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Tool and Die Tech Cell >
Tool and Die Article List
Tool and die related articles
There are 185 articles related to tool and die.
Tool design shortcuts, oversights, and errors can be costly. Following some fundamental design laws can help you anticipate and prevent possible problems, simplify operation and maintenance, and improve production and quality.
By: Tom Vacca, Contributing Writer - www.thefabricator.com, 10/27/09
Continuing 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/27/09
When 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 in...
The FABRICATOR®, 10/8/09
Pressure to shorten the time from order to
manufacture has never been greater. Because
of its process complexities, metal forming’s
bottleneck long has been diemaking. Industry
sources offer some helpful suggestions, tips
and tricks to abbreviate the die design-build-
tryout process. Software,...
www.thefabricator.com, 9/24/09
Continuing 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/25/09
...
www.thefabricator.com, 8/4/09
It seems like every time there is a problem making a good part, the
steel is blamed. Often the root problem is the process used to cut and
form the steel — the combination of the die, the press, and the
lubricant.
By: Art Hedrick - www.thefabricator.com, 8/1/09
Usually 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 o...
By: Rob Driver - www.thefabricator.com, 7/9/09
Thinking 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 6/9/09
Ultra Tool & Manufacturing launched a program to tackle sensor technology in an effort to errorproof the pressroom.
By: Tim Heston - The FABRICATOR®, 6/7/09
Ultra Tool & Manufacturing adds in-die projection welding to its capabilities, eliminating secondary operations and significantly reducing labor costs.
By: Tim Heston - The FABRICATOR®, 6/4/09
This article showcases the success story of stamper and tube
fabricator A.T. Wall Company, which gained entry with a new
customer and strengthened its foothold in a lucrative market segment
by redesigning a machined component as a stamped components,
saving costs for its customer in the process.
By: Kate Bachman - www.thefabricator.com, 5/28/09
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.
By: Art Hedrick, Contributing Writer - The FABRICATOR®, 4/14/09
Punch tooling innovations help die builders and stampers improve lead times, reduce waste, and expand design options as well as eliminate slug pulling and minimize stripping pressures.
By: Jerry Dwyer - www.thefabricator.com, 4/14/09
Ultra Tool & Manufacturing launches a program to tackle sensor technology in an effort to errorproof the pressroom.
The FABRICATOR®, 4/14/09
For the right application, magnetic die clamping can add significant flexibility to a stamping operation, eliminate physical clamps, and simplify maintenance.
The FABRICATOR®, 3/24/09
At nearly half the cost of conventional stamping equipment and a small footprint (3 to 210 tons), the pneumatic press
may be the answer for some operations. Traditionally, the technology has been associated with roll forming operations, but advances in the technology have made it an option for day-...
By: Richard Meyer - www.thefabricator.com, 2/24/09
Ensuring 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.
By: Drew Stevens, Contributing Writer - www.thefabricator.com, 1/13/09
Metal forming, stamping, and washing fluids traditionally have been thought of as “necessary nuisances” to be used once and thrown away. That mindset is changing.
Incorporating “green” or environmentally friendly fluids and fluid management systems can extend fluid life and minimize waste, providin...
By: Milton Hoff - The FABRICATOR®, 12/15/08
Effective 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 12/14/08
Master Mfg. Co. has built a thriving business as a supplier of high-quality small metal stampings and clips to the appliance, automotive, electrical, lighting, and other industry segments using fourslide presses, primarily. The manufacturer decided to increase its capabilities with a press purchase ...
By: Becky McCarty - www.thefabricator.com, 11/25/08
3-D die design software allows you to build the die on the computer screen, fully assembled and ready to run as if it were built and sitting out on the shop floor. SolidWorks-based Logopress3 software even allows you to then simulate the die running in the press. Even better, it detects crashing and...
By: Raymond Proeber, - www.thefabricator.com, 11/11/08
You’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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/28/08
Stamping 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 biobase...
By: Steve Lowery - www.thefabricator.com, 10/14/08
Carbide is a two-phase, powder-metallurgical (PM) material consisting of a hard material phase and a binder metal phase. The hard material provides the necessary wear resistance, and the binder metal guarantees appropriate toughness. To select the appropriate grade for a tool and die application, it...
By: Brian Ayers - www.thefabricator.com, 9/30/08
This 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?
By: Art Hedrick - www.thefabricator.com, 8/26/08
Among 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/12/08
Proper selection and use of tool coatings in HSLA and AHSS forming applications will extend tool life and yield the best part results.
By: Bernard J. Janoss - The FABRICATOR®, 7/29/08
Determining 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 6/17/08
Answers to frequently asked questions regarding lubricant preparation, lubricant application, and lubricant reclamation.
By: John W. Hayes - www.thefabricator.com, 6/17/08
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 coil-related problems.
By: Art Hedrick - www.thefabricator.com, 6/1/08
Know you need to implement quick die change in your shop, but don't know how? Start here.
By: Mark Scanlan - www.thefabricator.com, 5/13/08
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 can be the result of a poor carrier design. An improperl...
By: Art Hedrick - www.thefabricator.com, 5/1/08
...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 4/29/08
Die 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.
By: Art Hedrick - www.thefabricator.com, 4/15/08
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.....
By: Dr. Taylan Altan - www.thefabricator.com, 4/15/08
Sensor-driven errorproofing can help metal stamping shops prevent the production of bad parts. In addition, it can save tens of thousands of dollars in lost production due to crashed dies and downtime. How? Sensors detect the presence of metal—as material being fed into the press, being positioned, ...
By: Dave Bird - www.thefabricator.com, 4/15/08
Extrusion 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...
By: Art Hedrick - www.thefabricator.com, 3/15/08
Stamping 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.
By: Dan Davis, Editor-in-Chief - The FABRICATOR®, 3/11/08
Selecting 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 2/12/08
This article introduces beginning toolmakers, die maintenance technicians, engineers, and press technicians to tool and die components and their functions
By: Art Hedrick - www.thefabricator.com, 1/15/08
Diemakers 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- m...
By: Wilson J Cubides - www.thefabricator.com, 1/15/08
Successful 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.
By: Art Hedrick - www.thefabricator.com, 12/11/07
Variations 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 mon...
By: Taylan Altan - www.thefabricator.com, 12/11/07
The demands are increasing for forming with higher-strength work materials, particularly for automotive applications because of their lighter weights. It can be a challenge to find a tool steel material that does not chip, crack, or wear when used on high-strength steels. This article compares vario...
By: Brett Krause - www.thefabricator.com, 12/11/07
This 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 ...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 12/11/07
Slivers 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...
By: Art Hedrick - www.thefabricator.com, 11/6/07
BorgWarner Inc., a drive-train developer and manufacturer of four-wheel-drive and traction control parts for the automotive industry, was having a problem with punches used to deform the ends of shafts (axles) in the reduction carrier and differential carrier.
www.thefabricator.com, 11/6/07
There 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
By: Art Hedrick - www.thefabricator.com, 10/9/07
This 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/9/07
The 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.
By: Art Hedrick - www.thefabricator.com, 9/11/07
To 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 ste...
By: Art Hedrick - www.thefabricator.com, 8/8/07
High-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.
By: Jerry Dwyer - The FABRICATOR®, 8/8/07
Metal 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 ...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/8/07
To 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.
By: Art Hedrick - www.thefabricator.com, 7/10/07
This 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.
By: Art Hedrick - www.thefabricator.com, 6/12/07
Fineblanking 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 a...
By: Art Hedrick, Contributing Writer - The FABRICATOR®, 6/12/07
Determining 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.
By: Art Hedrick - www.thefabricator.com, 5/8/07
Minimizing 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.
By: Ron Demonet - www.thefabricator.com, 5/8/07
Pinch, 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 4/10/07
Determining 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.
By: Art Hedrick - www.thefabricator.com, 4/10/07
Glacier 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 sa...
By: - The FABRICATOR®, 4/10/07
How 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.
By: Art Hedrick - www.thefabricator.com, 3/13/07
Part 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 ...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 2/13/07
Numerous 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 ...
By: Art Hedrick - www.thefabricator.com, 2/13/07
Excessive 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.
www.thefabricator.com, 2/13/07
Cutting 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...
By: Art Hedrick - www.thefabricator.com, 1/9/07
Numerous factors contribute to the premature failure or breakage of piercing and cutting punches. Two obvious factors are operator error and incorrect die cutting clearance.
By: Art Hedrick - www.thefabricator.com, 12/12/06
This 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 par...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 12/12/06
Forming 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.
By: Paul Bosler Jr., Michael Brown, and Debra Reining - www.thefabricator.com, 12/12/06
Die 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.
By: Paul Van Every - www.thefabricator.com, 11/7/06
This 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 ...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/10/06
The relationships among part geometry, tool geometry, and control of the processing inputs are significantly different between the net shape and non-net shape processes.
By: Edmund Herman, P.E. - www.thefabricator.com, 9/12/06
This 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...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/8/06
A 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...
By: Art Hedrick, Contributing Writer - The FABRICATOR®, 8/8/06
Advanced 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 develop...
By: Edmund Herman, Contributing Writer - www.thefabricator.com, 7/11/06
In 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 ...
By: Edmund Herman, P.E. - www.thefabricator.com, 6/16/06
All 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 h...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 6/13/06
In 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.
www.thefabricator.com, 6/13/06
Like the molds he repairs, Five Star Tool Welding owner Joe Canfield finds that the welding equipment he uses at his company is getting smaller and smaller. Over the years GTAW equipment has evolved to better meet the needs of its tool and die welding users.
By: Stephanie Vaughan, Contributing Writer - The FABRICATOR®, 5/15/06
Draw 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, ...
By: Edmund Herman, P.E. - www.thefabricator.com, 5/9/06
A 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; an...
By: John Massenburg - www.thefabricator.com, 5/9/06
Conveyor 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.
By: Dan Zimmerman - www.thefabricator.com, 4/11/06
Although 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 me...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 4/11/06
In 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.
By: Stephanie Vaughan, Contributing Writer - The FABRICATOR®, 2/7/06
In-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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 2/7/06
Stamping 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 spring...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 12/13/05
Through 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.
By: Mark Cairney - www.thefabricator.com, 11/8/05
"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," ...
By: Todd Earl - The FABRICATOR®, 11/8/05
Unnecessary die repair stems from several basic shortcomings, namely poor die design, setup procedures, tool design, and maintenance techniques.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 11/8/05
In 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 alu...
By: Taylan Altan - www.thefabricator.com, 11/8/05
Stamping 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/11/05
The 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.
www.thefabricator.com, 10/1/05
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, a...
By: William J. Kohley, Ph.D. - www.thefabricator.com, 9/13/05
In 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.
www.thefabricator.com, 9/1/05
Overseas competition, high material costs, just-in-time schedules, demanding quality requirements, stringent safety standards, and industry consolidation are the forces driving trends in the quick die change industry, industry experts say. These forces have intensified the need for quick-die-change ...
By: Kate Bachman, STAMPING Journal® Editor - The FABRICATOR®, 8/9/05
Many 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/9/05
Reducing die changeover times is mandatory to become a world-class stamping operation. The most practical way to accomplish it is through careful evaluation of pressroom needs, and the implementation of cost-effective die change equipment and procedures. In today's manufacturing environment, lean bu...
By: Ron Demonet - www.thefabricator.com, 7/12/05
In the 1990s, Polaris Industries Inc. realized it needed to rethink the way tube fabricating was done at its Osceola, Wis., facility. Laser tube cutting proved to be the answer.
By: Dan Davis, Editor in Chief, and Eric Lundin, Editor, TPJ-The Tube & Pipe Journal® - The FABRICATOR®, 7/12/05
When considering a die lubrication method, you should be sure to evaluate its effect on your entire operation. While most of us focus on how lubrication affects just the manufacture of parts, a close look reveals that it affects many other aspects of running a plant. However, many of them are not ob...
By: Steven Rainwater - The FABRICATOR®, 6/14/05
This article—Part II of a series covering stamping die fundamentals—discusses different forming operations. Part I explained what a die is and described several metal cutting operations.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 6/14/05
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By: Frank Martin and Gary Gathen - www.thefabricator.com, 5/10/05
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By: Steve D. Benson, Contributing Writer - www.thefabricator.com, 5/10/05
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By: Art Hedrick, Contributing Writer - www.thefabricator.com, 4/11/05
Editor's Note: This article is adapted from Yury Madorsky's and Matthew Thompson's workshop "New Developments in Wear-resistance Tool Coatings for Stamping Applications" presented at the 2nd annual STAMPING Journal® Forum: Competing to Win With Less, May 11-12, 2004, Detroit.
By: Yury Madorsky and Matthew Thompson - www.thefabricator.com, 3/8/05
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By: Kate Bachman, STAMPING Journal® Editor - The FABRICATOR®, 2/8/05
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By: Art Hedrick, Contributing Writer - www.thefabricator.com, 1/11/05
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By: Kate Bachman, STAMPING Journal® Editor - www.thefabricator.com, 1/11/05
Depending 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...
The FABRICATOR®, 12/7/04
...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 12/7/04
How do you choose a store-bought cam for your stamping operation? Hundreds of cam designs are available today from numerous suppliers. Choosing the one that best fits your needs, as well as your budget, sometimes can be very confusing.
By: Art Hedrick, Contributing Writer - The FABRICATOR®, 12/7/04
...
By: Greg Dickerson, Contributing Writer - www.thefabricator.com, 11/9/04
Establishing 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 prem...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/12/04
Never before has competition been greater in the metal stamping industry, both domestically and worldwide.
By: William Pfister, Contributing Writer - www.thefabricator.com, 10/12/04
New requirements for clean, dry parts drive the need for efficient, flexible workcell parts cleaning.
By: Brad Jeffery, Contributing Writer - www.thefabricator.com, 9/14/04
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By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/10/04
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By: Ferdinand Oppel, Dr. Thomas Terzyk, and Chris Kane Contributing Writers - www.thefabricator.com, 7/13/04
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By: Art Hedrick, Contributing Writer - www.thefabricator.com, 6/8/04
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By: Art Hedrick, Contributing Writer - www.thefabricator.com, 5/4/04
Quick die change is not just a way of setting up dies; it’s a mindset for the elimination of waste.
By: Herb Kamphausen, Contributing Writer - www.thefabricator.com, 5/4/04
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By: Ed Severson and Brett Krause, Contributing Writers - The FABRICATOR®, 4/6/04
Successful metal forming, stamping, and deep drawing depend on three basic elements: the metal substrate, tooling, and lubrication.
By: Bob Trivett, Dale Elenteny, and Joe Manfreda, Contributing Writers - www.thefabricator.com, 4/6/04
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By: Art Hedrick, Contributing Writer - www.thefabricator.com, 4/6/04
2-D, or not 2-D; that is the question. Whether ’tis nobler to venture out into a brisk, bold, new world of 3-D or to stick with old, reliable methods in 2-D.
By: Robert W. Harper, Contributing Writer - www.thefabricator.com, 3/11/04
As steel prices rise and offshore competition increases daily, steel and overhead optimization are driving U.S. metal stamping and forming companies. Companies that survive and thrive are taking a different approach to managing change and cost and are discovering savings in areas never seriously con...
By: Brad Jeffery, Contributing Writer - www.thefabricator.com, 2/12/04
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By: Art Hedrick, Contributing Writer - www.thefabricator.com, 2/12/04
To thrive and experience growth and healthy profits, a stamping company must have systems in place that allow flexible manufacturing and minimize press downtime. Changing from one job to the next in the least amount of time possible is one of the primary factors impacting productivity and a company&...
By: Said Lounis, Contributing Writer - www.thefabricator.com, 1/13/04
Author's Note: Before I begin, I would like to take this opportunity to express my sincere thanks to thefabricator.com's readers. I hope you have enjoyed the stamping articles, and I am excited about writing for 2004. I also would like to wish all of you a great holiday season as well as a prosperou...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 12/11/03
All businesses tied to the metal forming industry are scrambling to find areas in which they can lower costs without sacrificing quality. Adding to this burden are a tight cash flow and a lack of financial resources to invest in process improvement equipment. Therefore, the savings must come from do...
By: Brad Jeffery, Contributing Writer - www.thefabricator.com, 10/9/03
Bend 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/9/03
The most disruptive type of failure in any tooling application is when the tool cracks. To prevent this type of failure in cold-work applications, it’s important to select the correct steel.
By: Thomas Hillskog, Contributing Writer - www.thefabricator.com, 9/25/03
Stretching or embossing, not to be confused with drawing, is the process in which the part’s geometry is obtained by stretching the metal into a forming cavity.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/28/03
It 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 magic behind the trick. I do this for a couple of reasons: first, to entertain the conference attendees, and second, to show them tha...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 8/14/03
A blank, stamped in the first station of a progressive stamping operation, usually is subject to subsequent forming processes to form a designated part. If the blank is subject to straining, deformation, bending, stretching, or lateral expansion in later stations, its edge condition should be carefu...
By: Young Seo, Contributing Writer - www.thefabricator.com, 7/24/03
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By: Steve D. Benson, Contributing Writer - www.thefabricator.com, 7/24/03
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By: Steve Chamberlain and Rodney Hewitt, Contributing Writers - The FABRICATOR®, 6/26/03
Market pressures to reduce tooling costs are pressing the tool and die industry to seek lower-cost tooling solutions. This column discusses different build approaches and the merits of an integrated build for trying out stamping dies (and molds) as part of the manufacturing validation process.
By: Jay Baron, Ph.D., Contributing Writer - www.thefabricator.com, 6/26/03
One 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 im...
By: Gary Zunker, Contributing Writer - www.thefabricator.com, 5/29/03
The two main reasons for applying die lubricant are to reduce friction and dissipate heat. Heat can build up between the tool surface and metal, causing the lubricant to break down. This results in metal-to-metal contact and galling.
By: Stan Reinke, Contributing Writer - www.thefabricator.com, 4/24/03
Perforating 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 mai...
By: Nick Tarkany, Contributing Writer - www.thefabricator.com, 4/10/03
Setting 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 ...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 4/10/03
With the tooling trade in its current challenging economic situation, some tool companies are being forced out of business, losing money, or entering into highly competitive markets.
By: Robert Harper, Contributing Writer - www.thefabricator.com, 3/13/03
If you're a die designer, a standard precision progressive die can present countless challenges for you. Some of these dies have to produce thin slots, small holes, or tricky coins.
By: Chester J. Punicki, Contributing Writer - www.thefabricator.com, 3/13/03
Today more than ever, the metal forming industry is economically challenged. Everyone is scrambling to find new ways to lower process costs without sacrificing quality. In the case of metal formability, a lot is at stake. With metal prices and operating overhead continuing to rise, any downtime or w...
By: Brad Jeffery, Contributing Writer - www.thefabricator.com, 2/27/03
Most automobile manufacturers have looked for alternatives to the steel traditionally used in car production; hence, the introduction of high-strength steel.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 2/13/03
Modern toolmaking methods and materials have reduced production time, cost, and headaches significantly over the last 20 years. But the rapid pace of the tooling revolution, coupled with extremely complex manufacturing technology, has left many people confused and misinformed.
By: Steve Chamberlain, Contributing Writer - www.thefabricator.com, 1/16/03
Quick 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.
By: Olav Vangstad, Contributing Writer - www.thefabricator.com, 11/21/02
Over 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 11/21/02
One of the most valuable high-tech tools introduced in the last decade has been finite element analysis (FEA) simulation software that stamping tool makers can use to test forming conditions and design dies in the virtual world. This reduces tooling and product design time and saves costs of prototy...
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/24/02
Keeping a couple key tips in mind can help you turn aluminum stamping from a source of frustration to a source of income and satisfaction in a hurry.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/10/02
Most metal forming operations use lubricants to protect the tooling and part from excessive wear caused by scuffing, scratching, scoring, welding, and galling. Four lubricant families are commonly used in pressworking, and thousands of formulations are available within each chemical family. The phys...
By: Joseph Hough, Contributing Writer - www.thefabricator.com, 9/26/02
Take this old maxim to heart: A stitch in time saves nine. The same goes for die maintenance and repair.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 6/26/02
This article outlines how operational changes, planning, and combinations and adaptations of existing technologies are upgrading quick die change. Die standardization and new technologies, such as mechanical die lifters, box-style lifters rolling bolsters and programmable logic controllers, is makin...
By: Patrice A. Kelly, Contributing Writer - www.thefabricator.com, 5/30/02
Learning how to get every bit of flow out of your metal while minimizing scrap -- doesn't that sound like a good idea?
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 3/14/02
This brief article describes how tool galling occurs in stamping and describes results of tests on how TiCN, Hard-Cr, and CrCN were used on sample parts to help reduce galling.
By: Peter Hodgson, Georgie Kelly, Dan Fabijanic, and Michael Cardew-Hall, Contributing Writers - www.thefabricator.com, 3/14/02
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By: ERC/ NSM, Taylan Altan, Contributing Writers - www.thefabricator.com, 2/2/02
This brief overview discusses rules for aluminum stamping involving: die clearance, die radius, punch radius, minimum bend radii, round cups, rectangular box parts, and overhang limit.
By: ERC/ NSM, Taylan Altan, Contributing Writers - www.thefabricator.com, 2/2/02
Federal government and U.S. automakers to develop technologies for a new
generation of vehicles to triple fuel efficiency without sacrificing performance, affordability, or safety.
By: ERC/ NSM, Taylan Altan, Contributing Writers - www.thefabricator.com, 1/31/02
Various 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.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 1/31/02
Liquid impact forming, a patented process developed by Greenville Tool & Die Co., Greenville, Mich., uses a conventional stamping press with a liquid medium to manufacture parts that otherwise would require hydroforming.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 1/24/02
Reducing the time it takes to change dies it important to all stampers, especially for custom stampers that run small-quantity jobs. This article summarizes the ways in which automation has helped in this process and then covers two die change methods that are used in a quick change system: the stan...
By: Patrice A. Kelly, Contributing Writer - www.thefabricator.com, 11/29/01
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By: Gerry Nord and Kevin J. Coughlin, P.E., Contributing Writers - www.thefabricator.com, 11/29/01
The 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 ...
By: Tom Ulrich, Contributing Writer - www.thefabricator.com, 11/29/01
You might be able to gain a competitive edge by learning how to reduce the amount of engineered scrap, or that material that was inteded to be scrap rather than scrap created because of defective piece parts.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 11/15/01
While 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.
By: Bill Bryson, Contributing Writer - www.thefabricator.com, 10/25/01
Recent changes in tooling technologies, material specifications, part quality requirements, and inventory levels have driven the demand for new developments in the way a mechanical press operates. This article discusses how link motion and bridge-frame structures help stampers. This includes a descr...
By: David G. Stone, Contributing Writer - www.thefabricator.com, 10/25/01
Knowing how steel tends to react when it is bent in a single operation can help you do the job right the first time.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 10/11/01
Decisions and compromises must be made when designing progressive dies to produce a part. Knowing ahead of time what this process entails just might help you.
By: Michael Korneli, Contributing Writer - www.thefabricator.com, 9/17/01
The article explains how EDM has been used to simplify die making as well as some design considerations for minimizing deflection during production.
By: David A. Smith, Contributing Writer - www.thefabricator.com, 9/17/01
Designing progressive dies has increasingly become a high-tech process. The more able an operation is to use computer technology, the more able it is to use the latest advances in the field in its own designs.
By: Robert W. Harper, Contributing Writer - www.thefabricator.com, 9/17/01
Using finger tooling and planning ahead of time to minimize costs can benefit your operation ahead more than you think.
By: Daniel R. Leighton, Contributing Writer - www.thefabricator.com, 8/16/01
Routine maintenance—grinding, using surface treatments, sharpening ejector pins, and minimizing potential grinding damage—can extend tool life and save you a lot of headaches.
By: Nick Tarkany, Contributing Writer - www.thefabricator.com, 8/16/01
Designers and manufacturers of progressive or stage tooling are faced with a project involving production of metal stampings that will be post-processed with painting, powder coating, or plating operations.
By: John Kaikis, Contributing Writer - www.thefabricator.com, 7/26/01
When 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.
By: Art Hedrick, Contributing Writer - The FABRICATOR®, 7/26/01
Want to know how powder metallurgical tool steels are produced and how their properties provide the material's toughness and wear resistance? Read on.
By: James Kaszynski, Contributing Writer - www.thefabricator.com, 6/15/01
A recently formulated approach to draw die development incorporates simultaneous engineering to identify and address potential problems before dies are built.
By: Greg Faucher, Contributing Writer - www.thefabricator.com, 6/13/01
A list of basic requirements must be met to begin the design process for a transfer die. You'll probably want to know why transfer dies are used, methods for loading material, the sequence of operations in a transfer press, and the details of manufacturing process before you start.
By: Edwin A. Stouten, Cmfg, P.E., and Daniel R. Leighton, Contributing Writers - The FABRICATOR®, 6/13/01
Successful deep drawing depends on many factors. Ignoring even one of them during die design and build can prove disastrous.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 5/30/01
The need for die protection has existed ever since the first die was produced. The most elementary form of protection has always been an alert, dependable operator. However, an operator cannot always react to a problem before it damages a die.
By: Harry J. Walters, Contributing Writer - www.thefabricator.com, 5/30/01
Knowing how metal bends and what factors come into play during bending -- especially wipe bending—can make a positive difference in your stamping operation.
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 5/15/01
Innovations in die technology are helping stampers adjust to the many variations that can occur during the stamping process.
By: Prof. Dr.-Ing. H.c. Klaus Siegert, Contributing Writer - The FABRICATOR®, 4/24/01
Addressing the difficulties in obtaining a wrinkle-free stamped part requires a good understanding of metal flow and how it is affected by draw beads…
By: Art Hedrick, Contributing Writer - www.thefabricator.com, 2/19/01
Demands for cheaper, better, and faster tooling for stampings and the pace of business continue to escalate. This trend is not going to reverse itself.
By: Michael Korneli, Contributing Writer - www.thefabricator.com, 2/19/01
Flatness is one of the most difficult part characteristics to achieve in a conventional stamping die.
By: Art Hedrick, Contributing Writer - The FABRICATOR®, 2/19/01
Draw 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.
By: The Ohio State University ERC for Net Shape Manufacturing - www.thefabricator.com, 1/15/01
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