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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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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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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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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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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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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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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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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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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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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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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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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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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Holding the line on metal costs: Reducing coil line scrap can expand your bottom lineStampers and roll formers can look at edge trim, heads, tails, skeletons, and coil damage for ways they can reduce scrap to hold the line on metal costs.
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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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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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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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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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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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Pressing through power failures:: Transfer press energy overcomes voltage fluctuations at BMWWhen BMW Dingolfing (Germany) decided to modernize one of its transfer presses, the desired benefits included increased line availability, increased production through the use of an electronic transfer system, and reduced maintenance. However, one of its highest priorities was to minimize or eliminate the risk of production loss caused by interruptions to the power supply.
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Collaboration in the stamping industry: More than a buzz wordWhat is the best way to determine the optimum combination of application, design, and costs? An effective collaborative process makes the difference. Teamwork and open communication throughout the process — from prototyping to production — ensure the best design and most efficient manufacturing process, which can save millions of dollars in large projects.
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Total transfer knowledge: The evolution of transfer pressesTransfer systems can deliver flexibility to perform a variety of tasks for current requirements, yet deliver the capability to carry the company at a competitive level over the long haul.
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A need for speed: Dana Corp. increases capacity with three automated hydraulic press linesCurrently, Dana's Chatham, Ontario division produces several heat shields for fluid-management systems including heat exchangers, valves, and coolers. With higher demand yields and new orders, the stamper needed an automated press line that could improve uptime, quality, and reliability.
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Stamping complex parts: Hydraulic presses expand deep-draw capabilitiesBy adding sophisticated hydraulic deep-draw press technology, Tools Inc. was able to greatly enhance its in-house forming and production capabilities.
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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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 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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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 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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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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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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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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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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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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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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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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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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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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