Smart materials for lightweighting
Servo, hydraulic hydraulic press showdown
EXPERTISE E XPERTISE TO HELP YOU TRANSFORM METAL INTO GOLD
Press feed trends
Mechanical Press Press Buyers’ Guide©
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JANUARY/FEBRUARY JANUARY/FEBRUARY 2020 2020
A FFABRICATORS A PUBLICATION PUBLICATION OF OF THE THE FABRICATORS FABRICATORS ABRICATORS & & ® MANUFACTURERS MANUFACTURERS ASSOCIATION, ASSOCIATION, INTERNATIONAL INTERNATIONAL®
An Official Publication of the Fabricators & Manufacturers Association, International®
VOL. 32 NO. 1 JANUARY/FEB JANUARY/FEBRUARY RUARY 2020
>> COVER STORY 24 8 Press feed technology trends for 24 simpler operation, servo syncing At least least eight press press feed feed challenge challenges, s, including including a workfor workforce ce shortshortage and high-strength materials, that have plagued stamping manufacturers are now being addressed with the most updated press feed equipment. New systems aim to halt problems that start at the feeder head-on.
On the cover: Cover photo courtesy of Cooper-Weymouth, Peterson, Clinton, Maine.
>> FEATURES p. 24
16 Steel, aluminum laminate a 16
>> DEP DEPARTMENTS ARTMENTS 6 Meet the Press In “Of press feeds, faceoffs, and farewells,” Editor Kate Bachman dishes on the issue’s content and relays some publication news. 8 News & Notes Fiat Chrysler, Peugeot merge; GM, LG Chem team up on EV batteries; Fagor Arrasate to open Chicago center; Ford debuts electric Mustang SUV; Auto/Steel Partnership presents 2019 awards
12 12 Stamping Solutions Custom forklift attachment contributes to safety safety,, productivity at stamping plant
13 13 Product Innovations Norgren Automation launches tooling system; Press monitor includes automated plunging depth feature 14 14 Die Science In “Recognizing the need for tooling changes,” Art Hedrick examines the considerations for tool changes, including financials.
smart alternative material for vehicle lightweighting In this Technology Spotlight, STAMPING Journal Journal looks at a new material for automotive lightweighting that is a formable, weldable, and paintable substitute for monolithic low-carbon steel at up to 35% weight savings at the same thickness.
20 Do servo mechanical presses replace 20 hydraulic presses? Those looking to replace old hydraulic presses may be trying to decide whether to get an improved version of the hydraulic press that has always worked or convert to a servo press instead. Consider the control, flexibility, speed, cost, and longevity advantages and disadvantages of each technology carefully. carefully.
32 Forming & Fabricating® 2020 Mechanical 32 Press Buyers’ Guide©
p. 16
30 30 Product News 41 41 Classified Advertising 41 41 Advertisers Index 42 42 Ask the Expert
Tom Vacca relays some helpful tips for tool and die apprentices.
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p. 20 STAMPING JOURNAL • AN FMA PUBLICATION
MEET THE PRESS
Of press feeds, faceoffs, and farewells farewells
Kate Bachman Editor
[email protected]
Changes in the new year his issue highlights press feeding trends, ing with “STAMPING “STAMPING Journal Brief.” Journal Brief.” looks at new lightweighting materials, Finally,, if you miss reading the R&D Update Finally and takes steady aim at resolving the in this issue, I understand. The column has hydraulic/servo press question. enriched STAMPING Journal with Journal with the reveal of As a rule, STAMPING Journal avoids Journal avoids direct cutting-edge research for decades, fortifying comparisons of competing technologies. the journal aspect of our publication. UnforHowever, for as long as servo mechanical press tunately, our beloved columnist, Dr. Taylan technology has entered the arena, stamping Altan, who has provided the column and manufacturers have questioned how they overseen his students’ research behind it, is are different and whether the new technolo- stepping back to actually retire, since he offigy obsoleted hydraulic press technology. “Do cially retired in 2012. He will write two more servo mechanical presses replace hydraulic columns, to appear in the next two issues, and presses?” penned by hydraulic press OEM that will wrap it up for him. Greenerd, tackles this question. (I invite more As I have gleaned over the years, Dr. Altan input and discussion on this topic.) is one of the most well-known and -respectThe stamping industry has centuries-old ed leaders in the stamping industry. As a proroots, sometimes resembling a slow-moving fessor and teacher, research lead, conference but earth-carving force, like a glacier. But the host, and outspoken influencer, he has used industry segments it serves, such as auto- his knowledge of and passion for the metal motive, aerospace, and medical, are rapidly forming industry to inspire and excite stuchanging. The article “How will the transition dents and readers alike, and even drive tech-
T
Dr. Taylan Altan is stepping back to actually retire since he officially retired in 2012.
from ICE vehicles to EVs affect stamping manufacture?” published in the Sept./Oct. issue prompted such a great response that we at FMA are hosting a conference, Stamping in an EV World. The one-day event will delve even deeper into what has been called “disruptive paradigm shift” and will focus on its effects on stamping specifically. I truly hope you can attend this exciting event, evstamping.fmanet.org. Speaking of industry segments, you may have noticed a new e-communication we are publishing, “STAMPING “STAMPING Journal Journal Industry Focus.” The publication aggregates news and
nology changes. Wee have been fortunate to have Dr. Altan W with us all these years. If you are so inclined, you can write him at the address below or to me and I’ll be happy to forward your messages to him. Dr. Taylan Taylan Altan can be reached at the Center Cent er for Precision Forming (CPF), The Ohio State University, 339 Baker Systems, 1971 Neil Ave., Columbus, OH 43210, 614-292-9267. S Got thoughts? I’d love to hear from f rom you.
[email protected]
reports on a specific segment that stampers serve in hopes of shining a light on new market opportunities. It posts in months alternat-
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Fiat Chrysler, Peugeot merge
(From left) Chairman of the Managing Board of Groupe PSA Carlos Tavares and FCA CEO Mike Manley.
STAMPING JOURNAL STAFF
field site and will include a bridge crane and offices. The company reports that the project is intended to strengthen its after-sales service, engineering, and spare parts inventory for U.S. customers. The company, with U.S. headquarters in Willowbrook, Ill., manufactures transfer and servo presses, high-speed press lines,transfer slitting and cutto-length lines with laser flat technology for aluminum, and full stamping lines.
A.L.P.’s Charlevoix facility certified to ISO
Fiat Chrysler Automobiles N.V. and Peugeot S.A. have signed a binding Lighting components manufacturer Combination Agreement providing for a A.L.P. A.L.P. has announced that its Charlev50/50 merger of their businesses to cre- oix, Mich., facility has earned ISO ate the fourth-largest global automotive 9001:2015 certification. This faciliOEM by volume, with expected annual ty and the company’s Dickson, Tenn., unit sales of 8.7 million vehicles. plant, certified to 9001:2015 since The combined entity will cover all November 2018, produce LexaLite® key vehicle segments, from luxury, pre- injection molded components. mium, and mainstream passenger cars The company provides specialized to SUVs, trucks, and light commercial services from product design and engivehicles. neering to tooling and prototyping, product testing, and contract assembly. Futura Automation partners with Production capabilities include press Gate Technologies sizes from 88 to 1,650 tons and secondary operations such as UV coating and Futura Automation LLC, Scottsdale, laser cutting. Ariz., a provider of automation and robotics equipment, has announced Ford expands Mustang line with it will represent Gate Technologies all-electric SUV throughout the western U.S., including the Rocky Mountain states. Previously known in North America as Cam Driven Systems, Gate is the North American marketing and sales partner of Betinelli SpA of Bagnolo, Italy. The company is a developer of patented cam-driven indexing rotary tables, indexing linked conveyors, and systems for automated and robotic small-part assembly.
Spain-based press manufacturer Fagor
For the first time in 55 years, Ford is expanding the Mustang family with the all-electric Mach-E SUV. When it arrives in late 2020, the vehicle will be available with standard and extended-range battery options with either rear-wheel drive or all-wheel drive powered by permanent magnet motors.
Arrasate has annou Arrasate announced nced plans to open a service facility in Chicago. Scheduled to be operational by the end of 2020, the new plant will be built on a green-
Equipped with an extended-range battery and rear-wheel drive, the SUV has a targeted EPA-estimated EPA-estimated range of at least 300 miles.
Fagor Arrasate to open Chicago area service center
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President & CEO, FMA Publisher
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[email protected] Web site www.stampingjournal.com STATEMENT OF POLICY
The STAMPING Journal’s objective is to disseminate new and complete information relating to the metal stamping industry. The main editorial text consists of articles and news releases designed to assist owners, managers, manufacturing engineers, supervisors and foremen in the evaluation of new methods and techniques. It is an official publication of the Fabricators & Manufacturers Association, International. The policy of the publisher and this journal is to be nonpartisan, favoring no one one product or company. The representations representations of facts and opinions expressed in the articles are those of the author and are not necessarily endorsed by the publisher and this journal. By including information on new products, products, new literature, news of the industry, articles, etc., this impartiality is strived for and extends to the mention of trade names. Unless product identification makes reference unavoidable, the generic name is used. We acknowledge that on occasion there may be oversights or errors; the editors regret such oversights and re-emphasize their policy to be impartial at all times. The Publisher reserves the right to refuse advertising it deems inappropriate for publication in STAMPING STAMPING Journal®, including ads for classes of products and services not considered of significant interest to the readership. (ISSN 1091-2460) STAMPING Journal is a trademark of FMA Communications Inc. All rights reserved. Publi Publications cations of FMA Communications Inc., maintain a policy of keeping editorial and advertising separate to ensure editorial integrity that most benefits our readership. Editorial content, including feature articles and press releases, is determined solely by the publisher.. Editorial content cannot be purchased, publisher purchased, nor can it be used as a benefit of advertising dollars spent. Editorial Editorial is free-of-charge, subject to space availability, and open to all interested parties that submit items meeting our editorial style and format as determined by the publisher. Standard Rate & Data Service lists our advertising rates in Section 88. Consult SRDS or our current rate card for full rates and data. Note: Some photographs printed in this publication may be taken with safety equipment removed for photographic purposes. However, However, in actual operation, it is recommended that correct safety procedures and equipment be utilized. a publication of FMA Communications Inc.
STAMPING JOURNAL • AN FMA PUBLICATION
NEWS & NOTES
Shape Corp. wins Swedish Steel Prize 2019
uniform rapid cooling feature, which combines HIP and heat treatment in a single process—high-pressure heat treatment—and streamlines the steps involved in material densification and heat treatment.
T. J. Snow S now announces 2020 dates for resistance welding seminars
Shape Corp., based in Grand Haven, Mich., has been named by SSAB as the winner of the 20th international Swedish Steel Prize. The award recognizes the company’s groundbreaking use of martensitic steel in a 3D-formed tube for automotive roof rail applications. Shape Corp. used 3D forming to shape SSAB Docol® 1700M martensitic steel into lightweight A-pillar and roof rail tubes with a minimal profile size. The A-pillars have an improved strengthto-weight ratio of more than 50%, which has led to an overall mass reduction of 2.8 to 4.5 kg per vehicle.
cago; April 8—Eastern Michigan; April 22—Cleveland; May 6—Frankfort, Ky.; June 24—Charlotte, N.C.; July 22 —Montgomery, Ala.; Aug. 12—Dallas; Aug. 26—Nashville, Tenn.; Sept. 9— Omaha, Neb.; Sept. 23—Grand Rapids, Mich.; and Oct. 14—Phoenix. For more information, visit tjsnow. com/seminars/training-regional-semi nars.
T. J. Snow has released the 2020 dates for its one-day Basics of Resistance Welding UAW reaches agreement with seminars. The seminar provides all the Ford basics needed to understand the process, covering resistance welding terms, The United Automobile, Aerospace and pneumatic systems and troubleshoot- Agricultural Implement Workers of ing, welding transformer operation and America (UA (UAW) W) has ratified its agreetroubleshooting, basic resistance welder ment with Ford Motor Co. setup and weld lobe development, elecTerms of the new agreement include trode selection and maintenance, quality increased use of temporary employees, assurance, operator safety, and identify- closure of one engine plant, special ing problems and solutions. retirement program, and no increase The 2020 seminar dates are March to pension obligations or payments to 11—Fort Wayne, Ind.; March 25—Chi- retirees.
GM, LG Chem team up for EV battery cell production General Motors and LG Chem have announced plans to mass-produce battery cells for future battery-electric vehicles. Together the companies will invest up to $2.3 billion through a new, new, equally owned joint venture company. The new company will establish a battery cell assembly plant on a greenfield manufacturing site in Lordstown, Ohio, that will create more than 1,100 new jobs.
Accurate Brazing adds second hot isostatic press from Quintus Technologies Quintus Technologies, Västerås, Sweden, has delivered a hot isostatic pressing (HIP) machine to Accurate Brazing, a provider of heat-treating services in Goffstown, N.H. This is the company’s second QIH 122 M URC® HIP machine. Both presses are equipped with the proprietary
AN FMA PUBLICATION • STAMPING JOURNAL
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NEWS & NOTES
Braner delivers slitting line to Calstrip Industries
Auto/Steel Partnership presents 2019 awards
Corp.; and Michael Karagoulis, General Motors Co. •Project Team—Stamping Team Calstrip Industries has installed a Auto/Steel Partnership, Southfield, Members: Jason Bigelow, Gestamp; Hi-Performance 72- by 0.250-in. Bra- Mich., has announced the 25 winners Mai Huang, ArcelorMittal; Haoling Jia, ner/Loopco Turret Head™ slitting line of its Award of Excellence for 2019. The AK Steel Corp.; Rick Johnson, FCA US at its new Blytheville, Ark., coil pro- award recognizes steel producers and LLC; Hokook Lee, POSCO America— cessing line is designed to automakers demonstrate innovaprocess center. 30-tonThe critical-surface-coated tion through that collaboration. carbon steel, aluminum, and stainless Award A ward selections were based on A/ coil in gauges from 0.015 to 0.250 in., SP project work conducted in 2018 with coil mechanical properties up to and voted on by the partnership’s 133,000 PSI. Joint Policy Council. Criteria included This equipment includes patent- demonstrating the technical expertise ed, no-hands Andiamo automatic coil necessary to execute or significantly threading and KEVIN QC+Automation contribute to project results with excelsoftware that generates slitter tooling lence and on time. setups; helps eliminate accidental proThe partnership announced the folduction of incorrect widths/gauges; and lowing winners: automatically establishes equipment •Individual—Adam Kotlarek, Gener Gener-operating parameters, programs slit coil al Motors Co.; Yu-Wei Wang, AK Steel data into the pack line, and generates Corp.; and D.J. Zhou, FCA US LLC QC and real-time production data. •Most Valuable Player—Mai Huang, ArcelorMittal; Dean Kanelos, Nucor
Detroit Office; Ford Motor Co.; PaulEvangelos McKune,Liasi, Martinrea Intl.; Vincent Millioto, Gestamp; Dillon (Zhi-Guo) Qin, General Motors Co.; Stuart Quinn, Ford Motor Co.; Feng Ren, Ford Motor Co.; Chris Roman, General Motors Co.; Yinong Shen, Ford Motor Co.; J.P. Singh, General Motors Co.; Thomas Stoughton, General Motors Co.; Weiping Sun, Nucor Corp.; Yu-W Y u-Wei ei Wang, AK Steel Corp.; Hong Yao, Ya o, ArcelorMittal; D.J. Zhou, FCA US LLC; Yongjun Zhou, FCA US LLC; and Hong Zhu, ArcelorMittal. •Key Collaborator—Daniel Schaeffler, Engineering Quality Solutions Group Inc.
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NEWS & NOTES
Laguna Tools completes acquisition of Dake Laguna Tools Inc., a manufacturer of automated metalworking machinery, has completed the acquisition of Dake Corp. from its parent company, JSJ Corp. Dake is a provider of machine presses and band saws. tools, including Laguna Tools currently occupies two main facilities in Irvine, Calif. (headquarters), and West Columbia, S.C. It plans to expand its operations into a third facility in Dallas in February 2020. It also has a location in Minnesota, and now Grand Haven, Mich., with the acquisition of Dake.
CCAI announces 2020 national scholarship program The Chemical Coaters Association Intl. (CCAI), Lakewood Ranch, Fla., has begun accepting applications for the 2020 Matt Heuertz Scholarship Program. The association has awarded more than $100,000 in scholarships over the past five years to students who currently are enrolled in programs that could lead to a career in the finishing industry. The primary objective of this program is to encourage students to pursue advanced education in finishing technologies. Award A ward amount amountss vary and are deter deter-mined by the Education Foundation and individual chapters. Scholarship recipients also will receive a free, one-year CCAI student membership. Awards will be announced in June. For more information, visit www.ccaiweb.com/page/scholarship.. The applicaweb.com/page/scholarship tion deadline is April 1.
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Xometry acquires Shift on-demand manufacturing marketplace Xometry, a marketplace for on-demand manufacturing based in Gaithersburg, Md., has acquired Munich-based on-demand manufacturing marketplace Shift. With this acquisition, Xometry has expanded to 12 countries, involving a worldwide network of more than 4,000 manufacturers.
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STAMPING SOLUTIONS
Custom forklift attachment contributes to safety, productivity at stamping plant Situation
At MiTek USA Inc., a stamping company Tampa, Fla., handling of steel coils wasinbecoming a problem. The coils are delivered by train, and the stamper receives them in batches of six or seven aboard each railcar; a train might have six cars. Three personnel were required to unload the coil, including one precariously positioned on the railcar truck. Using a 35,000-lb.-capacity lift truck with a wire rope sling strapped over the center of the 6-ft.-long forks, the workers would pass it manually through the eye of the coil and attach it with a swivel hook to complete the connection. “I put myself in the railcar to experience it from the rigger’s viewpoint, and it wasn’t satisfactory,” said Ken Jurgensmeyer, director of manufacturing operations at the facility. “Further, we often had to lift at an angle because of how far away we sometimes had to position the forklift. Once we picked the coil, it was taken to the loading dock and awkwardly swung into position so a second lift truck could move it onwards.” Not only was this method unsafe, but it took all day to unload a whole train.
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lbs. of steel per year, which equates to 94 coils per week. “The reality was, someone could have gotten injured, so when we were contacted by Ken, our first priority was designing a system that removed the need to manually rig the load,” explained Dan Mongan, special application support/ new product development specialist at Caldwell. “As a byproduct, we were also
coils (a wide roll of coiled steel, slit into many narrower coils), varying in weight from about 22,000 to 24,000 lbs. each. International deliveries are trucked to the facility, having been transported by ship and loaded at ports upon arrival in the U.S. However, currently 100% of the steel at the Tampa facility is from domestic suppliers, placing further demand on a quick turnaround of railcars.
This 24,000-lb.-capacity product has reduced the time it takes to unload a single car from one hour to 20 minutes and, more importantly importantly,, there is no
Resolution When MiT MiTek ek started taking delivery of longer trains from domestic steel suppliers, Jurgensmeyer contacted Caldwell for help. Caldwell manufactured a custom lifting product that attaches to a forklift truck to help unload steel coils from the railcars. The attachment, supplied by Caldwell distributor Certified Slings & Supply, is known on-site as the master coil lifter. This 24,000-lb.-capacity product has reduced the time it takes to unload a single car from one hour to 20 minutes and, more importantly, importantly, there
able to speed production considerably. Even the transfer to the second lift truck is improved because we can lower the coils onto a frame from where they are easily picked. “The coils can shift during transit, so they are very close to each other. In order for the grab to fit, the lifting
Following its successful implementation at the stamping plant in Tampa, another MiTek site in Phoenix, Ariz., has also adopted the equipment, where it again has improved safety and efficiency compared to previous methods. “Actually,” said Jurgensmeyer, “we have introduced the concept to [MiTek]
is no longer a requirement for a rigger beneath the forks. Jurgensmeyer Jurgen smeyer said that the coil lifter would be required to lift 110 million
shoes pivot and the legs are very thin,” he continued. The master coil lifter is only being used on domestic delivery of master
sites worldwide based on its inception here.”
JANUARY/FEBRUARY 2020
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longer a requirement for a rigger beneath the forks.
Caldwell Inc. www.caldwell.com
STAMPING JOURNAL • AN FMA PUBLICATION
PRODUCT INNOVA INNOVATIONS TIONS
Press monitor includes includes automated plunging depth feature
Tooling system designed to help optimize material handling tooling in space in a repeatable, accurate manner. When the arms are actuated to the desired location, pneumatic clutches lock them in place at 150 ft.-lbs. This provides a rigid tooling system similar
Marposs offers the Brankamp X3S monitoring, control, and measurement unit with a plunging depth feature for highspeed stamping presses. This capability automatically compensates for machine process parameters—such as sheet thickness, material hardness, tool, and machine temperature—that change during the stamping process via a connection with the press PLC. Although Althou gh adva advanced nced presses can automatically correct the ram position during the manufacturing process and adapt it to changed production speeds, the monitoring system enables a more extensive plunging depth control system. This approach can detect and evaluate stop block forces during the stamping process using special control algorithms to carry out a step-by-step adjustment of the ram position. The stamping process and its clamping forces at the machine’s lower reversal point are kept constant. At the same time, the machine operators are informed on-the-fly about plunging depth setting when the tools are set up, and the insertion height can be automatically adjusted to the optimum range. Depending on the complexity of the tool and the number of equipped stop blocks, a different number of limit stop forces can be included in the control system. The control system visualizes the calibrated force progressions and displays the control variables executed for the user. A standardized interface to the PLC simplifies connection of the control system to automatic stamping
Norgren Automation Solutions, part of IMI Precision Eng., has launched a tooling system designed to help optimize material handling applications. According Accor ding to the manu manufactu facturer rer,, the Transforming Tooling system can help reduce recurring tooling costs, eliminate manual tool change, allow instant tool changeover between different applications, reduce floor space requirements because of the elimination of manual tool storage, and optimize safety on the shop floor. The system is a series of arms driven by electric motion that help users place
to tooling.conventional Series of twoend-of-arm to 16 armsrobotic function in collaboration with each other. When the application requires a change in handling material, the arms automatically transform the end-effector system to suit the new application and lock in place, eliminating the need for tool changes. The system is suitable for applications in pressrooms, stamping shops, and general material handling. It comes with a variety of consumables, including end effectors that can be swapped on-the-fly, such as switching from vacuum cups and grippers. IMI Precision Eng. www.imi-precision.com/nas
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DIE SCIENCE
Recognizing the need for tooling changes BY ART HEDRICK
I
n my career as a professional consultant, I have seen numerous stamping processes that needed a major over-
Process Failure Of the two causes of stamping problems, process failure is the more catastroph-
design engineer designed the tool with an insufficient number of gas cylinders or perhaps used cylinders with insufficient
hauling. needed just minor adjusting,Some whiledies others needed to be completely redesigned and remade. In all cases, though, the stamping problems occurred as a result of process failure or die design error error..
ic to making correct.aSimTheorsolution would be to add more plyand put,more if theexpensive process for part force. cylinders use higher-pressure ones. is not correct, no matter how the die is Other classic examples of die design designed, it will not function properly. properly. errors are incorrect tool steel selection, For example, if you were attempting poor locating methods on die sections, to make an automotive oil pan and you poor pad guidance methods, incorrect decided to use a solid forming die instead forming and cutting clearances speciDie Design Versus Process of a drawing die for the first forming fied, excessive die shoe deflection, poor Design operation, the part would wrinkle and cam designs, and incorrect stop block Don’t confuse process design with die most likely wad up into a deformed, locations. design. Process engineers determine the double-metal mess during forming. No steps in which a part is to be made. In matter how you design the die, if a solid Time for a Change the case of a progressive die, they typi- forming process is used, it will fail. Items When you have a proce process ss failur failure, e, no cally determine how many stations are like oil pans and deep formed shapes shap es typ- matter how you change the die (unless it required to make the stamped part to the ically need to be drawn or stretch-formed. reflects a process change), you can expect specifications and tolerances determined Other examples of process failures are little or no improvement. Stampers often by the product designer. Once the pro- an insufficient number of drawing sta- want to make significant part improvecess has been determined, the process tions to make a part, incorrect binder ments but are unwilling to make any engineer may design a strip layout or pro- shape for a drawing and stretching oper- major process changes that could cost cess layout. This layout serves as the base ation, improper forming sequences, and short-term productivity. productivity. They want to do around which the tooling is designed. incorrect part tip angles. When a process something quick and inexpensive to the existing dies to get the desired results, but often they need an entirely new tool using a completely different process and are The best course is to focus a great reluctant to invest the time and money to make a new die. deal of time and effort at the beginning In most cases, the money lost because of downtime, scrap, rework, overtime, stages of your project. and risk far outweighs the cost of a new tool. Nobody wants to retool a job, and The process or strip layout not only error occurs, it usually requires that a sometimes the cost of correction can be defines the number of stations required to whole new die be built, but sometimes greater than the profit that can be gained. make the part, but also defines the pitch some of the secondary operations can be So the best course is to focus a great deal or progression of the tooling. The process salvaged. of time and effort at the beginning stages or strip layout also shows in detail how of your project. Be as certain as you can Die Design Error the part is to be formed or cut in each that you have the correct process in place station. It also might show how the scrap Altho Although ugh some die design errors can be to make your stamped part. will be cut away and how the part will be costly, most can be corrected by making If you discover later that you selected ejected from the die. a mechanical change in the design of the the wrong process, analyze the cost of cor A die die designer designer determi determines nes the mechanmechan- tool. In other words, the process for mak- rection and of not correcting the problem, ical means by which the predetermined ing the part was correct, but the die could and fix it when it makes financial sense. process will be executed. In other words, not achieve the results. Until next time … best of luck! S the die designer designs the tool to perFor example, let’s say that the presform accurately all the steps determined by the process engineer. The die designer determines the tool geometry and the best tooling materials to use. 14
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sure in the blank holder or drawing Art Hedric Hedrickk is pres president/se ident/senior nior consulta consultant nt pad pressure system is maxed out, and of Dieology, 10855 Simpson West Private, the part is still wrinkling in the binder Greenville, MI 48838, 616-894-6855, diearea. This failure would indicate the die
[email protected],
[email protected], www.dieology.com.
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Technology Spotlight Formable, weldable substitute cuts weight by a third By Kate Bachman
aterial Sciences Corp. has put into production a new material to support automotive lightweighting efforts. MSC Smart Steel® is a lightweight laminate that is a formable, weldable, and paintable substitute for A new engineered lamimonolithic, low-carbon steel at up to nate material comprising 35% weight savings at the same thicksteel or aluminum and a ness. It is produced as a coil. polymer core can reduce The lightweight laminate materipart weight by a third. al was a natural extension of MSC’s portfolio of acoustic laminated metals for quieting vehicles manufactured for years. R&D began in 2012 20 12 and production began in spring 2019. One of the manufacturer’s legacy products, developed in the 1990s, is called Quiet Steel®, which is a laminate for acoustic applications. Its typical uses are for vehicle body panels, such as dashboard panels and floor pans, as well as engine components such as oil pans, valve covers, and timing covers. More recently, the compaWhen used to form a truck’s bumper shell ny introduced Quiet instead of monolithic steel, MSC Smart ® Aluminum , which Steel can cut its weight by 15 pounds. offers all of the weight savings associated with aluminum but also the dampening characteristics needed for aluminum body structures and under-hood applications. MSC specializes in laminating metals, according to Matt Murphy, chief technology officer for Material Sciences. “As CAFE [corporate average fuel econo-
M
Steel, aluminum laminate
a smart alternative material
for vehicle lightweighting 16
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my] standards drove the automakers to improve fuel economy, materials that offer lightweight solutions without compromising performance become
STAMPING JOURNAL • AN FMA PUBLICATION
attractive. Our expertise in laminating acoustic laminates served as a great starting point for the development of MSC Smart Steel.”
Composition The material is a three-layer laminate. The outer skins are steel and the inner layer is a low-density, low-density, conductive, reinforced polymer core. The density of the polymer core is less than aluminum. Typical thicknesses evaluated for automotive applications range from 0.68 mm to 2.5 mm. The ratio of the outer steel skins to the inner core is a function of many factors, including weldability, formability, and part bending rigidity. A recent example under development is an automotive interior part stamped from 1.0-mm steel that weighs 3 pounds. MSC Smart Steel was engineered to meet all of the same vehicle requirements with a total thickness of 1.08 but results in a total weight of 2 lbs., Murphy relayed.
How It’s Processed MSC Smart Steel is compatible with existing manufacturing and painting processes, the company states. It can be stamped in typical dies without modifications, spot-welded with existing equipment, and processed through
monolithic steel Tooling. In terms of the stamping Tooling. dies, it is important to maintain sharp trim dies and tight clearances on the trim to cut through all three layers of the laminate, Murphy said. Forming Simulation. Simulation. Murphy said
standard electrocoat and paint systems that in the past, tool designers based with seamless integration with existing many of their decisions on experience manufacturing systems, according to and trial and error to anticipate items the company. such as springback and formability. “The polymer core is engi- However, modern tool designers rely Weldable. “The Weldable. neered to be conductive. As a result, heavily on forming simulation software when placed between the two skins of to design the entire die. “Today, there’s steel, the product can be spot-welded to a big reliance in our industry on prealmost any grade of steel with welding dictive capability. Automotive stampequipment found in any body shop,” ers use tools such as PAMSTAMP® or Murphy said. AutoForm® for their die designs. Very
Customized for the Part, Application The material is engineered to meet performance requirements of each application, and the stackup of each layer is customized. The steel thickness and grade and polymer core thickness vary from product to product. “We want to maximize weight savings, so we engineer each product for the application,” The OEM dictates the design and Murphy said. performance requirements of each Because the polymer is low density, component in the vehicle. As a result, the less steel and more polymer in the MSC engineers work closely with OEM laminate structure, the more weight can design teams for material selection, be saved, Murphy said. “But the calcu- joint design, fatigue and strength s trength critelation to determine how thick the metal ria, as well as weight targets, Murphy should be and how thick the polymer said. should be is a function of the part per A conductive particle inside the polyformance requirements.” mer is what makes the material weldStiff. The structure of the laminate able. This is the first spot-weldable Stiff. enables it to reduce mass while main- low-density steel composite laminate to taining bending stiffness—an attribute be used in a body application, the comthat is critical in many areas of the vehi- pany claims.
often, die build shops will construct the tooling 100% based on the software prediction,” he said. Because a laminate is a multilayered material and each layer has distinctly different properties, it is critical that the properties of each layer are modeled separately and correctly with the forming simulation program. Key attributes such as springback and formability exhibit a higher correlation between what the software predicts and what is actually stamped when Smart Steel is modeled in layers. “MSC is work-
cle. The company engineers the ratio of the metal skins to the core to maintain the stiffness or bending rigidity of that part as well as to save weight.
ing closely with AutoForm engineers as well as several tool and die shops to fine-tune that correlation between the software prediction and the actual
AN FMA PUBLICATION • STAMPING JOURNAL
Differences, Similarities Naturally, questions arise about the difNaturally, ferences between MSC Smart Steel and
This automotive package shelf is stamped from MSC Smart Steel using a regular die and assembled via resistance spot welding.
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stamped part,” he said, adding that the primary focus now is the draw process and springback. Finite Element Modeling. Meeting panel-bending rigidity is critical to many stamped vehicular parts. Similar to modeling Smart Steel for forming simulation, the laminate is also modeled with three discrete layers for finite element. While the input properties are different for finite element analysis (FEA), the core layer, which is typically 40% of the cross-section thickness thickness of the material, is significant. Therefore, it requires that both properties of the steel and the core are included in the data cards. MSC often performs FEA on all target applications applications but also provides this data to customers for their internal analysis, he said.
The material is a three-layer laminate. The outer skins are steel and the inner layer is a low-density, conductive, reinforced polymer core. The density of the polymer core is less than aluminum. the residual was sent to a lab for chemical analysis. The chemical composition was then compared to a monolithic steel test sample. “We were looking for anything in the recycled Smart Steel that would not be found in monolithic steel. The results showed that the samples were similar in both chemical composition and quantity. Some are fractionally higher or lower, but the results are very consistent,” Murphy said.
Weight Objective, Lightweighting Strategy
The same property-testing procedures for stress-strain curve and forming limit curve that are used to evaluate monolithic steel and aluminum are used to evaluate MSC Smart Steel and Smart Aluminum, Murphy said. “For our predictive stamping correlation effort, we’re stamping parts, scanning them as a 3D image, and then comparing the scan with the forming prediction. We have made great progress through the evaluation of different modeling procedures and material properties.” Recyclable. Although it’s a mixed material, the entire laminate can be recycled because its polymer inner layer
The automotive industry has focused intensely on the need to reduce weight, but every vehicle has different weight targets, Murphy said. “What it comes down to is, what is their threshold for mass? Depending on the size of the gap from actual weight to target weight, automakers may take more extreme measures to save weight. For example, converting the Ford F-150 body from steel to aluminum was a fairly bold strategy to save weight in that segment.” Ford’s adoption of aluminum in the Ford F-150 prompted a lot of speculation throughout the industry, he added. “Were General Motors and Dodge going to make the ‘all-in’ move to aluminum on the forthcoming redesign of their trucks? They did not,” Murphy said. “While they did use aluminum selectively, they each adopted mixed metals strategies. They used aluminum in certain parts of the car, such as doors, fenders, the tailgate, and the hood, while the truck bed itself remains in steel.” There are many material choices for the design of each subsystem of a vehi-
consists of conductive particles and carbon-based polymers, Murphy said. To prove its recyclability in a test, the laminate was melted to a molten state and
cle. “For example, plastic, aluminum, advanced high-strength high-strength steel [AHSS], or magnesium all could possibly be used for the same application. However, there
As a rule, automakers have a mixed materials strategy for each vehicle component. MSC Smart Steel or MSC Smart Aluminum can be part of that strategy.
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are trade-offs in selecting one over the other. While one material may have the lowest cost, it may add the most mass, need the most expensive tooling, or have the longest cycle time. OEMs consider all of these when selecting materials for vehicles,” Murphy said. Another important determining factor is material compatibility. Although aluminum and steel are very common vehicle materials, joining them requires extreme attention, he said. As a result of the difference between aluminum and steel in electrode potential, galvanic corrosion will result. To resolve this problem, typically one or both of the materials is coated before assembly to prevent corrosion. “All of these materials cannot be used everywhere,” Murphy continued. “For example, you would not typically use ultrahigh-strength steel for a hood. It is difficult to form and the surface isn’t going to meet appearance requirements. So there are criteria other than weight dictating where all these different materials can be used.”
Best Applications: Roofs and Bumpers The material is designed primarily for applications that require stiffness, rather than those requiring high strength, Murphy said. “There are many places on a vehicle where Smart Steel will have equal or greater stiffness at a 35% mass reduction. We are not targeting the A pillar, B pillar, and structural components made of AHSS,” Murphy said. “The parts we’ve been replacing are already as thin as they can go, and we can actually save more weight with this material.” Designed with a high stiffness-toweight ratio, the laminate is a viable option for stamped parts needing stiff-
STAMPING JOURNAL • AN FMA PUBLICATION
ness, such as roof bows, stamped bum- just the front and probably another 6 pers, and body-in-white stampings that lbs. off the rear, so about a 15-lb. weight typically are produced from cold-rolled cut on a full-size truck,” Murphy said. steel, according to Murphy. The Smart Steel’s first foray in pro- Award Winner duction was anti-flutter roof bows for MSC Smart Steel has been recognized roof panels. “The roof panels on SUVs for its material innovation with three
2019, and the Altair Enlighten Award in 2019. S
are massive and they’re very thin. At highway speeds, the roof actually flutters at a micro level and passengers feel an annoying pressure drop in their ears called booming,” Murphy said. “So these bows basically stiffen up the roof and prevent it from fluttering. A stiff roof bow is critical to solving this problem, and MSC Smart Steel provides that.”
6855 Commerce Blvd., Canton, MI 48187, 734-207-4444, smartinfo@materialscienc escorp.com,, www.materialsciencescorp.com escorp.com www.materialsciencescorp.com..
A recent application for the material is a steel bumper for a full-sized truck such as an F-150 or a Silverado. “Generally, the full-sized truck market in the U.S. is still using a steel bumper shell that weighs 35 to 45 lbs. They’ve been made like that for 100 years. Imagine a 30% weight savings in that application. So instead of saving half a pound on a roof bow, you’re saving up to 10 lbs. on a front bumper. A significant amount of development is going into this right now,” Murphy said. The customized bumper shell has an asymmetric construction. The visible surface, or outer skin, is made of HSLA 340 MPa and is thicker than the backside skin. This grade and thickness were selected because the bumper’s surface is cosmetic and has to meet dent requirements. The polymer core is similar to the roof bow core with a backside skin. The resulting weight savings is 30% to 35%. “You’re looking at 8 to 9 lbs. off
AN FMA PUBLICATION • STAMPING JOURNAL
awards: The Award for Steel Excellence in 2014 by the American Metal Market, the PACE Award by Automotive by Automotive News in
Editor Kate Bachman can be reached at
[email protected]..
[email protected] Images courtesy of Material Sciences Corp.,
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Do servomechanical pr presses esses replace hy hydraulic draulic presses? Consider advantages, disadvantages carefully By Mike Josefiak hose operating old hydraulic presses and deciding to upgrade to new equipment face a choice: Is it more advantageous to move to an improved version of the hydraulic press that has always worked, or convert to a servomechanical (servo) press instead? This is a more complicated decision than it seems at first. Much like choosing between a hydraulic press and a traditional mechanical press, there are a series of trade-offs. Critical attributes to consider when reviewing any press application are control, flexibility, speed, cost, and longevity.
T
Control
Choosing between a hydraulic press and a servomechanical press involves a series of trade-offs. Critical attributes to consider when reviewing any press application are control, flexibility, speed, cost, and longevity.
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Process control has become more critical as designers and manufacture manufacturers rs push the limits of new and existing materials. Servo mechanical presses provide a wealth of information on power power,, speed, force, and position. The servomotors driving the machine provide much of this feedback, using the same data that adjusts speed and power continuously. These adjustments and sensors are what enable servo presses to match preprogrammed process curves well. Servo mechanical presses perform particularly well in applications with high reverse tonnage and materials with significant springback tendencies. Advanced hydraulic presses use a network of sensors to achieve a similar goal. The force being applied is monitored in the pressurized fluid of each
STAMPING JOURNAL • AN FMA PUBLICATION
Hydraulic press designs are easily modified to fit an application, with designs ranging from 1 to 150 tons per sq. ft. Stamping large sheets of thin material on a hydraulic press may require only 5 tons per sq. ft. These four 400-ton hydraulic presses in a transfer line (at left) are sized for 8 tons per sq. ft., while the 1,000-ton hydraulic press at the right is sized for 110 tons per sq. ft.
Hydraulic presses have long been the default choice for deep forming applications because of their ability to apply full force at any point in the stroke. This enables them to produce parts that would require a servomechanical press at triple the capacity. Many servo mechanical presses lose 50% of their available tonnage just 1 inch above bot-
Speed all the products being manufactured manufactured.. Design flexibility of the press can also A hydraulic press can achieve speeds speeds of play a role in choosing the right tech- more than 1 meter per second during nology. Servo mechanical presses typi- a stroke. However, it requires idle time cally are ordered with a high force per each cycle for the shifting of hydraulic square foot of working area, generally valves, which generally limits the press speed to less than 30 strokes per minute (SPM). Ultimately, the right A servo mechan mechanical ical press’s slide speeds typically are below 0.5 m/s. However, they can improve mechanical press cycle choice of technology for times by increasing speeds outside the a press application will working portion of the stroke. Within a stroke, the servomotors can achieve very vary and should be high acceleration and can restrike a part within a tenth of a second. carefully considered with The ability of both press systems to each new project. adjust speed accurately throughout the stroke—especially slowing at material 25 to 50 tons per sq. ft. Hydraulic press penetration—results in longer die life designs are easily modified to fit an and superior stamped products. This application, with designs ranging from may be even more beneficial than reach1 to 150 tons per sq. ft. Stamping large ing top speeds. sheets of thin material on a hydraulic In large stampings, multiple complex
tom dead center. The size selection process for a servo press generally mirrors that of a mechanical press, with special attention paid to the forming depth of
press may require only 5 tons per sq. ft. Having a press that can match the tonnage requirements can improve production rates and reduce costs dramatically.
cylinder. Position and speed are measured directly with linear transducers that are accurate within 10 microns. This information is used to manipulate hydraulic valves that control the speed and force independently. The reliance on a fluid, instead of a mechanical connection, can lead to dampened corrections in force or speed with similarly dampened final accuracy. However, at steady forming rates, the difference in accuracy between hydraulic and servo may be only a fractional percent. percent.
Flexibility
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geometries can be forming at varying points throughout the stroke. Adjusting the slide speed accurately can help control strain rates in the material. The
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fixed speed of a less advanced hydraulic press or the one-size-fits-all sinusoidal motion of a traditional mechanical press can require complex tooling and generate high scrap rates in these large components. However, advanced hydraulic controls and servomotors can provide a
er are more moderate too. The total cost of ownership will tend to favor a hydraulic press in many applications, while the lower operating costs of a servo mechanical press may result in cost savings.
wider range of speed and force, opening up opportunities for increases in productivity and design freedom.
Servo mechanical press prices have been decreasing as the number of machines being produced has been rising. Generally,, though, servo presses still have a highly er initial price compared to hydraulic presses, and this cost differential increases at higher capacities. The servomotor and drive systems are the main reason for these high costs.
While many tradition traditional al hydraulic and mechanical presses are in operation today with more years of service than any employee, the same cannot be said of servo presses. The long-term cost of ownership of a servo mechanical press in various applications is still being evaluated. Regular maintenance items in a servo press are lower as a result of lower impact forces and fewer components. But the components can be specialized and expensive. A hydraulic press has more points of failure to contend with, yet repairs are generally quick and the
Hydraulic pumps cylinders have a morepress modest cost, and and the price increases that occur as systems grow g row larg-
parts readily Proper careavailable. of the equipment with correct work sizing and regular preventive
Cost
Longevity
maintenance will significantly improve outcomes, regardless of press type.
Careful Consideration Hydraulic presses can adapt to produce almost any product cost-effectively and often are the only option for systems with a high force demand early in the stroke. Servo presses represent an evolution in mechanical press technology, opening new opportunities for manufacturers with difficult processes or materials. While they increase the flexibility of the underlying mechanical press design, they still carry many of the same limitations. Ultimately, the right choice of technology for a press application will vary and should be carefully considered with each new project. S Mike Josefiak is a design engineer for Greenerdd Press & Machine Co., 41 Crown Greener St., Nashua, NH 03061, 603-889-4101, www.greenerd.com.. www.greenerd.com
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Press feeding trends simpler-to-operate features, more versatility versatility, , andequipment tougher builds to include help stampers confront forming challenges such as the need to train workers faster, manage tougher materials, and do more with less. Photo courtesy of CWP, CWP, Clinton, Maine.
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Press feed technology trends for simpler operation, servo syncing Halting problems that start at the feeder head-on
t least eight press feed challenges that plague stamping manufacturers are now being addressed with the most updated press feed equipment and systems. Challenges stamping manufacturers face related to a dearth of skilled workers are not isolated to press operations; they begin at the press feed. Advanced high-strength materials are as difficult to manage in press feeding as they are to form in the press. Servo press technology brings form-
always present, but speed cannot come at the expense of quality. Customer demands for zero defects equate to tighter quality control. Stampers need nimble flexibility in their feed equipment to adapt to a rapidly changing production environment. Can multiton machinery ever be too safe? Is there such a predicament as having too much space? Thought not. Today’s press feed equipment has been developed to help stampers address these challenges. Experts from feed systems OEMs Coe Press Equipment; Cooper-Weymouth, Peterson; and Dallas
1. Workforce Shortage: Simpler Operation
ing flexibility to address high-strength materials problems but can complicate feed operations. Pressures for higher productivity are
Industries explain how they have introduced new feed equipment capabilities to help stampers meet those challenges head-on.
navigate.” Coe Press Equipment’s next-generation PLCs have multiple advanced features designed to significantly reduce
By Kate Bachman
A
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“As a generation of experienced workers ease into retirement, a new generation of workers step into their roles,” said Coe Press Equipment President Reid Coe. This challenge can have a positive side, Coe maintains. “This is a prime opportunity for manufacturers to break the old-tech cycle. Bringing a new workforce into a modern, high-tech environment can create a new norm of safer, more efficient processes. “We have packaged our standard controls to be rich in features but simple to
STAMPING JOURNAL • AN FMA PUBLICATION
the time required to use the feeder. A new, user-friendly HMI guides operators through the setup process logically. Intuitive, pictorial main menus guide them as they navigate machine-specific control screens by selecting an image of the machine they want to operate.
the press speed and feed window. This requires an Ethernet connection with the press, Coe relayed. Another aspect of the skilled worker shortage are difficulties in getting repeatable results from a feed line setup because operators are often less experi-
can be stored in a job recipe, Heuring explained. “The calculator has proven to be very accurate and has been welcomed by our customers.”
Key to the new controls is a 10-inch touchscreen that makes it easy to enter machine setup information.
enced than in years past, said John Heuring, regional sales manager for Dallas Industries. In response, the company has added more automated setup axes to the feed line so that more adjustments are controlled via the job recipe, Heuring said. “Dallas uses a system called AutoSet to allow the line to automatically position any or all of the following points: feeder passline height, pilot roll lift height, and edge guides; straightener rolls and edge guides; and uncoiler brake b rake control and coil centering via coil guide rolls,”
Stampers need feeding and straightening equipment that can successfully process advanced high-strength steel (AHSS) and high-strength aluminum used in many automotive applications, Heuring said. “Many feed builders have recently updated their straightener designs to address the higher yield points of AHSS. Thankfully, Dallas’ straighteners were already built with many of these features for decades,” he continued. These features include high-torque screw jacks for adjusting straightener rolls, wide-
Heuring said. we have added a straight“In addition, ener roll calculator to the AutoSet package,” he said. The operator inputs the material width, thickness, type, and yield and the straightener roll calculator suggests accurate roll settings for removing coil set that then
faced gears, large supports. roller journals, and outboard journal “In recent years we updated our straightener backup design to a ‘Hi-Flight’ style with wider backup rolls (single or double row) to further enhance the straightener’s ability to run AHSS,” Heuring said. Coe Press Equipment redesigned
Coe Press Equipment’s new PLCs have user-friendly screens with pictorial cues, simulation, and automated functions to reduce setup and operation time. Image courtesy of Coe Press Equipment, Sterling Heights, Mich.
“Our process-oriented and pictorial menus have been met with enthusiasm from both operators and plant leadership. These improvements make processes easier and more efficient,” Coe said. Also, the company’s work roll adviser and feed roll adviser software now are embedded into the controls, contributing to simplified s implified setup and changeover. New simulation features include loop simulation, which shows how the straightener reacts to changes from the feed; press simulation that shows strokes per minute (SPM) changes, feed angles, pilot, start feed, and the stroke at bottom dead center; and work roll simulation, a visual guide to help operators see what’s happening inside the straightener. The control also has on-the-fly capabilities, and it automatically changes feed speed to adapt to press speed changes. In addition, it can automate straightener setup and feed setup. A smart speed function automatically automatically adjusts to optimal line speed based on
AN FMA PUBLICATION • STAMPING JOURNAL
2. Taming AHSS, HSLA: Tougher Equipment
CWP has introduced a servo piloting head and roll lift for its combination feeder/straighteners. Photo courtesy of CWP.
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its heavy-duty (HD) servo roll feeds in 2019 to increase speeds and precision and decrease cost of operation while being more robust and capable of handling thicker materials, the company said. The modular design is engineered to ease maintenance and the flexibility
complete Allen-Bradley controls platform that employs A-B HMIs, PLCs, and drives. This means the motion is controlled over Ethernet.” The company uses this architecture and its software to control the feed motion, loop height, axes automation, and brake control to
CEO Willie Chacko and John Heuring. “We have added an optional access control card reader to our feed lines,” Chacko said. With a swipe of a magnetic strip card, a person can gain any of four levels of access to the machine. The system maintains a log of access so there
to reconfigure machine options. Design changes included a 15% increase in journal and bearings sizes, enabling the feeds to handle material thicknesses up to 0.750 in. In addition, the company introduced its HD servo piloting feeds last year. They are programmable so that stampers can optimize the feed window and the pilot-release window for each die. These systems can process a variety of heavygauge materials, including advanced steels. Designed for high-speed environments, the larger journal and bearing
effectively tune the line so that it runs smoothly.
is a history of who made what changes and when. “With all the automation that is available today, it’s critical to secure the data that is available for each job,” Chacko said. Heuring explained how the badge access system works. Level 0 allows an operator to run a preprogrammed job and auto setup axes to job values. Level 1 permits the operator to adjust edge guides and recipe-controlled axes. Level 2 allows the technician to program all the job parameters, press strokes per minute, feed window, feed
sizes can deliver high torque, states. speed, and accuracy, the manufacturer The feeds have a response time of 5 milliseconds, the company says.
its heavy-duty (HD) servo roll feeds to be more robust and capable of handling thicker materials. Photo courtesy of Coe Press Equipment, Sterling Heights, Mich.
3. Servo Press Variable Timing: Better Synchroniza Synchronization tion Cooper-Weymouth, Peterson (CWP) is Cooper-Weymouth, addressing challenges related to servo press technology synchronization with new feed technology that is based on time instead of degrees. “Unlike a mechanical press that must complete a revolution before stamping the next part, a servo press can engage the material as soon as it is in position. By communicating the actual feed/move time to the servo press, a very efficient utilization of cycle/part production can be accomplished automatically within the servo press control,” said CWP National Sales Manager Kevin Enos. CWP has developed an alternative method of syncing an automatic feeder with a press, called servo sensor, that stops feeding automatically when it sees a registration mark. Dallas’ Heuring said that stampers are striving to maximize a servo press’s versatility via the feed line. “Making sure to have a flexible (Ethernet-based) controls architecture is a good start,” he said. Dallas often uses a 26
JANUARY/FEBRUARY 2020
WWW.STAMPINGJOURNAL.COM
Coe Press Equipment redesigned
4. Need for Speed: Servo Piloting Head On its combination ServoMax servo feeder/straighteners, CWP has introduced a servo piloting head and roll lift. This allows stampers to increase the straightener head roll lift speed for pilot pin registration. In turn, system production output can be doubled or even tripled, based on the application. While a feeder/straightener with a pneumatic straightener head lift for piloting might attain no more than 60 SPM because of the limitations of the pneumatic piloting operation, a servo piloting head system can reach up to 180 SPM. A side benefi benefitt of this techn technology ology is that it reduces plant compressed air usage because it doesn’t use compressed air in the roll lift and piloting operation.
progression, passline roll height, material width, straightening adjustment, and width of the coil guides and motorized keepers. At the highest level, level 3, the manager or operator can modify machine setup parameters and add or remove user access. “This replaces password-protected elements of the feed line control as these passwords are often shared and lose their effectiveness quickly,” quickly,” Heuring said.
6. Flexibility Demand: Traversing Feed
5. High Quality Standards: Better User Control, Traceability
Stamping manufacturers need flexibility to excel in a rapidly changing manufacturing environment, CWP’s Enos said. The OEM has implemented a traversing feed to accommodate the feeding of blanks into a press that is normally coil-fed. The traversing feeder can roll in and out of the way to allow for a destacker to be rolled into the press entry. It uses the same tracks and locking mechanisms so that stampers can switch from running coils to running blanks in a matter of minutes. This capability provides the versatility to run small production part quantities
Dallas introduced its new card reader that is designed to control levels of security access for its Allen-Bradley automated feed line, according to Dallas Industries
with a destacker and also large batches using a coil feed on one stamping press. Blank feeding can also eliminate the cutoff tooling in the first operation, which
STAMPING JOURNAL • AN FMA PUBLICATION
can allow parts to be manufactured on a press that might be too small—tonnage-wise or bed size-wise.
7. Need for Safety: Enhanced Safety Featur Features es The addition of technologies like safe torque off and safe limited speed enhances operator and machinery protection, Enos said. Safe torque off is used to prevent unexpected motor rotation while the drive remains connected to the power supply in the event of an emergency. Safe limited speed ensures the transition from the operating speed in automatic mode to the reduced speed in setup mode. If the monitoring function detects that the limit value has been violated, the drive will be shut down safely.
8. Space Constraints: Space Savers Dallas Industries offers the UnderLoop SpaceSaver™ feed line. It comprises
AN FMA PUBLICATION • STAMPING JOURNAL
Coe’s HD servo-piloting feeds have a 5-millisecond response time. Image courtesy of Coe Press Equipment.
a reconfigured threading system with a servo-driven synthetic tension roll,
the need for slide-on coil keepers. The servo feed with pull-through
lower threading table,Also andincluded rocker-arm debending assembly. are powered coil guide rolls that eliminate
straightener has and pilotstraightener release for rolls, both the upper feed making the line suitable for progressive
WWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2020
27
die applications. The system can have a footprint as short as 18 ft. because of the slack loop being developed under the coil reel. It is available with or without a load car.
Resistance to Making
“Unfortunately, the durability of antique machinery makes manual and inefficient processes the norm in many plants,” he said. “Coe works in partnership with our customers to evaluate the ROI of new methods and break these habits.” S
Editor Kate Bachman can be reached at
[email protected]. Coe Press Equipment, www.cpec.com Cooper-Weymouth, Peterson, Cooper-Weymouth, www.cwpcoil.com Dallas Industries, www.dallasindustries.com www.dallasindustries.com
the to Upgrade Coe Move expressed concern
for what he called a resistance to new technology and process improvements. “Many companies default to ordering a new machine just like the last one or disregard new machine features because ‘What we have works fine.’ “Old technology tends to linger in the stamping world,” Coe continued. Presses and feed equipment are built to be mechanically robust to survive the demands of a stamping operation, but the result is that equipment often stays
Dallas Industries’ UnderLoop SpaceSaver feed line can have a footprint as short as 18 ft. (At left.) AutoSet allows automated setup so that more
in operation for of even 30 years! “Thisof is nearly unheard in other segments industry.
adjustments are controlled viaDallas the job recipe. Photo courtesy of Industries, Troy, Mich.
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STAMPING JOURNAL
AN FMA PUBLICATION
Stamping in an
EV WORLD C
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C
Explore how the transition from ICE to electric vehicles affects stamping manufacturing at this conference.
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Where: The Inn at St. John’s Plymouth, Mich.
Co-located with ALAW 2020!
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PRODUCT NEWS
Press eliminates need for matched male/female die sets The Quintus Flexform™ fluid cell press uses hydrof orming technology, employing extremely high hydraulic pressure against a flexible rubber diaphragm to shape sheet material against a single tool half. The process enables the forming of a variety of geometric shapes out of sheet metal alloys from soft aluminum to high-strength steels. It is suitable for prototyping and low-volume parts production. The diaphragm acts as a universal die, eliminating the need for matched male/female die sets. Tooling can be made quickly from a variety of materials including steel, aluminum, 3D-printed materials, and laminated hardwood. Quintus Technologies LLC • quintustechnologies.com
PLC’s simulation, automated PLC’s functions help reduce press feed line setup time
See the PSA is action on our
website at www.guildint.com www.guildint.com// psa-2000-portable-shearwelder
World Leader in Coil Joining Equipment for the Steel Processing, Tube Producing Producing and Stamping Industries Since 1958
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Coe Press Equipment has introduced its next-generation PLC with multiple features that help reduce the time required to commission new press feeding lines. New loop and press simulation capabilities enable the company to test, debug, and perform a complete startup before shipping, helping to decrease setup time at the customer. The HMI guides operators logically through the setup process, and the company’s Work Roll Advisor and Feed Roll Advisor software is embedded into the controls. Other new features include Ethernet diagnostics and pictorial main menus. Coe Press Equipment • www.coepress.com
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JANUARY/FEBRUARY 2020
WWW.STAMPINGJOURNAL.COM
STAMPING JOURNAL • AN FMA PUBLICATION
PRODUCT NEWS
Magnetic gripper lifts thin sheets one by one assembling steel parts; and handling of punched steel parts, blanks, and perforated steel sheets in robotic applications. The lightweight gripper is fitted with
able for lifting and transporting thin steel sheets one by one. The rubber pad at the end ensures that the workpiece does not slide during vertical pickup and prevents the workpiece from being
permanent neodymium magnets that can be switched on and off by means of compressed air. The system is suit-
damaged. Goudsmit Magnetics • www.goudsmitmagnets.com
The recently improved magnetic gripper from Goudsmit Magnetics is used for the automated pickup, placement, or positioning of steel and other ferromagnetic objects. Applications include removing sheet metal from presses; destacking products from boxes;
Monitoring system detects hazards before parts can be damaged Schuler has developed Visual Die Protection, a camera-assisted monitoring system that detects the presence of foreign bodies such as wrenches or punch scraps; checks if the die is properly connected; and verifies that the blanks have been correctly inserted, formed, and removed. It also recognizes cracks in the part and potential damage to the centering and ejector pins. If any abnormalities are found, the press is stopped to prevent the situation from getting worse. The cameras first create reference images of the relevant die before production begins. During this imaging process, operators mark critical areas that require particularly accurate monitoring, such as the centering and ejector pins. While the production process is running, artificial intelligence on a separate computer performs a real-time comparison of current images with the original condition of the die, thereby allowing an immediate response if any discrepancies are found. Schuler Inc. • www.schulergroup.com
Take Your Best Shot! Win a Free VIBRO Air Transporter* by Entering Our Photo Contest At VIBRO, we believe in quality and reliability, which we’ve put into every 100% air-operated transporter we’ve made over the past 36 years. And our customers know k now it too...that’s why we want to show our appreciation for your loyal support by offering the chance to win a new VIBRO Transporter in our 2020 photo contest and have your photo featured in an upcoming campaign! Are you running a unique application?? Has your transporter application operated relentlessly for relentlessly for years? Or is there another way to proudly showcase your VIBRO Transporter on-the-job on-the-job??
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AN FMA PUBLICATION • STAMPING JOURNAL
WWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2020 WWW.STAMPINGJOURNAL.COM
Suspension Points
Gearing Arrangement
Clutch/Brake
r
Model
Capacity Range (tons)
c i t a m u e n P
c i l u a r o d v y r e H S
a e g n o r r a n - a e l e G e G e e e l h l b w g u k n o i y i n l F S D L
e r l e g h n t i O S
e l p i t l u M
Stroke Length (min. max., inches)
3-10
, n w o D d e r ) a s d e i l d h S n c a n d t i e s . , B / x r ( e w m a v p O U t t . n h n i g e i m e m , H t e s t u k u j o h d r S A t s
Guiding
Structure
d o R e i T t u o i h t h t W i t e W i n d e o i d s i J t s - e l h t h k g g i i c a u r a r n t t S S K
d o R e i T
M P S m u m i x a M
t n i o P 4
t n i o P 6
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
AIDAAMERICA | Dayton, OH NS1 Series
80-200
3
3
NS2 Series
110-300
3
3
MC X
315-1,250
3
NC1 Series
35-250
NC2 Series
110-250 3
3
3
3
4. 4.3-11
9.8-17.7
130
13.721.6
100-35
3
3
3
3
3
3
3 3
3
3-12
3
9.8-17.7
130
3
3
3
3
3
4. 4.3-11
13.721.6
100
3
3
24-40
90
PMX Series
300-1,000
3
SMX Series
300-2,000
3
3
3
3
To spec.
24-40
30
3
3
TMX Series
300-4,000
3
3
3
3
To spec.
24- 40
30
3
3
3
HMX Series
80-400 3
NSU Series
200-400 3
NST Series
300-1,200 3
3
3
3
3
3
6-16 6-
3
.8-3
800
8-12
100- 65
3
3
3
3
10-24
To spec.
60-40
3
3
2-12
9-21.6
100
3
3
3
2-12
9-18
125
3
3
AMADA AMERICA INC. | Buena Park, CA TP-EX Series
49.5-275
3
3
TPL Series
49.5-330
3
3
TPW Series
121-330
3
3
TPWL Series
110- 550
3
3
SDE Series
49.5-330
3
3
SDEW Series
220-330
3
3
3
3 3
3
3
3-12 3-
10-20
125
3
3
3
3-12 3-
10- 20
125
3
3
3
0-12
11.421.6
225
3
3
3
3-10 3-
10-17, 12-19
60, 80
3
3
3
BLISS PRESS | Hastings, MI C1-60
66
3
3
3
5.1
11. 8
85
3
3
C1-60 HS
66
3
3
3
1.9
13. 3
160
3
3
3
3
3
3
3
C1-80 C1-80 HS
88 88
5. 9 2. 3
13 14. 7
75 140
3
3
3
3
3
The information presented was provided by the manufacturers. ©Copyright 2020 by FMA Communications Inc. Reproduction in full or in part without written permission of the publisher is prohibited. Buyers’ guides are a part of the Forming & Fabricating Industry Industry Directory. Go to www.thefabricator.com/directory www.thefabricator.com/directoryto to add your free company listing.
31
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JANUARY/FEBRUARY 2020
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STAMPING JOURNAL • AN FMA PUBLICATION
• • • • • • • •
System 5100 Clutch/Brake Press Control Color 10.4” LCD Touch Screen Display Up to 80 Die Protection Inputs Up to 96 PLS Outputs Tonnage and Analog Signal Monitor Automatic Shut Height & Counter Balance Control Servo Feed Interface LinkNet Pressroom Monitoring
• • • • • • •
System 5100 Clutch/Brake Press Control Color 5.7” LCD Touch Screen Display 4 Die Protection Inputs Up to 8 PLS Outputs Peak Forward/Reverse Tonnage Tonnage Monitor Servo Feed Interface LinkNet Pressroom Monitoring
• • • • • • • •
Integrates with Existing Press Control Color 10.4” LCD Touch Screen Display Up to 80 Die Protection Inputs Up to 96 PLS Outputs Tonnage and Analog Signal Monitor Automatic Shut Height & Counter Balance Control Servo Feed Interface LinkNet Pressroom Monitoring
444 McNally Mc Nally Drive, D rive, Nashville TN 37211 37211 Tel: 615.833.4168 • 615.833.4168 • Fax: Fax: 615.834.1984 www.LinkElectric.com
Suspension Points
Gearing Arrangement
Clutch/Brake
r
c i t a m u e n P
c i l u a r o d v y r e H S
a e g n o r r a n - a e l e G e G e e e l h l k w g b y i n u n o i l F S D L
e l p i t l u M
Stroke Length (min. max., inches)
, n w o D d e r ) a s d e i l d h S n c a n d t i e s . , B / x r ( e w v p a m O U t t . n h n i g e i m e m , H t e s t u k u j o h d r S A t s
Guiding
Structure
d o R e i T t u o i h t h t W i t e W i n d e o i d J s i - s t - e l h t h k g g c i i a u a r r n t t S S K
d o R e i T
M P S m u m i x a M
t n i o P 4
t n i o P 6
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
Model
Capacity Range (tons)
C1-110
121
3
3
3
7.1
13.7
60
3
3
C1-125
137
3
3
3
2.75
14.5
60
3
3
C1-160
176
3
3
3
7.8
15.7
55
3
3
C1-200
220
3
3
3
7.8
17.7
50
3
3
C1-250
275
3
3
3
9.8
17.7
45
3
3
C2-80
88
3
3
3
6.3 6.
14.9
75
3
3
3
3
3
3
3
C2-110 C2-250
121 275
3
3
3
7 9.8 9.
15.7 21.6
65 40
3
3
SC2-250
275
3
3
3
9.8 9.
21.6
40
3
3
SC2-400
440
3
3
3
9.8 9.
21.6
35
3
3
SC2-630
693
3
3
3
11.8
23.6
25
3
3
e r l e g h n t i O S
BRUDERER BRUDE RER MACHINERY MACH INERY INC. IN C. | Ridgefield Ridgefield,, NJ BSTA 100
10
3
3
.28-1.5
5-6.5
500 3
3
BSTA 180
18
3
3
.31 31-1 -1.6 .6
7.57. 5-9. 9.77
1,40 1, 4000 3
3
BSTA 200
20
3
3
.31.3 1-1. 1.55
7.13 7. 13-9 -9.3 .3
2,00 2, 0000 3
3
BSTA 280
28
3
3
.51 51-1 -1..9
6.7 .7--9. 9.44
2,00 2, 0000 3
3
BSTA 410
45
3
3
.31.3 1-1. 1.99
8.18. 1-11 11.7 .7
1,60 1, 6000 3
3
BSTA 510
60
3
3
.633-2 .6
8.18. 1-11 11.6 .6
1,1 ,120 20 3
3
60/75 3
3
.8-3
7.3-11.5
700 3
3
9.59. 5-13 13.4 .4
1,00 1, 0000 3
3
BSTA 60 BSTA 810
90
3
3
.62.6 2-2. 2.55
BSTA 1250
125
3
3
.62-2.9 10.615.21
850 3
3
BSTA 1600
160
3
3
.75-2.9 10.615.16
825 3
3
BSTA 2500
250
3
3
.63 - 2.4 16.1419.8
710 3
3
EAGLE PRESS P RESS & EQUIPM E QUIPMENT ENT CO. LTD. | Oldcastle, Oldcastle, ON Canada Canada SC2
100-1,000 3
3
3
SE2
400-2,000 3
3
SE4
600-3,500 3
3
3
3
3
3
2-20
To spec.
80
3
3
3
3
3
3
8-30
To spec.
60
3
3
3
3
3
3
8-32
To spec.
60
3
3
3
34
JANUARY/FEBRUARY 2020
WWW.STAMPINGJOURNAL.COM
STAMPING JOURNAL • AN FMA PUBLICATION
Suspension Points
Gearing Arrangement
Clutch/Brake
r
Model
Capacity Range (tons)
c i t a m u e n P
c i l u a r o d v y r e H S
a e g n o r r a n - a e l e G e G e e e l h l k w g b y i n u n o i l F S D L
e r l e g h n t i O S
e l p i t l u M
Stroke Length (min. max., inches)
, n w o D d e r ) d a s e i l d h S n c n d a i e t s . , B / x r e w v ( p a m O U t t . n h n i g e i m e m , H t e s t u k u j o h d r S A t s
Guiding
Structure
d o R e i T t u o i h t h t i W t e W i n d e o i d J s i - s t - e l h t h k g g c i i a u a r r n t t S S K
d o R e i T
M P S m u m i x a M
t n i o P 4
t n i o P 6
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
FAGOR ARRASATE USA INC. | Willowbrook, IL Servo Presses High Speed Press Line
250-2,500
1,00010,000
3
10-40
25-50
1 00
3
3
3
3
30-55
40-65
30
3
3
3
3
3
3
3
3
3
3
3
Transfer
250-4,000
3
3
3
3
3
3
20-45
30-65
50
3
3
Linked Transfer Presses
800-6,000
3
3
3
3
3
3
20-45
30-65
40
3
3
Blanking
250-1,500
3
3
3
3
3
3
7- 18
35-60
100
3
3
Double Action
650-3,200
3
3
3
20- 45
35-60
25
3
3
General Purpose
250-4,000
3
3
3
3
3
3
3
20- 50
20- 60
80
3
3
Progressive Die
250-2,500
3
3
3
3
3
3
3
10- 30
20- 50
100
3
3
Tryout
600-3,000
3
3
3
3
3
3
30- 55
40- 65
30
3
3
Forging
400-2,000
3
3
3
3
3
3
3
16-24
30- 50
60
3
3
Monoblock
200-1,000
3
3
3
3
3
3
3
10-30
20- 50
160
3
3
3
1- 14
6.75-32
1 80
3
3
3
3
1- 12 2- 10
1.75-26 12-20
1 20 1 15
3
3
3
3
3
3
3
3
3
3
3
3
3 3
HEIM GROUP, THE | Chicago, IL Single Point Gap Frame
15- 300
3
3
3
Two Point Gap Frame Single Po Point St Straight SiSide
40- 300 90- 300
3
3
3
3
Two Point Straight Side
40- 400
3
3
3
3
1- 12
5-28.25
1 15
3
3
S2 Series Maxi-Stamper Straight Side
200-1,000
3
3
3
3
6- 12
20-42
80
3
3
H2 Series Maxi-Stamper Straight Side
100-300
3
3
3
3
1-4
13.5-23
2 00
3
3
S1 Series Maxi-Stamper II
90- 300
3
3
2- 10
12-20
1 50
3
3
2-11.8
7.7-18.9
2 40
2-23.6
20. 549.2
106
0-9.8
8.2-17.7
2 30
3
3
3 3
3 3
3
3
3
3
KOMATSU AMERICA PRESS TECHNOLOGY DIV. | Rolling Meadows, IL OBS Ser Seriies Gen Geneeral Pu Purp rpoose
29- 220
H2FM Series Straight-side Servo Presses
400-1,600
H1F Series Gap Frame Servo Press
29-220
3
3
3
3
3
3 3
3
3
3
3 3
3
3
3
3
3
AN FMA PUBLICATION • STAMPING JOURNAL
WWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2020
Suspension Points
Gearing Arrangement
Clutch/Brake
r
c i t a m u e n P
a e g n o r r a n - a e l e G e G e e e l h l k w g b y i n u n o i l F S D L
c i l u a r o d v y r e H S
Model
Capacity Range (tons)
H2W Series Solid Fram Framee Servo
220-330 220-3 30
E2W Seri Series es Gen Genera erall Pur Purpos posee
121-33 121 -3300
3
G Ser Series ies Ge Gener neral al Pu Purpo rpose se
22022 0-4, 4,50 5000
3
3
3
M Ser Serie iess Pr Prog ogre ress ssiv ivee Di Diee
22022 0-3, 3,00 0000
3
3
3
S Series Auto Class Transfer B Se Seri ries es He Heav avyy Bl Blan anki king ng C Series Forging
3
Structure
d o R e i T t u o i h t h t W i t e W i n d e o i d J s i s t - e l h t k g h g c i i a a u r r t t n S S K
d o R e i T
M P S m u m i x a M
t n i o P 4
t n i o P 6
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
3
5.9 5.9-1 -13. 3.88
19.7-19.7 23.6
85
3
3
3
3
4.3 4.3-1 -11. 1.88
14.7-14.7 21.6
100
3
3
3
3
3.9 3.9-3 -32. 2.66
20.1-20.1 37.4
150
3
3
3
3
3.9 3.9-1 -11. 1.88
18.7 18 .7--
150
3
3
18 18.9 .9-4 -43. 3.55
27.5 25.6 25 .6-65.5
30
3
3
3
3
22022 0-55 5500
3
3
3
3
3
3
3
3
3
e l p i t l u M
e r l e g h n t i O S
Guiding
3
1,0005,000
176-2,200
Stroke Length (min. max., inches)
, n w o D d e r ) a s d e i l d h S n c n d a i e t s . , B / x r e w v ( p a m O U t t . n h n i g e i m e m , t e H s t u k o j u h d r S A t s
3
3
3
3
3
3.93. 9-11 11.8 .8
17.8-17.8 25.6
100
3
3
3
3
3.5 3.5-1 -15. 5.88
13.4-13.4 55.1
75
3
3
3
3
1.181.18-15 15.7 .755 To sp spec ec..
3755 37
3
3
3
3
3
3
3
NIDEC PRESS & AUTOMATION | Minster, Minster, OH E2H/E2HF Series E2 Series
250-600
3
200-1,600
3
3
3
4-24 4-
19-50
150
9.84-19.69
24-44
70
3
2.952.95-7. 7.87 87
11.0011.0 023.62
250
.79.79-7. 7.88 88
8.98. 9-23 23..6
6000 60
11- 2 0
600
FX2
200-600
P2H-FX
100-160
P2H Series
71-180
P2 Series
60-200
PM4 Series
250- 600
3
3
3
1. 1.18 18-1 -1..57
To sp spec ec..
PM3 Series
125- 300
3
3
3
1.0-2.5
NTCH
3
3
3
3
3
3
3
3
3
3
10- 25
3
1 -8 1-
.472
3
3
3
3
3
3
5355 53
3
3
15- 1 7
800
3
3
7.0678.067
1,200
3
3
MMC Series S.S.
110-1,200
3
3
3
3
3
3
3
3
5.12-3 5.12-31.5 1.500
15.7515.7551.18
120
MMC Series Gap
25-400
3
3
3
3
3
3
3
3
1.97-16.00 9.8421.65
200
Minster Kyori ANEX
15-125
3
3
.39-1.97 8.6613.78
1,800
3
3
3
3
3
3
3
3
3
35
36
JANUARY/FEBRUARY 2020
WWW.STAMPINGJOURNAL.COM
STAMPING JOURNAL • AN FMA PUBLICATION
Suspension Points
Gearing Arrangement
Clutch/Brake
r
Model
Capacity Range (tons)
Minster Kyori VX
40-80
HB Series
66-90
Arisa Presses
c i t a m u e n P
c i l u a o r d v y r e H S
a e g n o r r a n - a e l e G e G e e e l h l k w g b y i n u n o i l F S D L
3
e r l e g h n t i O S
3
3
3
, n w o D d e r ) a s d e i l d h S n c n d a i e t s . , B / x r e w v ( p a m O U t t . n h n i g e i m e m , H t e k t s u u j o h d r S A t s
Guiding
d o R e i T t u o i h t h t W i t W e n d e i i o d s i J s t - e l h t k g h g c i a i u a r r n t t S S K
d o R e i T
M P S m u m i x a M
e l p i t l u M
Stroke Length (min. max., inches)
3
.63-1.97
9.4512.60
1,000
3
.59-2.5
13-19.0
1,000
11.8129.53
26.7575.67
80
400-4,500
Structure
t n i o P 4
t n i o P 6
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
3
3
3
3
3
3
3
OAK PRESS SOLUTIONS INC. | Sturg Sturgis, is, MI 3
3
LP Series SS Series
30- 300 30-60
3
3
P1 Series
30-45
3
3
CP Series
120-160
3
3
3 3 3 3
3
3
1.00-3.00 .50-2.00
4 00 1, 500
3
3
1.00-2.00
1, 000
3
1.00-3.00
400
3
3 3
PRESS AUTOMATION INC. | Elkhart, IN 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
SANGIACOMO PRESSES PRESS ES AMERICAS AMERIC AS LLC | Huntsville, Huntsville, AL C-Frame Fl Flywheel Pr Presses
10-75
C-Fr CFram amee Back Back Ge Gear ared ed Pr Pres esse sess
50-4 50 -450 50
Straight-side Presses Single Connecting Rod
50-250
Straight-side Presses Double Connecting Rod
125-500
3
3
3
3
3
3
.24-5.51 (Adjustable)
6.712.21
230
3
3
3
3
.47-9.84
11.42-
100
3
3
3
(Adjustable)
23.62
.47- 9.06 (Adjustable)
11.8121.65
200
3
3
3
.55-15.75 (Adjustable)
17.7227.56
90
3
3
3
3
SCHULER INC. | Canton, MI SPE S Series Prog. Die
1,1001,750
3
3
3
20-24
48-52
50
3
3
STL4 S Series Ser ies Transfer
1,3503,500
3
3
3
24-36
5- 60
30
3
3
3
3
16
39. 455.1
60
3
3
3
20
39. 455.1
50
3
3
PME2 and PME4 Progressive Die
880-3,600
3
PML2 PM L2 and PML ML44 Pr Prog og.. Di Diee
88088 0-3, 3,60 6000
3
3
3
AN FMA PUBLICATION • STAMPING JOURNAL
WWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2020
Model
Capacity Range (tons)
TME2 an and TM TML2 Tr Transfer
880-3,600
c i t a m u e n P
c i l u a r o d v y r e H S
MSD Servo Drive
280-900
TMK Transfer & Progressive Die
220-1,100
3
3
175-275
3
880-2,800
3
13713 7-55 5500
3
SML4 Car Body SALL Hi SA High gh-S -Spe peed ed La Lami mina nati tion on
3
3
To spec.
SAKK Hi SA Higghh-Sp Speeed Bl Blaanking
r a e g n o r r a n - a e l e G e G e e e l h l k w g b y i n u n o i l F S D L
3
TML4 Transfer
Suspension Points
Gearing Arrangement
Clutch/Brake
e r l e g h n t i O S
e l p i t l u M
Structure
d o R e i T t u o i h t h t W i t e W i n d e o i d s i J t s - e l h t h k g g i i c a u r a r n t t S S K
d o R e i T
M P S m u m i x a M
t n i o P 4
t n i o P 6
20-36
47.255.1
40
3
3
To spec.
To spec.
To spec.
3
3
2.4-16
24-39
130
3
3
3
3
1.5-10
15-30
140
3
3
1- 2
15-17
800
3
3
3
36-43.3
To spec
20
3
3
1.2-1.4
16-23
1, 000
3
300
3
3 3
3 3
3
13- 23
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
3
3
3
Guiding
3
3
3
Stroke Length (min. max., inches)
, n w o D d e r ) a s d e i l d h S n c a n d t i e s . , B / x r e w v ( p a m O U t t . n h n i g e i m e m , H t e s t u k u j o h d r S A t s
3
3
3
3
3 3 3
XS Impact Extrusion
165-1,350
MSK Se Serv rvoo Kn Knuuckle Joint
280-1,100
3
3
3
6-12
23- 3 1
160
3
3
TSD/TSC Servo Drive
900-3,375
3
3
3
6-30
39- 5 5
50
3
3
3
SEYIAMERIC SEYIA MERICAA INC. | Tullahoma, Tullahoma, TN SAG2/SAG4 & SLG2/SL SLG2/SLG4 G4 Straight Side
330-1,320
3
3
3
3
3
3
To spec.
To spec.
To spec.
3
3
SE2/SE4 & SEL2/SEL4 Eccentric Gear Straight Side
440-2,640
3
3
3
3
3
3
To spec.
To spec.
To spec.
3
3
SNS2 Straight Side
176-550
3
3
3
3.15 3. 15--11 11.8 .811
15.7515.7 523.62
115
3
3
SLS2 Link Motion Straight Side
176-550
3
3
3
5.1125. 2-11 11..81
15.7515.7 523.62
90
3
3
SNS1 Straight Side
88-330
3
3
3
2.36 2. 36-1 -11. 1.02 02
11.81111.8 19.69
150
3
3
SLS1 Link Motion Straight Side
88-330
3
3
3
3.94-9.84
1 1. 8117.72
110
3
3
SN2 Gap
121-330
3
3
2.75 2. 75--11 11.0 .022
13.7813.7 821.65
120
3
3
SN1 Gap
28-275
3
3
1.38-9.84
7.8717.72
180
3
3
SM2 High Speed Link Motion Straight Side
220-660
3
3
7.87-9.84
17.7229.52
120
3
3
3
3
3
3
3
3
3
3
37
38
JANUARY/FEBRUARY 2020
WWW.STAMPINGJOURNAL.COM
STAMPING JOURNAL • AN FMA PUBLICATION
Gearing Arrangement
Clutch/Brake
Model SM1 Heavy Stamping Link Motion Straight Side SDG2/SDG4 Straight Side Servo SDE2/SDE4 Eccentric Gear Straight Side Servo SD2 Double Point Servo SD1 Single Point Ser vo
c i t a m u e n P
Capacity Range (tons)
3
330-880
c i l u a r o d v y r e H S
r a e g n o r r a n - a e l e G e G e e e l h l k w g b y i n u n o i l F S D L
3
440-1,320
3
3
3
3
Suspension Points
e r l e g h n t i O S
e l p i t l u M
3
3
3
Stroke Length (min. max., inches)
, n w o D d e r ) a s d e i l d h S n c a n d t i e s . , B / x r ( e w v p a m O U t t . n h n i g e i m e m , H t e s t u k u j o h d r S A t s
Guiding
Structure
d o R e i T t u o i h t h i t W t e W i n d e o i d s i J - s t - e l h t h k g g c i i a u a r r n t t S S K
d o R e i T
M P S m u m i x a M
4.72 4. 72-1 -11. 1.81 81
15.75 15. 75-29.50
70
To spec.
To spec.
50 @ full
t n i o P 4
t n i o P 6
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
3
3
3
3
3
3
revolution
3
440 2,640
3
3
3
To spec.
To spec.
30 @ full revolution
176 - 550
3
88 - 330
0-13.78
3
3
3
3
3
3
3
17.7225.59
60 @ full
12.9921.65
80 @ full
1.57-11.81
9. 6521.26
180
3
3
4.33 4. 33-1 -11. 1.02 02
15.75 15. 75-21.65
100
3
3
3.94-7.87
11. 817.7
110
3
3
4.33-11.02
15. 821.7
90
3
3
0-11.81
revolution
revolution
STAMTEC INC. | Manchester, TN OCP Single Point Gap Frame Presses
25-260
3
3
3
3
G2 Series Two Point Gap Frame Presses
110-250
3
3
3
3
GL1 Link Motion Single Point Gap Frame Presses
80-200
3
3
3
3
3
GL2 Link Motion Two Two Point Gap Frame Presses
110-260
3
3
3
3
3
SC1 Single Point Straight Side Presses
160-287
3
3
3
3
3
3.15-7.87
13.7818.11
115
3
3
SC2 Two Point Straight Side Presses
121-275
3
3
3
3
3
3.15-7.87
13.7818.11
115
3
3
S1 Single Point Straight Side Presses
165-660
3
3
3
3
3
5.91-12.2
15.7530.12
120
GTX Two Point Straight Side Presses
160-440
3
3
3
3
3
5.12 5. 12-1 -11. 1.81 81
17.72 17. 72-21.65
85
S2 Two Point Straight Side Presses
165-660
3
3
3
3
3
3
5.91-12.2
15.7530.12
120
SLX Link Motion Two Point Straight Side Presses
160-300
3
3
3
3
3
3
3.94-5.91
17.72
1 00
HSD High-speed Straight Side Presses
60-300
1.18
13-17
5 50
4-Point Straight Side
To 3,000
3
3
3
3
3
To spec.
To spec.
To spec.
Transfer Presses
To 3,000
3
3
3
3
3
To spec.
To spec.
To spec.
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
AN FMA PUBLICATION • STAMPING JOURNAL
WWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2020
Model
Capacity Range (tons)
c i t a m u e n P
c i l u a o r d v y r e H S
Suspension Points
Gearing Arrangement
Clutch/Brake
r a e g n o r r a n - a e l e G e G e e e l h l k w g b y i n u n o i l F S D L
e r l e g h n t i O S
e l p i t l u M
Stroke Length (min. max., inches)
, n w o D d e r ) a s d e i l d h S n c n d a i e t s , B / . r ( w a x e v p m O U t t . n h n i g e i m e m , H t e k t s u u j o h d r S A t s
Guiding
Structure
d o R e i T
M P S m u m i x a M
t n i o P 4
t n i o P 6
t n i o P 8
e m a r F - e C l r b o a n - i p l a c n G I
u o h t h i i t W t W e n d e i i o d s i J s t - e l h t k g h g c i i a u a r r n t t S S K
KP, KT, KL, KW2 Series Forging Presses
250-2,000 3
3
3
3
3
To spec.
To spec.
To spec.
3
3
F2 Series Warm-Hot Forging Presses
700-3,000 3
3
3
3
3
To spec.
To spec.
To spec.
3
3
.79-1.57
8.267.87
1,200 3
3
.79-1.57
8.0710.04
1,000 3
3
SUPERIOR STAMPING TECHNOLOGIES | Ridgefield, NJ CIVIC 25
25
3
3
CIVIC 45
45
3
3
HD 220
220
3
3
3
1.18
15.75
500
3
3
HD 300
300
3
3
3
1.18
20.47
400
3
3
HD 350
350
3
3
3
1.18
20.47
400
3
3
SAGA 45
45
3
3
3
3
1.97-5.51
29.84
200 3
3
SAGA 60
60
3
3
3
3
2.36-6.29
11.02
160 3
3
SAGA 80
80
3
3
3
3
2.75-7.08
11.81
140 3
3
CIVIC 120
120
3
3
3
3.15-7.87
12.6
320 3
3
SAGA 160
160
3
3
3
3.94-8.66
13.78
100 3
3
SAGA 220
220
3
3
3
4.72-9.84
15.74
80 3
3
.40-1.97
9.4514.37
4.72-7.87
13.78
70 3
3
APEX 30-80
3
3 3
30-80 3
3
3
1,400
3
3
SAGA 120 II
120
3
3
SAGA 160 II
160
3
3
3
5.51-8.66
15.74
55 3
3
SAGA 220 II
220
3
3
3
6.29-9.84
17.72
50 3
3
YAMADA YAM ADA DO DOBB BBYY AME A MERI RICA CA | Harrisburg, Harri sburg, NC NC NX T
30-150 3
3
.5-4
8-16
1,300 3
3
MXM
30-220 3
3
.4-2.3
9.4-20
1,500 3
3
EPS
30-330 3
3
.4-2
9-24
3,000 3
3
ALPHA
30-220 3
3
.7-2
8.4-18
1,000 3
3
3
.2-.6
9-10
4,000 3
3
3
.2-.8
7-9.5
3,000 3
3
OMEGA ALT
10 7-30
3
3
d o R e i T t
39
40
JANUARY/FEBRUARY 2020
WWW.STAMPINGJOURNAL.COM
STAMPING JOURNAL • AN FMA PUBLICATION
CLASSIFIED ADVERTISING
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ADVERTISERS ADVER TISERS INDEX
Admiral Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Jier North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . .2
[email protected]
www.jier-na.com
Agathon Machine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Komatsu America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
203-730-8741
AIDA - America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 www.aida-america.com
www.komatsupress.com
. 33 Link Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 www.linkelectric.com
Beckwood Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 www.beckwoodpress.com
SEYI-America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bunting Magnetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
www.seyiamerica.com
www.buntingmagnetics.com
T J Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Colt Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 . .5
www.tjsnow.com
www.coltauto.com
. 29 Fabricators & Manufacturers Association, Intl. . . . . . . . . . . .29
Tower Metalworking Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 www.toweroil.com
www.fmanet.org
Greenerd Press & Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 www.greenerd.com
Guild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
[email protected]
Vibro Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
www.guildint.com
717-527-2094
. .7 Industrial Magnetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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STAMPING Journal® (ISSN 1091-2460) is published bimonthly by FMA Communications Inc., 2135 Point Blvd., Elgin, IL 60123. STAMP STAMPING ING Journal
is circulated free upon request to those who qualify and who are involved in metal stamping. Subscription to all others is $65.00 per year. Foreign subscription is $95.00 per year. Periodical postage paid at Elgin, IL and additional mailing offices. Postmaster: Send address changes to: STAMPING Journal, 2135 Point Blvd., Elgin, IL 60123. Copyright 2020 by Re production in whole or in part without written wr itten permission 2020 by FMA Communications Inc. Reproduction of the publisher is prohibited.
AN FMA PUBLICATION • STAMPING JOURNAL
WWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2020
ASK THE EXPERT
Helpful tips for tool and die apprentices BY THOMAS VACCA
ver the years I have had the opportunity to observe the work of many tool and die apprentices
tight-sleeved shirts, safety glasses, and no ties. In my opinion, the two most important rules are don’t wear gloves
blow off a grinder. •Always pull when using a wrench if possible.
during their training. From those observations, I’ve collected the following bits of advice. Some may seem obvious, but all newcomers and trainees in the tooling industry only know what they know, know, and that can cause many problems, including wasted time, damaged equipment and workpieces, and even injury to themselves and others.
Maintain Your Computer Skills. ComSkills. Computers are becoming more and more a part of all toolroom equipment. In our
while operating machinery and always wear your glasses (with side shields) in the shop. Don’t Use the Support Table on Your Disc Sander When Deburring Thin I have seen the plate get sucked Plates. I Plates. into the small opening between the disc and the support, which pulls the apprentice’s thumbs into the disc. Hold your plate above the support table. Apprentices should practice how they plan to execute an operation on a piece of equipment. Mount the stock in the machine and clamp and support it properly. Espe-
•When using an end mill for heavy roughing cuts, minimize the length of the mill that is exposed outside of the collet for maximum maximu m rigidity. •Use masking tape to help keep a straight line when using letter and number stamps. •Try •T ry using toilet paper p aper to apply Dykem ink. •Pay attention to safety, and especially watch out for your hands, eyes, and feet. •Run edge finders at 800 to 1,200 RPM for optimal performance. •Understand the difference between
toolroom, the lathes, mills, jig grinders, jig borers borers,, and grinder grinderss are CNC, and you likely have a similar setup. It only promises to become more technical with time.
cially on lathe work, you may see you will need additional stock supports. Be Be Careful With Compressed Air. Air. Be aware of the dangers that compressed air presents to you and those around you.
absolute and incremental measurement. •Use a drill press vise upside-down to hold round stock when using a band saw. saw. •When machining, aim to miss your dimensional goal to the safe side. You can always take off more material but it’s hard to put it back! •Use a magnet to see if material is stainless steel. •Know the countersink angle of your screw and match the tooling. Metric screws use 90 degrees, standard English screws use 82 degrees, and aircraft screws use 100 degrees. •Know that a micron is a millionth of a meter. •Stop milling if you are getting a lot of cutting smoke—it’s a sign you’re doing something wrong. •Don’t stone the chuck on your grinder or any accurate machine surfaces with a brown stone—you can very quickly affect the flatness of very precise surfaces. •Do ask questions! The more you know why and how things work, the better decisions you can make. Good luck, and happy stamping! S
O
Learn From Their Mistakes
Newcomers and trainees in the tooling industry only know what they know know,, and that can cause many problems. Learn to Use Your Indicator. I Indicator. I often Again, keep your glasses on. Do not use see trainees who don’t use an indicator full line pressure to clean off parts you because they don’t know a good way to are holding in your hand. Never use use air to fixture it to take a measurement. Actual- blow chips off a machine. And be aware ly, indicators can be used in an infinite of the people working around you—you number of ways to measure very accu- can easily blow debris across the room. rately. Try to keep the indicator plane in line with the indicator. This will yield the Quick Tips for the most reliable measurement method. And Inexperienced use a minimal amount of preload on the Following are a few more common mistip so that you can move on and off the takes I see. These practices are second work plane with little risk of shifting the nature to an experienced journeyman, zero setting. but not to an apprentice: •Never hammer gauge pins. Wear Safety Glasses, Not Gloves. Gloves and loose clothing around •Don’t use a diamond wheel to grind machinery are killers! They can easily steel—it gums up the wheel. snag on rotating spindles. New appren•Don’t use the granite surface as an tices learn dozens of safety rules, includ- anvil! ing wearing the proper shoes and pants, •Never ever use compressed air to
Stumped by a shop floor stamping or tool and die question? If so, send your questions to
[email protected] to be answered by Thomas Vacca, director of engineering with Micro Co., www.micro-co.com.
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JANUARY/FEBRUARY 2020
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STAMPING JOURNAL • AN FMA PUBLICATION
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