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Supporting technological growth and opportunity in sheet metal forming
As the skilled labor pool decreases, metalworkers need to learn as much as possible about new tech
- By Bill Frahm
- March 22, 2020
- Article
- Automation and Robotics
We are crossing the threshold into a new frontier. We have new materials and technology. Aluminum use is increasing, and third-generation advanced high-strength steels (AHSS) present new challenges and capabilities. Servo presses allow us to manage forming energy in ways we couldn’t with our flywheel-clutch mechanical presses. IoT promises to help us learn about our operations in ways that weren’t available before.
We have wondrous opportunities, and with those opportunities comes risk. Our greatest risk, however, is merely to accept the status quo and fall into mediocrity.
We need bold leaders, experienced professionals, and inquisitive young newcomers to share experiences and challenge old traditions. Mostly, we need to nurture our understanding of materials and technologies, to know not just how things happen, but why.
Where do we start?
Prioritize Continuous Learning
Each of us must make a commitment to learn and support the development of our employees and ourselves. We need to start with materials and technology fundamentals and move on from there. We must understand why materials behave the way they do in the press. With that, we can open opportunities to explore the forming new materials.
Recently introduced steels, particularly third-generation AHSS, have changed the nature of the historic tradeoff between strength and elongation. This step up in material strength has altered the requirements and dynamics for forming and lubrication.
The graphs shows automotive steels used in 1990 and today. The graph of 1990 steels shows a distinct banana curve, and tensile strength is clustered below 1,100 MPa. The graph of today’s automotive steels looks more like a football graph, as observed and recommended by Danny Schaeffler. Material strength increased significantly.
Newer steel grades also offer greater formability for a given tensile strength, which has changed the requirements for successful forming and challenged our joining capabilities. These new opportunities require new knowledge and a commitment to experimentation and learning.
Support Your Supply Chain
We must share knowledge across our supply chains. Sheet metal forming is accomplished by a large population of small to medium-size companies and a handful of large companies. My casual observation is that much of our knowledge rests with large global enterprises, and advances in materials, processes, and technology often fail to trickle down to smaller providers because there is little to know effort to share it. In fact, in automotive, customers frequently place obstacles to sharing information.
This is a naive and dangerous way to conduct business. It serves the supply chain to share knowledge. Efficient production will lead to higher quality parts, shortened production lead times, reduced scrap, lower costs for consumables, and greater communication and coordination among partners. For suppliers pinched by razor-thin margins, this knowledge sharing helps support their corporate health, as well as a healthy and less troublesome supply chain.
Dare to Challenge Conventional Wisdom
We can no longer accept tradition and rules of thumb in our forming operations. The introduction of hundreds of new material grades forces us to approach sheet metal forming as a science rather than an art. The increased precision of component specifications and changes in sheet metal properties require adherence to material and forming tolerances.
Our old mild steel traditions no longer account for the requirements of stronger materials to manage heat and friction, control springback, and prevent splitting and wrinkling. We need new rules based on real property measures, statistical observation, and experience.
Build a Supportive and Challenging Work Environment
Attracting young employees and new ideas to manufacturing remains a problem. Our inability to attract young workers soon will threaten our capabilities as our workforce ages.
There are several reasons why manufacturing is viewed as an unattractive option for many young employees, but much of the problem is in past command-and-control cultures that discouraged our most capable and inquisitive employees. David Allan Coe’s “Take This Job and Shove It” (sung by Johnny Paycheck) served as an anthem for a generation disillusioned by bullying bosses, dirty work environments, and disrespectful management. It’s no wonder parents didn’t want their children to work in manufacturing, especially as other industries were evolving.
We’re in a hole and need to dig ourselves out. Motivated young employees want a clear vision of their career opportunities. They want challenging jobs and respect for their efforts. They also want a workplace that encourages learning and collaboration. A work environment of gray cubes and drill sergeant management is no longer productive, nor is it good business. Let’s make sure our workplaces support employees. We need to acknowledge our old unproductive ways and promote our change of heart.
We work in an exciting, dynamic, and challenging industry. Sheet metal forming is critical to our manufacturing economy. It’s time we began collaborating to support our supply chains, attract new talent, and allow tiered suppliers to pursue evolving materials and technologies.
About the Author
Bill Frahm
P.O. Box 71191
Rochester Hills, MI 48307
248-506-5873
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The Fabricator is North America's leading magazine for the metal forming and fabricating industry. The magazine delivers the news, technical articles, and case histories that enable fabricators to do their jobs more efficiently. The Fabricator has served the industry since 1970.
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