysisYou're not afraid of automation. You already have automated several cells around high-volume parts. But now you have a new challenge: Integrate several large presses while still maintaining the flexibility to run lower-volume parts?
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Coil feed line considerations when stamping HSS: Making adjustments for stronger steelWith its higher tensile and yield strengths, HSS is stronger at any given gauge than conventional "mild" steels. Initially, lighter-gauge HSS was used to replace heavier-gauge mild steel to reduce weight in many automotive parts, and this continues to be the most widely used application for HSS. However, as a new trend to run thicker and thicker gauges of HSS continues, stamping fabricators are evaluating their press feeding and coil handling equipment, as well as press tonnage capacities and die designs to ensure that these harder parts can be formed effectively. The dynamics of HSS have a bearing on feeding, straightening, and coil handling equipment.
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Understanding press feeds: A primer for the ‘nontechie’Major technology shifts in how stamping presses are fed have allowed press feed technology to evolve, enabling stampers to realize increased processing speeds, improved processing flexibility, easier setup, and better quality and reliability. Even with today's advancements, a press feed must meet three basic and important criteria to be successful: Setup must be flexible. It must deliver the material with sufficient precision into the tool and die. It must feed at the correct time. Advancements in feed technology include pilot release, space-saving line configurations, transfer/progressive operations, and scratch-free processing.
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Optimizing a single probe, gap-tolerant, double sheet detector system: A guided tour of its working principles, capabilities, limitationsDetecting the presence of two sheets in a press feeding operation uses scientific principles, but the process is not an exact science. A typical press-feeding situation involves an air gap between the detector and the first sheet in the stack or an air gap between the top two sheets, and these air gaps reduce the detector's effectiveness. Understanding the capabilities of the detector and the limitations imposed by imperfect conditions can help stampers set up an effective double-sheet detector system.
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Stamper rebuffs recession with retool: Magnetic die handling, new press cell, coil feeder provide means to weather stormRichland Manufacturing, a subsidiary of Eagle Wings, a tiered automotive supplier, retooled with a new stamping press cell equipped with an electromagnetic die handling system. The retool efffort also included installation of a 330-ton tie-rod type press, and a compact coil feeder.
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Evolution of the beast: Mechanical presses adapt to meet current stamping challengesThis article outlines how mechanical presses are changing to meet a new marketplace. Stampers are adding extra stations to create a more complete part and stamping harder alloys. Servo-driven mechanical presses will make traditional flywheel presses obsolete because they use less energy and can be adjusted midstroke. Technological advances include real-time press monitoring, automatic die changes, and computerized troubleshooting.
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Exploring upgrades in stamping presses: The top 10 improvements in the past 50 yearsThe years have brought a host of improvements to stamping presses as technology has made presses more efficient, safer, and easier to use.
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Absolute Control: Implementing a master control system for hydraulic press linesAdvanced master control systems in hydraulic press lines are designed to help achieve shorter changeover times, transparency of line operation, minimize personnel requirements, and increase productivity levels and uptime.
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Shock reduction methods for hydraulic presses: Tips for keeping your stamping operation running smoothlyEver wonder how to determine and fix shock on hydraulic pressing operations? The author offers an explanation on how to step a press, reduce blank shock, and eliminate up-stroke shock.
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Meet the Press: Deciding when to consider hydraulic power for your stamping operationThe article briefly covers stamping terms and discusses press considerations for those purchasing a hydraulic blanking, stamping, or deep drawing press.
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Choosing a Lubricant for Deep Drawing |
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Rapid evolution, not revolution: Big changes work their way through appliance stamping shopsChanges are taking place in stamping operations in the appliance industry, with more on the way. And the science of stamping is improving significantly as a result. In this article, appliance industry executives express their opinions of the state of this technology.
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Recovering from press overload: Protection systems help to sense overload and minimize machine, tool damageThis article discusses what hydraulic overload protection system is and gives a brief description of the three main types.
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Leaving the lab behind: Australian students move stamping research to the plant |
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Stamping out bad partsSheet 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.
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Sizing up servo presses: A look at tonnage and energyServo-powered presses will not replace all flywheel mechanical presses. Each technology has its advantages and disadvantages, depending on the stamping application.
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Using Monitoring Systems to Improve Stamping 'Batting Average'What do baseball players, weather forecasters, and typical stamping plants have in common? Most are less than 60 percent effective.
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Controlling double sheet in stamping operations: Sensor options and helpful suggestions |
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Sequence scheduling in automotive scheduling: Weekly routines demystify production schedules, inventory levels |
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Servo-driven mechanical presses meet HSS head-on: Control of slide motion, velocity puts stamper in the driver’s seatA recent mechanical stamping press innovation, the servo drive is designed to meet challenges related to stamping high-strength steels (HSS).
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Advanced lubricants improve high-strength steel forming: New data uncovers measured results |
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Optimizing spray nozzle performance for lubrication:: The importance of selection, maintenance, and automation |
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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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AHSS Tooling Requires Greater Protection: Forming fluids for extreme frictional forcesTools are subject to extreme wear during AHSS forming. Using the right lubricant can help increase tool life.
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Blanking questions have you on the edge?: Understanding blanked edge characteristics improves stampingReducing the damaging effects of fractures, burnishing, burrs, and rollover improves subsequent forming processes. The blanked edge condition can be improved by adjusting the punch and die clearance tolerance, shaving the area of the defected blanked edge, designing an appropriate contact profile of the tool and die, and understanding the mechanical properties of the sheet metal used.
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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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Pairing the right hydraulic press with your application: Getting the best return on investment with the right returnChoosing the right hydraulic press for your application is crucial. Identifying the right press capability up front can eliminate additional costs and startup delays. Four primary hydraulic press return capabilities are return on position, return on pressure, return on pressure with dwell capability, or combinations of the three. Shown is a press with return on pressure capabilities.
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Knockout punch: Hand-in-glove fit between application and process has Sanmina-SCI punching out profitsThe system Sanmina-SCI uses to produce rails for Sun Microsystems' large servers is a key factor in Sanmina-SCI's competitiveness when it comes to processing a large, heavy-gauge, complet part, delivered in large volume on an as-needed basis for computer server systems and other similar applications.
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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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Feeling overwhelmed with pressures?: Die changeover is just one area to bang out inefficienciesStampers face increasing pressure, from external and internal customers, every day. This, combined with increasing responsibilities, can cause production personnel to feel overwhelmed. Long die changeovers gobble up precious time that could be used for better purposes, leaving many production teams operating in a firefighting mode. Doing a thorough time study and using the results to eliminate time-wasting steps is the first step in implementing quick die change, freeing up some time for value-added activities, and getting control over your production processes.
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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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Implementing Press Automation: Updates and advancementsTo compete in a global market, all stampers need adapt their manufacturing processes. By mixing automation with electronic controls, job shops can increase output and exceed past manufacturing goals.
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A closer look at self-piercing riveting: Computer simulation is a noteworthy alternative to physical testing of jointsSelf-piercing riviting, an alternative sheet joining method, is being used more to join aluminum sheets. The finite element method can be employed to study the SPR process and joints, perhaps even leading to the elimination of physical testing of these mechanical joints.
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Die building: Three important processing questionsIn any stamping process including progressive dies, transfer dies, or line dies, three factors are essential to consider when processing a piece of flat metal into a finished part: What is the metal? What is the metal's thickness? What are the part tolerances?
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The modern mechanical press: Link motion, servo technology, and slide guide advancementsEnd-user demands for new product configurations, materials, and press capabilities continue to have an impact on the metal forming arena. Mechanical press design improvements and flexibility are keeping up with stampers' changing applications.
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The process of fineblankingFineblanking can achieve flatness and cut edge characteristics that are unobtainable by conventional stamping and punching methods. Fineblanking is described in relation to conventional methods to encourage a better understanding of its benefits and limitations.
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Getting hydraulic press problems under control: Control system upgrade solves reliability problems, expands press capabilitiesArco Industries Inc. bought a 15-year-old, 500-ton Tranemo hydraulic punching press with an antiquated control system. For about one-quarter the cost of a new press, Arco was able to rejuvenate an obsolete press by providing it with contemporary levels of control and productivity.
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Draw forming: ArrayArray
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Meeting global challenges through employee rewards: Gainsharing can be a big step toward staying competitiveArco Industries Inc. bought a 15-year-old, 500-ton Tranemo hydraulic punching press with an antiquated control system. For about one-quarter the cost of a new press, Arco was able to rejuvenate an obsolete press by providing it with contemporary levels of control and productivity.
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Unique forming short cutsDie designers often are faced with how to make a part feature that is unique and possibly difficut to form. Short cuts are discussed for twisting a part, creating a return flange, and making a 90-degree bend.
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Setting up progressive dies: ArrayProper feeding, scrap removal, and shut height calibration are essential for good die setup.
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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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Drawing on new experiences: Whirlpool Corporation's new line is a flexible approach to refrigerator door fabricationIn the past metal forming in the appliance industry meant giant presses with expensive tooling. Lead-times were forever, and change didn't come easy. Whirlpool Corp. in Fort Smith, Ark., is taking a new approach to metal forming, and flexible technologies are the key.
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Multipoint-control die cushion systems for stamping complex parts: ArrayArray
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Designing dies 2-D or 3-D?Both 2-D and 3-D die design packages have advantages and disadvantages, which are discussed here, but true success lies in the designer's ability, not the software's.
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Viking's range of choices: Appliance-maker chooses a hydraulic press system with precise stamping capabilitiesThe stainless steel stampings Viking Range produces often require complex draws and piercing, as well as sharp corners and creases—with flawless exterior finishes. Viking has moved from outsourcing its stampings to using press brakes to investing in hydraulic presses of increasing capacity and sophistication—all in an effort to gain greater control over the design, quality, and availability of stamped parts.
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Hot-stamping boron-alloyed steels for automotive parts: ArrayArray
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Protecting metal stamping dies: How to prevent die crashes with sensorsOne of the most difficult problems to overcome in any die protection application is protecting the components from the environment in which they must function. In a typical stamping application, oils, coolants, and other liquids and lubricants often are present that can wreak havoc on components.
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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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Steel thixoforming: Emerging technology may help steel parts compete with other materialsThe demand for lightweight, high-strength components is increasing at the expense of traditional steel parts.Emerging technologies, such as steel thixoforming, may help reverse this trend. Thixoformed steel parts are significantly lighter than equally strong parts formed by conventional means.
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How to keep hydraulic presses running: Know thy press: In sickness and in healthSeveral preventive maintenance steps can help extend hydraulic press life. Press operators who stay in tune with their press and establish good, consistent maintenance practices from the beginning will benefit the most.
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Flexibility in the press shop: Arranging equipment to produce a variety of partsTo stay competitive, stampers must be prepared to run a variety of dies, many of which have been designed to run on customized and complex OEM equipment. In addition, stamping concepts tend to differ among the automotive OEMs. For the tier stamper, flexibility is key to surviving these fiercely competitive times.
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Stamping research gains support: Forming lightweight alloys, UHSS emphasis of studyGlobal competition continues to force the metal forming industry to reduce costs, improve technology, and increase productivity. With these trends in mind, the Ohio State University (OSU) and Virginia Commonwealth University (VCU) established in June 2006 the Center for Precision Forming to focus on the needs of the metal forming industry.
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Evaluating film lubricants for stamping: Deep-drawing test makes the most senseThe ERC/NSM conducted extensive deep-drawing tests to evaluate various dry film lubricants for several companies. Compared with other commonly used friction tests such as draw bead and twist compression tests, deep drawing emulates realistic friction conditions that exist in stamping operations in terms of the pressure and forming speed interface .
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Blanking developments: ArrayArray
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Mechanical presses primed for powerful performances: New materials create a need for high-tonnage presses, larger bedsMetal stampers are using more high-strength steel, which is more difficult to form, requires more tooling stations, and more press tonnage. As a result, stampers are moving away from traditional production methods and investing in presses with higher tonnage capacity and larger beds.
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Turning it around (fast): Flexible hydraulic press technology helps stamper meet tight customer deadlinesWhile other Midwest manufacturers are struggling, plumbing manufacturer Bradley Corp. is projecting it will double in size in the next four years. This growth is attributed to the company's flexibility—its ability to adapt equipment, processes, and scheduling to quickly turn around incoming customer orders.
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Ridin' the storm out: ArrayArray
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Clearing the springback hurdle: Knowledge and planning are keys to successSpringback is a fact of life for stampers, but knowing what causes it and how to deal with it -- through stabilization, compensation, and verification -- can help them overcome the problem.
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A new standard in forming bathtubs: American Standard introduces new technology to a older forming lineThe main hurdle to automating American Standard's bathtub forming line in its Salem, Ohio, facility was integrating new material handling tools into the older press line.
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Retrofit Rxfor automaker's aging press: Modular hydraulic cushion upgrade eases maintenance, improves performanceAn automotive OEM's 4,000-ton transfer press produces parts with difficult draws, such as pickup door panels, in the 1,600-ton first station. Facing problems finding obsolete parts for repair and also considering crucial performance requirements in that first drawing operation, the automaker had Schuler Inc. upgrade the press with a modular hydraulic bed cushion.
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Stamping with third-generation dry-film lubricants: Characteristics and User ApplicationsA third-generation dry-film lubricants consist primarily of blends of various polar and low- to nonpolar plymers with different molecular weights. They are designed to form extremey thin, highly cohesive bonds to the metal surface. This article explains how they differ from previous generations of dry-film lubricants and presents several application examples.
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Metalforming lessons learned abroad: What U.S. stampers can learn from global counterpartsAfter World War II, equipment manufacturing companies in Asia and Europe designed production systems that were more flexible in nature than systems in the U.S., which were designed for high-volume production. Today this trend is hitting U.S. shores, and U.S. stampers are looking overseas for inspiration in finding ways to work more efficiently.
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Cómo mantener las prensas hidráulicas operando: Aprenda todo lo que pueda sobreLa posicin inicial de la parte plana est hacia el lado equivocado o est al revs de su flujo natural? Usted est trabajando de izquierda a derecha cuando su movimiento natural es de derecha a izquierda? La clave para un doblado exitoso es acomodar la prensa de forma que usted trabaje con su flujo natural.
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Dissecting defects: ArrayArray
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8 Things you should know about your hydraulic press: Press checks and maintenance keep it running at peak performanceWhat should you do to keep your hydraulic press running? Know your press--when it is working properly or when it needs attention. You can extend press life and maximize your investment by keeping your eyes and ears tuned and by performing 8 preventative maintenance steps.
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Stamping 101: Anatomy of a Mechanical PressStamped components are made by forming, drawing, trimming, blanking, or piercing metal—in sheet or coil form—between two halves (upper and lower) of a press tool, called a die. The upper member (or members) are attached to slide (or slides) of the press, and the lower member is clamped or bolted to the bed or bolster. The die is designed to create the shape and size of a component. The two halves of the die are brought together in the press. Both force (load) and accuracy are required to achieve the repeatability and tolerance demands.
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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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Applying parallelism technology in hydraulic presses: Active leveling control offsets press, tooling problemsActive leveling control (ALC) counteracts the negative effects of off-center loading; significant breakthrough shock common with high-strength steels (HSS); and reverse shock loading associated with nitrogen springs in dies.
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Hydraulic presses for hot stamping meet weight, safety mandates: It's all in the dwellHot stamping of automotive structural safety components developed in response to mandates levied by the U.S. National Highway Traffic Safety Administration (NHTSA) 1 to improve vehicle crash integrity while also reducing vehicle weight to help meet fuel efficiency standards. Heating a high-strength steel (HSS) component of a boron-steel alloy to the austenitic range—a super-heated solid solution state, ~ 1,700 degrees F (950 degrees C)—improved drawability, and then quickly cooling the part in a water-cooled die, or quenching, transformed the crystalline structure, increasing the formed component's strength-to-weight ratio.
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Next-generation large-tonnage presses rely on new software for virtual integration: How system design can make flexible systems easier to manageOperating large flexible press systems without sacrificing speed and quality can be a complex undertaking. New software takes CATIA to the next level. Users can really learn how to "drive" their large presses optimally by virtually integrating the slide motion, the transfer movement in a way that allows 1) the press to be built, 2) the transfer to be integrated and 3) the die to be built to most efficiently run in the system--a quantum leap. Now being used by Ford and Magnum.
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In-die joining transforms press into assembly system: Part I: Fastening — How it all fits togetherIn-die joining systems help stamping shops to expand their operations to include sub-assemblies and full assemblies without additional downstream equipment and processes, so they can carve out a bigger share of the production work.
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In-die joining transforms press into assembly machine: Part II: Laser weldingIn-die joining systems help stamping shops to expand their operations to include sub-assemblies and full assemblies without additional downstream equipment and processes, so they can carve out a bigger share of the production work.
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Metal former today, compression molder tomorrow: If you have a hydraulic press, you have a great foundation for exploring a whole new world of composites formingThe difference between a hydraulic press used to form metal stampings and a compression molding press used to form parts out of composite materials isn't that great. Could a metal former make the jump into composites forming? With a lesson in materials handling and some customers, a metal former might be able to make the jump.
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10 Hot-stamping HSS FAQs: The hows, whys, and what-fors of hot formingHot stamping, also called hot forming or press hardening, is the process of forming metal while it is very hot (in excess of 900 C degrees) and then quenching it (cooling it quickly) in the die. The process converts low-tensile strength metal to a very high-strength steel (150 to 200 kilopounds per square inch (KSI).
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The pressure is on: Prolonging die life with the help of sensor filmThe traditional method of measuring pressure distribution in stamping operations—the die spotting blue technique—reveals the pressure points without actual pressure readings, making it difficult to balance in relation to other die components. A thin, flexible, Mylar-based sensor film that instantly captures and permanently records pressure distribution and magnitude between any two mating or contacting surfaces has emerged as an alternative to traditional pressure testing.
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Actualizaciones para laprensa vieja de un fabricante de autos |
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Mild steel to HSS: Not just a spec change: Part I: Cutting, forming HSS requires press, die readdressArray
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Mild steel to HSS: Not just a spec change - Part II: Cutting, forming HSS requires press, die readdressArray
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Setting up progressive dies - Part II: Establishing a good setup procedureProper feeding, scrap removal, and shut height calibration are essential for good die setup.
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Multipoint-control die cushion systems for stamping complex parts - Part II: Forming stainless steel double sinksIn deep drawing of complex, asymmetrical parts such as stainless steel kitchen sinks, blank holder force (BHF) needs to be controlled locally to regulate the flow of the sheet metal. An MPC blank holder system allows this control by placing individually programmable cushion pins around the blank perimeter, with an appropriate BHF selected at each pin location.
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Multipoint-control die cushion systems for stamping complex parts - Part III: Predicting blank holder forceWith constant BHF, conventional steel sheets can be formed with few tryouts. However, with the increasing use of lightweight materials and high-strength steels with low formability, there is a need for precise, localized control of metal flow using MPC systems.
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Hot-stamping boron-alloyed steels for automotive parts Part I: Part I: Process methods and usesHot-stamped parts are being used increasingly in cars in Europe and North America. Ultrahigh-strength steels, like boron alloys, which meet automotive safety and crash requirements, are difficut to form with cold stamping, so hot stamping with die quenching has been applied.
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Hot-stamping boron-alloyed steels for automotive parts Part II: Part II: Microstructure, material strength changes during hot stampingCompared with cold-formed parts, hot-stamped parts provide better formability at high temperatures and exhibit no springback on the final part.
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Hot-stamping boron-alloyed steels for automotive parts Part III: Part III: Tool design and process simulationTo accurately model the hot-stamping process, FE simulation needs to account for the mechanical, thermal, and microstructural changes in the workpiece.
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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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Servo press forming applications Part III: Part III: Forming at room temperature, elevated temperaturesThis column discusses several applications of servomotor-driven mechanical presses for forming at room temperature and at elevated temperatures.
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Blanking developments Part I: Fineblanking process and tool design: Part I: Fineblanking process and tool designFineblanking allows the production of sheet metal components with smooth edges in a single press stroke. This column discusses basic terminology and the principles of this process.
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Blanking developments Part II: Fineblanking part, process design: Part II: Fineblanking part, process designFineblanking in various forms is increasingly becoming accepted by the automotive industry for producing sheet metal components with smooth edges that don't require additional finishing operations.
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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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Blanking developments Part III: High-speed blanking, FE methods: Part III: High-speed blanking, FE methodsDuring high-speed blanking, press stroking rate and punch speeds, are higher than in conventional blanking. As a result, the shear zone has a higher strain rate, which affects a workpiece's sheared surface temperature and the tool surface.
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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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Dissecting defects Part II: Testing for incoming sheet coil variation: Part II: Testing for incoming sheet coil variationTwo main types of defects are typically observed in stamped automotive body components: Surface defects, such as cracks and necking, and form defects, such as fall-in, wrinkling, and marking lines. These static defects, such as surface imprints, are not process-related but instead are caused by contaminated die or tool faces. These defects are corrected by simply cleaning the die or tool surface before stamping. Dynamic defects are process-related and are caused by the forming process.
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Reducing Negative TonnageOver time negative tonnage can cause significant press and die damage. Understanding the factors that influence the amount of negative tonnage can help you control it.
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Getting the most from your deep-drawn materialLearning how to get every bit of flow out of your metal while minimizing scrap -- doesn't that sound like a good idea?
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Die design for double bendingKnowing how steel tends to react when it is bent in a single operation can help you do the job right the first time.
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Know your bending basics—Part 1Knowing how metal bends and what factors come into play during bending -- especially wipe bending—can make a positive difference in your stamping operation.
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Deep drawing irregular sheet components: How cushion systems and die stiffness affect the operationInnovations in die technology are helping stampers adjust to the many variations that can occur during the stamping process.
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Forming high-strength materialsVarious shape defects can be encountered in flat-rolled ferrous and nonferrous strip. Knowing their mechanics and origins and how to correct them can be very useful in times of need.
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Preventative maintenance as a way of life: Die shop sparks plantwide process control renaissanceThe 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.
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Warm forming of aluminum alloys: Academic exercise or practical opportunity?Federal government and U.S. automakers to develop technologies for a newgeneration of vehicles to triple fuel efficiency without sacrificing performance, affordability, or safety.
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Improving in-press transfer preformance with tooling: Plan ahead for optimum designUsing finger tooling and planning ahead of time to minimize costs can benefit your operation ahead more than you think.
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The ROI for Quick Die Change: How to recognize and quantify its benefitsQuick die change equipment is a capital investment, and i competes for funds with other capital investments. Therefore, it's critical to understand the benefits of implementing quick die change.
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Cryogenics—Putting the Freeze on Wear Answering Some Commonly Asked QuestionsWhile 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.
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Know your bending basics—Part 2When 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.
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Designing large die sections with reparability in mindThe article explains how EDM has been used to simplify die making as well as some design considerations for minimizing deflection during production.
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How to draw round cups deeperDraw 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.
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Improving perforating die performance: The effects of stress, clearance, materialPerforating 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.
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Establishing a die setup recipe for progressive diesSetting 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.
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Reducing Die Changeover Time without Capital ExpendituresOne 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.
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Toolmaker tricksIt 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.
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Controlling bend anglesBend 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.
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Stamping tools for UHSS get tougher: New automotive materials force tool material to shift into high gear |
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Next-generation synthetic forming fluids: Advanced-technology lubricants can improve productivitySuccessful metal forming, stamping, and deep drawing depend on three basic elements: the metal substrate, tooling, and lubrication.
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Pitch notch or not? Factors to consider when designing progressive dies |
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Eliminating slug pulling during piercing operations |
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Saving time and reducing waste with quick die change: Why and how to justify the costQuick die change is not just a way of setting up dies; it's a mindset for the elimination of waste.
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Acoustic emission monitoring for stamping presses: Optimizing production for better quality, longer tool life |
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Tackling cutting and piercing problems in stamping operations |
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Chemical-free cleaning of HSP lubricantsNew requirements for clean, dry parts drive the need for efficient, flexible workcell parts cleaning.
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Using forming assessment tools to make wise die-buying decisionsEstablishing a good buying procedure is a critical aspect of the tool purchasing process. All too often tool supplier expectations are not communicated and executed effectively. Miscommunication can cause you to purchase a die that doesn't produce good parts, needs constant attention, wears out prematurely, or has other problems.
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Making a case for in-die tapping: Combining operations to compete in the global marketNever before has competition been greater in the metal stamping industry, both domestically and worldwide.
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High-performance coating helps stamper fight downtime: Dies last longer, need no regrindingDepending on the severity of the application, some stamping dies require frequent reconditioning or recoating. However, some coating processes are done at such high temperatures that the dies become distorted and unuseable, requiring further regrinding. Omni Mfg. encountered this problem in stamping a heavy-duty hinge. It then discovered FortiPhy UltraEndurance™ from Phygen Inc., which increased the hit count on its dies from 20,000 to 200,000 between recoatings. The coating is applied at a relatively low temperature, so distortion is not a factor.
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Regaining flatness in stamped parts |
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Implementing a stamping sensor program—uphill: Gaining cultural acceptance the most difficult part |
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Die Basics 101: Part I |
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Die Basics 101: Part IIIMany factors must be considered when choosing a production method for stamping. This article discusses and explains the advantages and disadvantages of line dies, transfer dies, and progressive dies.
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Taking a look at automated spray control:: What can it do for your company?Spray systems often are regarded as simple on-off valve and regulation systems. In reality, though, spray nozzles are precision components designed to yield very specific performance under specific process conditions. Just because nozzles are spraying doesn't mean that they are spraying precisely, and precision spray performance makes a difference in throughput, quality, and bottom-line profits
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Die basics 101: Part IVStamping dies can comprise many components. This article discusses the basic components, including die plates, shoes, die sets, guide pins, bushings, heel blocks, heel plates, screws, dowels, and keys.
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Cushioning the blow: Detroit-area toolmaker aims to draw a bead on new opportunitiesHercules Machine Tool & Die Co. has intalled a fully programmable hydraulic cushion onto a mechanical press in hopes that it can cut down on try-out time and attract more business involving specialty stamped parts
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Quick die change and the trend toward larger presses: As machines get bigger, QDC keeps paceThrough the use of such tools as T-tables, die carts, and rolling bolster systems, stamping companies can help increase the uptime of their pressroom operations, increase levels of operational safety, and improve their bottom lines.
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Okay with tool coating: Thermal diffusion extends stamping die life, reduces press downtime"Okay Industries, New Britain, Conn., serves diverse market segments including medical, automotive, electronics, defense, and specialty industrial. The stamper produces a roller finger follower for automotive applications. There are 14 stations on the die. The TD process is used on three of them," DeVecchis said. "It has given us better product quality, less scrap, faster throughput, longer die life, and reduced die dressing."
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Die maintenance. Die repair.: What's the difference?Unnecessary die repair stems from several basic shortcomings, namely poor die design, setup procedures, tool design, and maintenance techniques.
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Evaluating dry film lubricants for automotive applications: ArrayArray
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Die basics 101: Part VStamping dies comprise many components. Continuing the discussion of common stamping die components began in Part IV of this series, this article focuses on pads, including stripper, pressure, and drawing; the methods used to secure them—spools, shoulder bolts, keepers, and retainers; and springs—gas, coil, and urethane.
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A new energy in appliance manufacturing: 13 SEER provides springboard for revamped manufacturing strategiesIn January 2006, a new 13 SEER mandate for appliancemakers takes effect. Although it isn't the only thing driving change in manufacturers' product designs, it is providing a springboard for manufacturers to make changes in their products that will help meet increasing customer demands.
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Die basics 101: Part VIIn-die tapping units, rotary benders, pierce nut units, HYDROCAM®s, and thread-forming punches/buttons are among the specialty dies that can help reduce the number of required operations and costs to produce holes in stamped parts. This article discusses these components and their applications.
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Keep it moving: How to choose the right conveying system to move parts, scrapConveyor jam-ups or slow-downs can offset machine tool productivity and damage high-production equipment. The solution: a reliable conveyor system that promotes a smooth, uninterrupted production flow.
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Die Basics 101: Part VIIAlthough many metals are used in stamping, all fall into one of two basic categories—ferrous and nonferrous. All metals have certain characteristics that must be considered when determining which stamping dies, production processes, and equipment to use. This article introduces the most basic metals and their properties.
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Do you need a die transport system?: Determining your requirements and choosing a systemA die transport system may be needed if current production requirements cannot be met with existing presses, and opportunities for additional contracts are limited by current equipment production volumes; parts can be produced competitively in large batches, but not if the part count is smaller; and shop safety needs to be improved.
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Draw forming: ArrayArray
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Die Basics 101: Part VIIIAll metals, both ferrous and nonferrous, have mechanical properties that must be considered when determining which stamping dies, production processes, and equipment to use to form them. This article discusses basic properties, including tensile strength, ductility, elongation, yield strength, and hardness, and methods for measuring these properties.
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21st century stamping material specificationsAdvanced technology in the metal stamping industry has rendered obsolete traditional methods of selecting, specifying, and supplying material. Using modern technology to quantify materials can reduce the occurrence of material variation exceeding the die and process capabilities and make die development a much more efficient process.
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Die Basics 101: Part IXThis installment in the Die Basics 101 series picks up where Part VIII left off in describing the mechanical properties and behavioral characteristics of metals used in stamping operations. Among the topics discussed are strain, springback, stress, stretch distribution, n value, r value, and surface topography.
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Die basics 101 starts with eight basic components: Getting to know stamping diesA stamping die is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a desired shape or profile. Most dies are constructed of several basic components, including die plates, shoes, die sets, guide pins, bushings, heel blocks, heel plates, screws, dowels, and keys. Dies also need stripper, pressure, and drawing pads, as well as the devices used to secure them—spools, shoulder bolts, keepers, and retainers; and gas, coil, or urethane springs.
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Die Basics 101: Part XThis article, Part X of a series covering stamping die fundamentals, begins an in-depth look at the metal cutting process. It covers piercing and cutting clearance and discusses some common piercing misconceptions. Descriptions of and links to the first nine articles in this series can be found at the end of this article.
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10 common quick die change problems: Tips to improve changeover timesDie changeover is one of the few times when a press isn't making money. Why do some die changeovers take hours? It might be the press, operator, die, material, lift truck, crane, or the tools.
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Die Basics 101: Part XIThis article, Part XI of a series covering stamping die fundamentals, offers an overview of slug pulling—a problem that can damage parts and tools significantly—and explains the different causes. Part XII will cover corrective and preventive actions. Descriptions of and links to the first 10 parts in this series can be found at the end of this article.
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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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Solving punch breakage problems: ArrayArray
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Die Basics 101: Part XIIPart XI of this series covering stamping die fundamentals defined slug pulling and discussed some underlying reasons that it occurs. This article describes some methods for resolving slug pulling problems. Descriptions of and links to the first 10 parts in this series can be found at the end of this article.
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Solving the problem of punch breakage: Part III: Punch production and press issuesNumerous factors contribute to the premature failure or breakage of piercing and cutting punches. In addition to problems with the punches themselves, such as tool steel and problems with EDM and grinding, the press itself can cause problems through deflection, and bridge strippers also can cause punch breakage.
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Cleaning up: Roller lubrication system helps stamper convert gallons into profitsExcessive fluid on finished parts, which required secondary cleaning operations, and additional cleaning of floors, aisles, and racks in the areas where parts were moved and stored were remedied by installing a roller system with a programmable controller.
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Tips for grinding and wire machining tool steelHow tool steel is machined can make a big difference in its performance and life. A poor grinding job might look good, but unseen stress can cause premature failure.With the correct grinding and wire burning techniques, tool steel results can be optimized.
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Die Basics 101 -- Part XIIIPinch, breakout, and shimmy trimming are cutting methods often used in stamping operations. This article, which is a continuation of a series on die basics, discusses these processes. Descriptions of and links to the first 12 parts in this series can be found at the end of this article.
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Developing forming dies: ArrayArray
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Tooling coating extends die life, reduces die rework: Stamper's tooling stands up to aluminumGlacier Vandervell's Bearing Group, a division of Dana, manufactures bearing components—bushings and thrust washers—for the automotive industry. It uses about 40 alloys and encounters many abrasion problems in its stamping operations, especially those involving aluminum. Its die coatings were not satisfactory because the heat used to apply the coatings would cause many of its dies to warp. It switched to FortiPhy™, a coating provided by Phygen Inc., and the tools now warp less and last longer.
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Stop wasting time!: Integrated die handling, storage systemsMinimizing changeover times is accomplished with effective die change procedures and equipment. Applying quick die change basics is a necessity, such as standardizing die parameters and clamping, prestaging dies, and using proper tools and personnel.
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Die Basics 101: Part XIVFineblanking and GRIPflow® are cold metal extrusion processes used to produce what appear to be blanked parts. These processes are alternatives to casting, forging, and machining. This article explains these processes. Descriptions of and links to the first 13 parts in this series can be found at the end of this article.
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Cutting tooling costs: ArrayArray
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12 ways to boost punch life: Advanced materials require time-tested techniquesHigh-strength, low-alloy (HSLA) steels require new ways of thinking about extending punch life. At the same time, there are many tried- and-true techniques that still work.
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Die Basics 101: Part XVMetal bending often is perceived as the simplest metal forming operation. This article describes wipe and V bending and discusses the advantages and disadvantages of both. It also addresses ways to reduce springback. Descriptions of and links to the first 14 parts in this series can be found at the end of this article.
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Stamping aluminum: It’s not as easy as you may thinkThe reality is that aluminum is not steel. It doesn't behave like steel, it doesn't flow like steel, and it certainly doesn't stretch like steel. So does this make aluminum hard to form? No, not if you think like aluminum.
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Finding, addressing the root cause of die galling failures: 6 Questions to answer in preventing premature gallingThere is no best tool steel type, coating, or way of keeping the punches from breaking. The best solution for each of these problems can be found by collecting specific data with respect to why each of the problems occurs
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Die Basics 101: Part XVIThis article continues the discussion of bending in stamping operations. It focuses on rotary and reverse U bending and addresses the advantages and disadvantages of rotary bending. Descriptions of and links to the first 15 parts in this series can be found at the end of this article.
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Piercing, cutting aluminum sans slivers: Stopping sliver formationSlivers are the result of the aluminum interfacing with the cutting sections or punches. To reduce the production of slivers the severity of friction at the point where the two surfaces interface must be reduced. The general rule for cutting materials is the softer the metal the smaller the cutting clearance.
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Why is it Dieology, not Dieologism?: It's not art, it's scienceSuccessful dieworkers are very methodical and data-driven in the way they approach a problem. They carefully study each problem, determine its root cause, and take both short- and long-term corrective action.
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Dissecting defects: ArrayArray
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Die Basics 101: Part XVIIThis article in a series about stamping fundamentals is an introduction to deep drawing. It defines drawing and differentiates between drawing and stretching. It also lists and explains basic drawing components. Descriptions of and links to the first 16 parts in this series can be found at the end of this article.
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Stamping 101: Die basics: Introduction to stamping dieThis article introduces beginning toolmakers, die maintenance technicians, engineers, and press technicians to tool and die components and their functions
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Controlling slug pulling with hole lapping: A step-by-step method to eliminate the problemDiemakers have several options for slug-pulling problems, such as knockout pins, vacuums, punch or die dulling, oil viscosity, wire EDM hole slots, punch/die clearance changes, edge shearing, mechanical grippers, air jets, and cuped-shaped punches. Another method to help stop slug pulling is bell- mouthing the die, which essentially involves cutting a funnel shape around the hole.
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Getting the most from your cutting punches: Part ISelecting the right cutting clearance and tool for an application is among the challenges stampers face. Material properties and other factors influence this decision. Following some basic guidelines presented in this article can help you select or design the best tool for your needs.
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Coming to your sensors: Misconceptions keep metal formers from committing to stamping sensorsStamping sensors can go a long way in protecting valuable dies and eliminating downtime associated with repairing dies after crashes. So why aren't more shops using them? Perhaps it's because their misconceptions get in the way of making a wise investment.
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Successful Extruding: Part IIDie design and building is a critical part of a successful extrusion process. ironing—vertically squeezing the metal between the punch and the die to increase the surface area—helps refine the extruding process, as does preforming.
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Lubrication and galling in stamping of galvanized AHSS: Part III: B-pillar simulations and the Strip Drawing Test (SDT)Forming of galvanized AHSS involves higher contact pressures at the tool-workpiece interface compared to forming mild steel. Under these severe interface conditions, improper selection of lubricants, tool materials and tool coatings may result in high scrap rates and galling in stamping production.. Based on SDT results, polymer-based lubricant with EP additives and water-soluble DFL were found to be most effective, Synthetic lubricants showed also reasonably small frictional responses with a PVD coated die in forming GA coated strips.
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Getting the most from your cutting punches: Part II |
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Measuring forming severityDetermining a part's forming severity, something that is critical for a successful stamping operation, takes into account various data. This article discusses the different types of data and how each is obtained. It also compares circle grid analysis to square grid analysis.
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Successful extruding: Part IExtrusion is the process in which a continuous radial stretch flange is created by expanding a hole. Of all of the factors controlling the success of an extruding operation, material type and its mechanical properties are the most influential. Materials exhibiting good stretch capability and stretch distribution characteristics are best suited for extruding.
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3 deadly tool design sinsAmong the many factors to consider when designing and building a stamping die are the material to be processed, the press that will run the die, and specified part tolerances. Inadequate knowledge of these factors can contribute to die failure and production and quality problems.
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Reading progressive die strips — Part ILooking at the results of a process—in this case, the strip produced in the die—certainly can lead to good data indicating the root cause of a problem. Distorted, elongated pilot holes, mismatched cuts are common defects. Distorted pilot holes can be the result of a poor carrier design. An improperly set up feed release can cause misfeeds, pilot hole elongation, and bent, broken, or galled pilots, as well as poor part location and gauging.
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Reading progressive-die strips—Part IILooking at the results of a process—in this case, the strip produced in the die—certainly can lead to good data indicating the root cause of a problem. This Part II of a two-part series discusses hard marks, poor die design, and coil-related problems.
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Stamping stainless steel: Part 1: Know your materialThis part I of a 2 part series discusses the behviour of stainless steel. The article answers the question: What is stainless steel and what is it used for?
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Green lubes under a microscope: Clarifying misunderstandings, dispelling mythsStamping parts with vegetable oil is becoming more a reality every day. For a metal working lubricant—whether it be soluble, semi-synthetic, or synthetic—to be USDA-classified as biobased, it must contain, at minimum, 40 percent to 57 percent of renewable resources. Just because a product is biobased, made from a varying percentage of renewable resources, it does not necessarily make it readily or ultimately biodegradable. Green lubricants offer enhanced lubricity and a high viscosity index. These oils are less toxic to the environment and are easier to dispose.
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Buying time—by weldingYou're almost at the end of a production run and your stamping die fails. What do you do? Replace the failed component? Attempt a repair? How do you decide which option is best? These questions—along with basic guidelines for repairing a die by welding—are answered in this article.
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Revealing the Magic — Using data and conducting experiments to solve metal forming problemsEffective stamping professionals rely on scientific principles and not magic to determine and correct production problems. Find out how to troubleshoot wrinkles and rips and take corrective action by following a basic procedure that can be modified to troubleshoot almost any stamping issue.
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Using analog technology to errorproof the stamping processEnsuring part quality and protecting dies are important considerations for any stamping operation. In-die analog sensors can help stampers reduce setup errors and downtime while achieving optimum part quality. This article discusses different applications for analog sensors.
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The ins and outs of magnetic die clamping: Magnetic clamping of dies adds flexibility to stamping operationsFor the right application, magnetic die clamping can add significant flexibility to a stamping operation, eliminate physical clamps, and simplify maintenance.
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Sheet Metal Stamping 101: ArrayArray
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Measurement, assembly, and welding: Ultra Tool's quest for in-die perfection: ArrayArray
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Designing speed-friendly dies: How to run tooling at maximum speed with minimal breakageUsually the first place stampers look to reduce cost is the labor burden per part, which leads to the inevitable pursuit of producing parts faster. The speed capability of a stamping die is determined by how fast the part physically can be produced and at what speed the tooling fails. The strength of the carrier, how high the part must be lifted, and the mechanical limits of the springs and side action cams (mandrels) limit how fast the tool can run.
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'Bad' steel -- the ultimate scapegoatIt seems like every time there is a problem making a good part, thesteel is blamed. Often the root problem is the process used to cut andform the steel — the combination of the die, the press, and thelubricant.
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Design, build, troubleshoot: Three critical phases of die productionWhen a quality stamped product is needed, operating as a team, communication and a solid understanding of the plan is paramount in efficiently producing a stamping die. The three critical phases of producing a capable stamping die are design, build (manufacture) and troubleshooting. Each phase is intertwined and dependent on one another. A design review is an excellent opportunity to develop a plan and review the construction and manufacturing methods that are going to be used to make the components. Ultimately, the challenge is to have gained a profit for your company and produced a stamping die of superior quality.
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Diseñando dados amigables con la velocidad: Cómo operar el herramental a velocidad máxima con roturas mínimas |
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Design for Manufacturability: Collaboration on design leads to serious pressroom savingsBachman Machine collaborates with customers,and often, tweaking the part design--just a little--enters the picture.
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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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Draw forming Part I : Processing functions: Part I : Processing functionsDraw forming is one of the net shape processes, and, as a result, many of the technology advances in the general field of manufacturing have not been as beneficial to draw forming as one would expect. All too often, such advancements as lean manufacturing, statistical process control, just-in-time, and six sigma, have not resulted in benefits for draw forming.
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Draw forming Part II: A matter of metrics: Part II: A matter of metricsIn draw forming, measurement and quantification are essential to ensuring part quality for the customer. However, the product requirements and the product input variables have different metrics and different conceptual meanings, which seems to defy direct engineering. Three processing variables can be adjusted during production to ensure the part is formed correctly.
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Solving punch breakage problems - Part II: The roles of cutting shear and retainersCutting shear, or the angle ground into the end of a punch, has a big effect on punch deflection and breakage, as well as press tonnage required. Retainers, which hold the punch to the die shoe, also are important. The backing plates, ball lock punch retainers, and headed styles of punches and retainers all require careful consideration.
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Solving punch breakage problems Part I: Typical causes of premature failureNumerous factors contribute to the premature failure or breakage of piercing and cutting punches. Two obvious factors are operator error and incorrect die cutting clearance.
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Developing forming dies Part I: Part I: Nonuniform contoured 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 to make complex geometries.
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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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Cutting tooling costs How to save money without sacrificing die quality: How to save money without sacrificing die qualityTo reduce tooling costs, key items such as high-quality tool steel and quality die components some companies ignore or substitute which usually results in premature tool failure, excessive downtime, and scrap. Sometimes you have to invest a little more in your tooling to be successful.
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Cutting tooling costs Part II: Part II: Selecting the proper tool steel, design softwareTo stay competitive in today's market, stampers must build dies from materials that adequately perform with as little maintenance as possible. Appropriate tool steels can be cold-rolled steel to solid carbide. The key is to know when to use a lower-grade steel and when to use a higher-grade tool steel.
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Dissecting defects Part III: Stamping process control: Part III: Stamping process controlVariations in incoming sheet material quality, tool temperatures, press and tool deflection, and lubricant performance result in deviations in formed part quality. Thus, besides initial tryout, adjustments are routinely made during production to maintain formed part quality. Real-time or online monitoring of the stamping process has become essential to improving stamped part quality and preventing interruptions in production.
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Sheet Metal Stamping 101 Part I: Who does what?: Part I: Who does what?Metalworking professionals who possess diverse proficient skills have an edge in a tight job market. This first installment in a new series by tool and die expert Art Hedrick presents an overview of the metal stamping industry and describes the various careers available in the sector.
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Measurement, assembly, and welding: Ultra Tool's quest for in-die perfection Part I: Part I: Errorproofing with in-die measurementUltra Tool & Manufacturing launches a program to tackle sensor technology in an effort to errorproof the pressroom.
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Sheet Metal Stamping 101 Part II: Material and equipment: Part II: Material and equipmentThinking about adding metal stamping to your capabilities? Read this primer about the materials and equipment, including the different types of stamping presses, and view images of stamped parts, which can be both highly functional and aesthetically pleasing.
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Sheet Metal Stamping 101 Part III: Dies and cutting: Part III: Dies and cuttingContinuing his series about sheet metal stamping, tool and die expert Art Hedrick focuses on die basics, including die materials and rudimentary maintenance. He also explains the cutting process and what happens to metal when you cut it with a stamping die.
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Sheet Metal Stamping 101 Part IV: Cutting processes: Part IV: Cutting processesContinuing his series about sheet metal stamping, tool and die expert Art Hedrick explains common cutting operations used in stamping: trimming, piercing, blanking, notching, shearing, lancing, and pinch trimming. Find out how they work and which applications are appropriate for each.
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Sheet Metal Stamping 101 Part V: Forming operations: Part V: Forming operationsHow are bending, flanging, coining, embossing, stretching, curling, hemming, ironing, necking, and drawing related? They all are common metal forming operations. Find out more about these processes in this final installment of stamping expert Art Hedrick's sheet metal stamping series.
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DIEVESTIGATION: Designing stamped parts: How material selection affects downstream operations and costsIn his first installment of DIEVESTIGATION, a new column about using research and data to solve stamping problems, tool and die expert Art Hedrick discusses how the metal specified during part design affects downstream operations and costs. What should you consider when selecting the metal?
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Safeguarding tube benders with laser scanners: Noncontact, minimal-interference method ideal for large, irregularly shaped areasTube benders require safeguarding around the perimeter of the machine and area in front of the machine, where the tube is bent, and in the back where the tube is fed. Laser scanning devices offers several advantageous features. Because laser scanning is a noncontact method, it minimizes interference with the machine operation, and because the scanner mounts at the foot of the machine and out of the way of the tube bending action, it allows full access to the work area.
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Opening the gate to efficiency: Farm equipment-maker combines new, custom machines to boost productivitySince 1945 family-owned and -operated Tarter Gate has grown in staff and sales as it has changed the design of its products. To keep up with sales, continue growing the company, and absorb as many rising costs as possible — particularly in steel and fuel prices — the company uses custom machines and new technologies to its advantage.
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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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Programmable lubricant application accelerates stamper's die changes: Stamper gains control, eliminates excess sprayRed Rock Stamping, Chandler, AZ, airbag and seatbelt components manufacturer, looked for ways to improve its die change processes to handle the anticipated business volume increases. A lot of cleanup had been required around the machines as a result of the lubrication system. By installing a new fluid application system by UNIST, the stamper gained more control over the spray volumes and locations and reduced die change times. Fluid disposal was eliminated as well.
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Bend allowance and springback in air bending: How to predict it and compensate for itThis study illustrated that, when the thickness and stress-strain curve of the sheet material are known, it is possible to predict with acceptable accuracy the bend allowance, springback angle, and punch stroke to obtain the desired final product dimensions.
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