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Feed with care
Although many of the traditional coil-handling rules apply, processing coated coil material requires additional considerations. Stampers need to check for equipment clearances and alignment at every point where
the finished material surface may...
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Managing coil more cost-effectively
A supply chain is only as strong as every link. That's why more metal formers are leaning on their material suppliers to improve their coil and sheet management. A couple of metal service centers offer up some advice for those metal stampers...
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Straightening out coil terms
The nomenclature associated with some coil processing equipment suggests they might perform the same jobs, but reality suggests that flatteners, levelers, and straighteners serve completely different purposes for the metal former working with...
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Toll processor far from finished
Becky and Michael Miniea purchased processing company that was in dire financial straits in the months after 9/11, and with a commitment offerings and its customers, Specialty Metals Processing is now in a position to survive whatever this economy...
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The integrated approach to coil lines
Modern press lines are very integrated, combining coil feeds and press capabilities from a single control area and using commonality of components to optimize results.
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5 process applications to tackle during a slow economy
The decision to upgrade a section or an entire coil processing line involves plenty of intelligence gathering from the shop floor if the right decision is to be made.
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Controlling flat-rolled shape
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...
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Reducing setup time in strip leveling
Equations help leveler operators significantly reduce the traditional trial and error during setup.
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What you should know about stamping coated coil
More 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,...
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Die shop transitions to production stamper
Third-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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Reading progressive die strip — Part II
Looking 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...
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Reading progressive die strips — Part II
Looking 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...
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Reading progressive die strips — Part I
Looking 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...
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Rolling to market - Part II
A variety of methods help push a roll forming operation's efficiency. Various coil handling methods offer different levels of efficiency and automation, each suiting certain applications. The key is to analyze an operation, calculate the time...
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Dissecting defects - Part III
Editor's Note: This article is part of a three-part series. Part I categorizes defect types and discusses the factors that affect formed part quality; Part II covers various destructive and nondestructive tests for evaluating incoming...
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Choosing between feeding your new stamping line coil or blanks?
Stampers today need to process more grades and types of material than ever before, yet are under relentless pressure to reduce costs. They increasingly rely on systems integrators and equipment suppliers to design and install versatile stamping...
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New generation of levelers tames high-strength steels
A new generation of levelers is equipped to meet today's demands to flatten the high-strength materials.used more prevalently in the automotive industry than ever. To tame the coil set, crossbow, twist, and edge camber in high-strength steel (HSS)...
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Dissecting defects
Dissecting Defects is a three-part series.
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Reducing lubricant waste
The 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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Dissecting defects - Part I
Editor's Note: This article is part of a three-part series. Part I categorizes defect types and discusses the factors that affect formed part quality; Part II covers various destructive and nondestructive tests for evaluating incoming material;...
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For flawless cosmetic finish, start at the head
Stamping 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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Leveling flat-rolled strip
Operating 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...
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6 ways to focus on slitting lines
By 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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Implementing a coil-end joiner
After 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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Keeping stainless flawless for appliance stamping, fabrication
Before 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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Technological quantum leap
Arme 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...
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A guide to fabric slitting line tension rolls
Coil processors have several choices in the rolls they use to put tension on the coil. One of these choices is a pair of nonwoven rolls. They act like sponges in that they remove lubricants, dirt, and metal fines from the metal. Understanding how...
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Reducing scrap, inventory costs with coil optimization software
Coil optimization software is a valuable tool that fabricators can use to attack the problems of high scrap and high inventory. It offers the ability to quickly and easily make sound decisions regarding the purchase and use of master coil sizes....
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Roller leveling 101
Every 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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The big payoff
Traditional 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...
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Holding the line on metal costs
Stampers 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
A 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...
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Feed to registration
For 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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New handling instructions
In 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...
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Getting a handle on coil handling
Coil 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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How to avoid slit-in coil slitting problems
Problems that can arise during metal slitting include poor edge quality, edge burr, edge wave, camber, crossbow, knife marks, and slit width that is out of specification. Some slitting problems can be attributed to poor metal quality; however, it...
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Straightening mistakes
As 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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Maintaining a slitting line
A 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...
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Achieving consistent stock lubrication with less oil
Low-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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Straight to the point
The 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...
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A focus on slitting lines
As manufacturing has moved overseas, the U.S. slitting market has become saddled with overcapacity. Coil processors can improve efficiencies by upgrading the equipment they use in the following areas: coil storage, changeovers in coil and slitting...
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Evaluating in-house coil slitting
As the cost of steel rises and profit margins shrink, small to medium-sized stampers are looking for ways to reduce costs and streamline operations while maintaining quality. One area to consider is the cost of slitting steel. Shops that...
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Analyzing coil handling equipment purchases
Refurbishing can be a cost-effective way to breathe new life into an old piece of equipment. This cam feed was originally built in 1974. Recent economic growth finally has spilled over to the manufacturing sector, so this might be a...
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The cutting edge of cut-to-length lines
When a company plans to invest in a cut-to-length line, basic line configuration is the first decision—and one of the most important—to make. The fixed-shear line is a common configuration. It can be an entirely stop-start...
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Keep on stamping
To be competitive in a global economy, U.S. stampers must provide defect-free parts, reduce waste, and eliminate downtime while contending with increasing raw material costs and limited availability of some metals. Because stampers have no...
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Survival of the fastest
Because metal fabricators and OEMs have increasingly strict requirements, many suppliers of sheets and blanks must provide high-quality metal stock in terms of flatness, finish, and dimensional accuracy. Competition for every bid is tight,...
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Slitting ultrahigh-strength steels
The automotive industry's search for stronger and lighter materials spawned new steel grades to meet higher strength-to-weight ratio requirements. While these materials allow automotive engineers to design lighter and stronger components,...
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Sizing up pallet decoilers
The 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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New Features in Coil-to-Coil Slitters
Years ago it was customary for coil processors to have dedicated slitting lines for specific materials and gauges. Today's larger, stronger, and thinner-gauge coils, however, require service centers to be able to process many materials and gauges...
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Protecting surface-sensitive materials in coil processing - Three potential danger areas
As manufacturers worldwide strive to reduce costs and streamline their production processes, the market for surface-sensitive materials continues to expand. Surface-sensitive materials include all prepainted steel products and nonferrous...
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