Making it makable before it's in the die - PMI LLC
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Forming stainless at Servo press quells In-die forming
microscopic level reverse tonnage designs
EXPERTISE TO HELP YOU TRANSFORM METAL INTO GOLD WWW.STAMPINGJOURNAL.COM MARCH/APRIL
MARCH/APRIL 2021
2021
Making it
makable before
it’s in the die
A PUBLICATION OF THE FABRICATORS &
MANUFACTURERS ASSOCIATION, INTERNATIONAL®
AA PUBLICATION
PUBLICATION OF
OF THE
THE FABRICATORS
FABRICATORS &&
MANUFACTURERS
MANUFACTURERS ASSOCIATION,
ASSOCIATION, INTERNATIONAL
INTERNATIONAL®®
Cover_MarchApril21SJ.indd 1 3/8/21 11:25 AM
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ToC_MarApr2021SJ.indd 3 3/8/21 7:59 AM
An Official Publication of the
VOL. 33 NO. 2 MARCH/APRIL 2021 Fabricators & Manufacturers Association, International®
>> COVER STORY
22 Design for manufacturability
The process of stamping parts from the initial RFQ, through the
tooling design/build process, and finally to the stamping produc-
tion can be a long and winding road with a large gap between
what is designed and what can be manufactured. A well-designed
part with manufacturability in mind will run the smoothest, with
the least amount of downtime caused by tooling design-to-pro-
duction disconnects. If a tooling house knows a feature’s func-
tion during the tool tryout process—or better yet at the time of
RFQ—that can be highly beneficial in bridging the gap between
p. 22 product design and tooling.
On the cover: Victory Tool
>> DEPARTMENTS
6 Meet the Press
>> FEATURES
In “President Biden’s Made in America order will help U.S.
stampers,” Editor Kate Bachman cites the improvements to the 28 Servo press puts reverse
Buy America Act of 1933 and dwells on the consumer versus tonnage in reverse
makers conundrum inherent in protectionism.
Stamping manufacturer Clips & Clamps was forming a 1/8-in.-
8 Readers Respond thick, 78 Rockwell hardness stainless steel part on a 300-ton
A reader recounts his lesson in Class A dies.
mechanical press and encountered extreme reverse tonnage.
8 News & Notes The press, tooling, and entire system took a beating that even
Industrial Magnetics acquires Walker Magnetics; President Joe a hydraulic dampening system couldn’t quell. The company
Biden to replace government’s fleet with U.S.-made electric
installed a 330-ton servo-mechanical press on which to run the
models; Greenheck to acquire Metal Industries; Daimler Trucks
NA’s Portland, Ore., truck manufacturing plant achieves car- part and realized a complete reversal of the reverse tonnage and
bon-neutral production the problems it created.
14 Stamping Solutions
Automotive component-maker future-proofs press line with 34 How do titanium, stainless steel
new control system. grain structures affect part forming?
15 Product Innovations A microscopic view into how metal bends, forms, and breaks
System tracks stamping press downtime, lubricant use; Vacuum
generator designed for automotive press shop automation
shows that the selection of stainless steel and aluminum alloys
often is centered around strength, ductility, elongation, and
16 Die Science hardness. These properties indicate how a metal’s building
Columnist Art Hedrick shares the essential tooling checklist.
blocks behave in response to an applied load. Benefits can be
18 Engineering Angle gained by peering one layer deeper into the grain structure that
The researchers at Oakland University’s Center of Advanced governs a metal’s mechanical behavior.
Manufacturing and Materials dissect ways to control edge split-
ting in sheet metal part production.
44 Forming & Fabricating® 2021
40 Product News Stamping Lubricant Buyers’ Guide©
49 Advertisers Index
50 Ask the Expert
A reader asks Tom Vacca, “What designs are available for
in-die forming?”
4 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
ToC_MarApr2021SJ.indd 4 3/9/21 11:27 AM
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ToC_MarApr2021SJ.indd 5 3/8/21 7:59 AM
MEET THE PRESS
President Biden’s Made in America
order will help U.S. stampers
Closes loopholes, ups content share, provides transparency
T
he Buy American executive order that Pres- ‘American-made’ goods,” according to a Forbes
ident Biden signed on Jan. 25 will benefit article, “Biden Signs ‘Buy American’ Executive
U.S. stamping manufacturers and metal Order—Here’s What It Means For Businesses.”
fabricators supplying the federal government, Additional good news for stampers and fab
despite the requirement that the materials they shops is a provision for small and midsize busi-
purchase be produced domestically as well. By nesses for better access to information about con-
Kate Bachman strengthening existing Buy American rules, the tracting with the federal government and com-
Editor order is positioned to boost U.S. manufacturing petitors’ waivers so they have a better chance of
kateb@thefabricator.com because it requires preference to domestic produc- having a seat at the government contracts table.
ers and removes much of the price suppression
that accompanies global cost competition. Consumers Versus Makers
Although the Buy American order applies only The American-made requirement resurfaces the
to federal government spending, that pot is siz- age-old arguments about whether or not pro-
able—$600 billion—and applies to everything tectionism—required preference for nationally
from military contracts and postal and other feder- manufactured products—is good for Americans
al vehicles to construction components. and the U.S. economy. Free trade arguments
The order, another in a long line of “adjust- enter in.
ments” to the 1933 Buy American Act that directs Global competition reduces the price consum-
government spending to procure a majority of ers have to pay for goods produced. Low-cost, for-
materials and products from U.S. sources, includes eign-produced goods threaten the survival of U.S.
significant improvements over previous iterations. manufacturers—which are also employers.
It does so by redefining “U.S. content,” pressing to That conundrum has existed for decades, as the
The order, increase the content percentage, closing loopholes U.S. trade surplus has eroded since NAFTA. The
in the waiver process, and providing oversight and U.S. trade deficit is a stark marker of the result of
another in a accountability. manufacturing migration.
According to the U.S. Government Account- Charles Fishman’s 2003 Fast Company article
long line of ability Office (GAO), “Problems in administering “The Wal-Mart You Don’t Know” revealed in pain-
“adjustments” the act involve definitions of ‘substantially all’ of ful detail how U.S. shoppers buying China-manu-
the components and definitions of ‘manufactured factured goods at Walmart—then the U.S.’s largest
to the 1933 Buy in the United States.’” Additional snags have been importer of products from China—unwittingly
in the “public interest” waiver: “The provisions of hastened the demise of their own factory jobs.
American Act, the act may be waived if the head of the procur- So, what’s the better trade-off—being able to
ing agency determines the act to be inconsistent buy inexpensive products but losing manufactur-
includes with the public interest or the cost of acquiring the ing jobs and revenue, or more expensive goods
domestic product is unreasonable.” and a healthy U.S. manufacturing industry?
significant The executive order creates a new position in
the Office of Management and Budget and impos- Balance Is Key
improvements es scrutiny of the waiver process that has been I suspect that stamping manufacturers concede
over previous abused in the past. that at least the U.S. government should be
“The percentage of Defense Department con- required to buy U.S.-manufactured products,
iterations. tracts receiving waivers … jumped under Trump. especially for military operations and national
Such waivers are a key target of Biden’s executive security. And who wants American flags to be
order,” according to a Jan. 27 Washington Post made in China?
article. The key is to ensure that the price that U.S. man-
“Biden’s ‘Buy American’ plan will make it more ufacturers pay to manufacture products doesn’t
difficult for federal agencies to contract with com- exceed the financial benefits of supplying them. S
panies overseas to purchase foreign products by
reducing loopholes and waivers in existing Buy
American rules and changing the definition of
6 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
MeetThePress_MarApr21SJ.indd 6 3/9/21 11:20 AM
Maximum
Productivity,
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STAMPING JOURNAL STAFF
President & CEO, FMA Edward Youdell
Minimal
Vice President of Publishing & Events Andy Flando
Editor-in-Chief Dan Davis
Editor Kate Bachman
Senior Editor Tim Heston
Bunting MagSlide
The WELDER Editor Amanda Carlson
Downtime.
TPJ Editor Eric Lundin
Senior Copy Editor Teresa Chartos
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Conveyors. Strong.
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Director of Circulation Kim Clothier
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STAMPING JOURNAL EDITORIAL ADVISORY BOARD
Paul Belanger, R&D Director, Steve Peplin, CEO,
• No oil to drip out
• Stainless steel slider bed
Gestamp North American Talan Products
Research Center
Donna Russell-Kuhr,
Christopher Fagnant, President, President/CEO, PTM Corp.
Qualtek Manufacturing
Fred Simonson,
Hale Foote, President, Scandic General Manager, Victory Tool
Ken Kaufmann, President,
CEP Technologies
Sergey Golavashchenko, PhD,
Engineering Angle
800.835.2526 or 316.284.2020
Ramie Melvin, Sr. Director of
Manufacturing Operations, Kapco
Art Hedrick, Die Science Sales.Newton@BUNTINGMAGNETICS.COM
Visit www.BUNTINGMAGNETICS.COM
Tom Vacca, Ask the Expert
Eric Nelson, Director of
Engineering, Aranda Tooling
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The STAMPING Journal’s objective is to disseminate new and complete
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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
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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, new literature, news of the industry,
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names. Unless product identification makes reference unavoidable, the generic
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deems inappropriate for publication in STAMPING Journal®, including ads
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a publication of FMA
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AN FMA PUBLICATION • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2021 7
MeetThePress_MarApr21SJ.indd 7 3/8/21 7:56 AM
NEWS & NOTES
Industrial Magnetics acquires Andritz Herr-Voss Stamco Inc., and Lauyans & Co. Inc.
Walker Magnetics Andritz Metals Inc. have been merged Lauyans, a manufacturer of convey-
to form Andritz Metals USA Inc., a new or and permanent magnet systems, will
Industrial Magnetics Inc. has announced legal entity based in Callery, Pa. continue to operate out of its current
the acquisition of substantially all of the The company maintains locations in facility in Louisville, Ky.
assets of Walker Magnetics Group Inc., Ambridge, Pa.; Canonsburg, Pa.; Con-
a provider of custom and standard mag- way, Pa.; Homestead, Pa.; Novi, Mich.; Amada Orii America
netic products for workholding, material Rockhill, S.C.; Chesterton, Ind.; South changes name to Amada
handling, and separation applications in Holland, Ill.; and Amsterdam. It is par- Press System America
Worcester, Mass. ent company to Schuler.
Industrial Magnetics is a provider of Amada Orii America Inc., Erlanger, Ky.,
permanent and electromagnetic sys- Greenheck Group to has changed its name to Amada Press
tems, based in Boyne City, Mich. acquire Metal Industries System America Inc. This aligns with
the name of Japan-based parent com-
Group Andritz merger creates The Greenheck Group, Schofield, Wis., pany Amada Press System Co. Ltd. and
Andritz Metals USA has signed a letter of intent to acquire represents its full-system press business,
Metal Industries, a manufacturer of including coil handling equipment and
Group Andritz has announced changes grilles, registers, diffusers, and air ter- press-to-press transfer robots.
to its corporate structure in the U.S. minal products used in commercial and The company continues to offer Orii
Andritz Asko Inc., Andritz Asko BV, institutional buildings. metal stamping automation equipment,
Metal Industries will continue to oper- MEC springmaking machines, leveling
ate under the current leadership team of casters, and pads.
READERS RESPOND Grant Tyson, president, and David Haw-
ArcelorMittal North America to
kins, COO, and both will remain active
partners in the company. The company add capability in Canada
Class A Lesson Recalled is based in Clearwater, Fla., with man-
ufacturing operations in Bushnell, Fla.; Flat-rolled steel producer ArcelorMittal
Art Hedrick’s Die Science column, Marion, N.C.; and Reynosa, Mexico. Dofasco has added aluminum silicon
“What Makes a Class A Die a Class A (Alusi) coating to its No. 5 hot-dipped
Die?” [January/February 2021 issue] LaserCoil Technologies galvanizing line in Hamilton, Ont. This
took me back to an early contract job updates website $18.7 million project will allow produc-
at Chrysler and my first time in a high- tion of the company’s patented Usibor
light room. I worked body-in-white LaserCoil Technologies LLC, Napo- press-hardenable steel for automotive
(BIW) dimensional management with leon, Ohio, has updated the look and structural and safety components.
responsibility for panel fits. When I first content of its website at www.lasercoil. No. 5 line is expected to produce up
saw a pre-production BIW coated with com to provide more comprehensive to 160,000 tons of Alusi-coated steel.
highlight oil under the long fluores- information on its coil-fed laser blank-
cent tubes, I was appalled at the waves ing systems. Auto Notes
in the panels and the discontinuities The Technology section has been
across the gaps between them, but very updated to include benefits of laser President Joe Biden has announced
relieved that my job, the panel fits, were blanking from coil, as well as features plans to replace the government’s cur-
good. The next time I saw a BIW in the specific to the company’s systems. Addi- rent fleet of vehicles with U.S.-made
highlight room, the tool- and diemak- tionally, a Video and Resource page has electric models.
ers and the stamping team had worked been added that is populated with new The time period for this action, which
their magic and the tube reflections videos and links to technology articles. will affect about 650,000 vehicles, has
ran straight across the panels and the not been specified.
gaps—proof that the new panels came W.M. Kelley Co. acquires Daimler Trucks North America
off of Class A dies. Lauyans & Co. (DTNA) has announced that its Port-
land, Ore., truck manufacturing plant
Mike Matusky W.M. Kelley Co. Inc., New Albany, achieved carbon-neutral production in
Engineer Ind., a 100% employee-owned man- 2020 with reduced energy consump-
Clever Fabrications ufacturer of material handling equip- tion and the offset of on-site emissions.
Everett, Wash. ment, custom metal fabrication com- DTNA plans to incorporate CO2-neu-
ponents, and assemblies, has acquired tral production at its remaining truck
8 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
NewsNotes_MarchApril2021SJ.indd 8 3/9/21 11:23 AM
NEWS & NOTES
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Initial production of the Detroit ePow-
ertrain is expected to begin in late 2021.
Fiat Chrysler Automobiles N.V.
(FCA) and Peugeot S.A. (Groupe PSA)
have completed a merger to create
Stellantis N.V.
Ford Motor Co. has announced it
will invest at least $22 billion in elec-
tric vehicles (EVs) through 2025, with
plans to develop high-volume, connect-
ed electric SUVs, commercial vans, and
pickup trucks. The recently released
Mustang Mach-E will be followed by
the first E-Transit commercial van in late
2021 and an all-electric F-150 pickup in
mid-2022. EVs also will be fundamen-
tal to the Lincoln luxury brand and the
Transit commercial lineup.
In addition, by mid-2026, 100% of its
passenger vehicle range in Europe will
be zero-emissions-capable, all-electric,
AN FMA PUBLICATION • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2021 9
NewsNotes_MarchApril2021SJ.indd 9 3/8/21 7:54 AM
NEWS & NOTES
or plug-in hybrid and will be complete- plies stamped metal parts, blanks, and mal interface materials at the cell and
ly all-electric by 2030. Its commercial sheet metal assembly to the automaker’s pack level. Demand for these materials
vehicle range will be zero-emissions-ca- North American assembly plants, an will increase rapidly as the market for
pable, all-electric, or plug-in hybrid by employee died Dec. 30, 2020, in a fork- EVs grows.
2024, with two-thirds of its commercial lift accident. Employees were moving a Britain-based luxury carmaker Jag-
vehicle sales expected to be all-electric floor-to-ceiling wall unit of metal tubing uar has announced its plan to phase out
or plug-in hybrid by 2030. welded together. It was not yet secured internal combustion engines by 2025.
to a floor or connecting beam. Mark The company also said the Land Rover
McKnight, who was working near the brand will produce its first all-electric
wall, was killed when an employee acci- model in 2024. To make the switch, the
dentally backed his forklift into the wall, automaker will move production from
which fell and struck McKnight. its Castle Bromwich factory, which could
Reuters has reported that Hyundai be repurposed for battery production, to
Motor Co. expects sales to increase 12% nearby Solihull.
in North America in 2021, driven in part Lordstown Motors Corp., Lord-
Spearheading Ford’s advance into an by the launch of new electric cars. The stown, Ohio, has received more than
all-electric future is a new $1 billion automaker is expected to introduce an 100,000 nonbinding production res-
investment to modernize its vehicle EV-only platform that will use its own ervations from commercial fleets for its
assembly facility in Cologne, Germa- battery technology. The company also Lordstown Endurance all-electric pick-
ny, for EV production. Its first Europe- anticipates sales to jump 28% in China, up truck, with an average order size of
an-built, volume all-electric passenger where it plans to release the electric ver- nearly 600 vehicles per fleet.
vehicle for European customers will be sion of its Mistra sedan. The automaker has taken several steps
produced at the facility from 2023. to prepare for production of the full-size
In recognition of the automaker’s pickup beginning in September 2021,
commitment to reduce CO2 emissions including initiating metal stamping and
from its facilities and vehicles and its welding for the first 57 prototypes. In
focus on powering facilities with renew- addition, it has signed a multiyear sup-
able energy, the World Environment plier agreement with LG Energy Solution
Center has presented Ford with the 36th Groupe Renault has unveiled its stra- to broaden its battery cell supply chain.
annual Gold Medal for International tegic plan, which includes an emphasis Lordstown also has been added to the
Corporate Achievement in Sustainable on EVs and clean energy. The automak- U.S. General Services Administration
Development. er says it will launch seven electric and listing, the first step toward being able to
General seven C/D segment vehicles by 2025. sell to government fleets. And construc-
Motors will sup- All new models will have an electric or tion continues on an 800,000-sq.-ft.
ply its Hydrotec hybrid version. The brand also will offer propulsion renovation at the company’s
fuel cell power hydrogen systems for light commercial Ohio headquarters.
cubes to auto- vehicles (LCVs). In addition, the com- Finally, the automaker has accept-
maker Navistar for use in its production pany’s Re-Factory in Flins, France, will ed an invitation from the U.S. DOE to
model fuel cell EV, the International RH recondition more than 100,000 used start the due diligence process toward
semitruck. The vehicle will get energy cars per year and convert diesel LCVs securing an Advanced Technology Vehi-
from two fuel cell power cubes, each of into biogas and EVs. cles Manufacturing loan to help increase
which contains more than 300 hydrogen A new report from IDTechEx, “Mate- production capacity to get the Endur-
fuel cells along with thermal and power rials for Electric Vehicle Battery Cells ance to customers more quickly while
management systems. and Packs 2021-2031,” identifies and also advancing R&D of future vehicles.
The automaker also has announced analyzes trends in the materials used for
plans to bring production of its Bright- the assembly and production of battery
Drop electric light commercial vehicle, cells and battery packs in the EV market.
the EV600, to its CAMI manufacturing The report also provides granular mar-
plant in Ingersoll, Ont. The nearly $800 ket forecasts for more than 20 key mate-
million, two-year project will transform rial categories, both by demand (tons)
the CAMI plant from its current produc- and market value. EV manufacturer Rivian has closed
tion of the Chevrolet Equinox. The lithium-ion batteries in EVs an investment round of $2.65 billion.
At GM’s Marion Metal Center stamp- require such materials as nickel, cobalt, The company now has raised $8 billion
ing plant in Marion, Ind., which sup- lithium, copper, insulation, and ther- since the start of 2019 for the launch of
10 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
NewsNotes_MarchApril2021SJ.indd 10 3/8/21 7:54 AMNothing Beats Turn Key
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the R1T, the R1S, and Amazon commercial
delivery vehicles. These vehicles will be
produced at the automaker’s manufacturing
plant in Normal, Ill., with customer deliver-
ies expected to begin in summer 2021.
The U.S. International Trade Commis-
sion (ITC) has announced it will issue a
limited 10-year exclusion order against SK
Innovation, prohibiting it from importing
lithium-ion batteries into the U.S. Accord-
ing to Reuters, the ITC will permit SK to
import components for domestic produc-
tion of lithium-ion batteries and parts for
Ford (four years) and Volkswagen of Amer-
ica (two years). The ban is a result of the
ITC’s determination that SK misappropriat-
ed trade secrets related to EV battery tech-
nology from LG Chem Ltd.
The Shyft Group, a specialty vehicle
manufacturer, has announced plans to hire
new manufacturing employees at its Char-
lotte, Mich., campus in the coming months
as the company continues to receive new
vehicle orders and ramps towards pro-
duction of its Velocity F2 walk-in van. As
it ramps up production, the automaker
also is pursuing state incentives for facility
upgrades and workforce training.
Smart Press Shop GmbH, the joint
venture between Porsche and Schuler in
Halle, Germany, has added a ServoLine 20
servo press line. The new press shop man-
ufactures the body parts of the Porsche
Macan II, which then are assembled at the
Porsche plant in Leipzig, Germany. The
line has an output of up to 20 SPM, with
numerous functions from Schuler’s Indus-
try 4.0 kit.
12 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM
NewsNotes_MarchApril2021SJ.indd 12 3/8/21 7:55 AMNewsNotes_MarchApril2021SJ.indd 13 3/8/21 7:55 AM
STAMPING SOLUTIONS
Automotive component-maker future-proofs press
line with new control system
Situation BMW, Jaguar Land Rover, and Ford.
Norway-based Neuman Aluminium Its factory in Raufoss, Norway, has two
Raufoss is a manufacturer of lightweight three-press lines from AP&T. Installed in
aluminum chassis components for the the late 1990s, the lines are used to man-
automotive industry, serving as a global ufacture various types of aluminum parts
VB_6567AD.QXD_VB_6567AD.QXD
Tier 1 supplier to Volvo, Daimler,8/11/16
GM, 11:24 AM aPage
through 1
complex process with many
Vibro Transporters are
different operations. Production requires
short cycle times and basically runs 24/7,
which means demands on reliability and
availability are high.
To help future-proof its equipment,
Raufoss consulted with AP&T about
upgrading one of its lines with a modern
control system for the presses and new
automation.
Resolution
“The work started in mid-October
[2019] and was completed right before
Christmas,” said Anders Rundén, project
manager at AP&T. “We replaced several
old linear robots with new SpeedFeeders
and replaced the old control system with
the newest generation, which is adapted
to AP&T’s newest software and our new,
To eliminate the inherent problems and hazards associated with user-friendly HMI.”
electric conveying systems, the Vibro Transporter operates exclusively on In addition to a more stable process,
100% air pressure. Safe and efficient, the Vibro Transporter saves money the upgrade also enables much shorter
by eliminating the chance of downtime due to electrical short circuits cycle times.
caused by metallic shavings or moisture. And unlike conventional belt “The installation was completed with-
conveyors, the oscillating force of the Vibro Transporter safely absorbs in the agreed time frame, and we have
accidental resistance without damage to equipment or injury to personnel. reduced our cycle time and ensured
Four models are available and all come with a 2-year warranty, long-term access to spare parts,” said
Register online or call us Hans Jørgen Lundstein, project manag-
to receive your product line kit, er at Neuman Aluminium Raufoss. “And
application video, engineering Engineered First to Last it was easy for our operators to switch
over from the previous system to the new
support, or to locate the sales 717.527.2094
representative nearest you. www.vibroindustries.com
one. In other words, we have achieved
our goals.”
Global Distribution
MADE IN
USA
FOSMO MASKIN A.S., Norway • UPTON & SULLIVAN CO., LTD., Canada • MTI Monterrey, Mexico AP&T • aptgroup.com
14 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
StampingSolutions_MarchApril21SJ.indd 14 3/8/21 7:41 AMPRODUCT INNOVATIONS
Vacuum generator designed for
automotive press shop automation
Piab has introduced piINLINE plus, a
configurable platform for decentralized
vacuum generation in automotive press
shops. The compact, ultralightweight vac-
uum ejectors feature an integrated auto-
matic release mechanism, available in
two optional designs: Atmospheric Quick
Release and Exhaust Block Release.
Designed with ports for compressed air
and vacuum inline, supported by quick-fit
push-in connectors of varying diameter,
they are mounted directly onto the hose,
close to the point of suction.
Piab • www.piab.com
System tracks stamping press
downtime, lubricant use
IRMCO has devel-
oped iNSIGHT, a
patented technolo-
gy that allows metal
stampers to quanti-
fy their actual con-
sumption of lubri-
cant, control and
document lubri-
cant concentration,
and monitor press
line stoppages
and efficiencies in
real time, whether
in-plant or remote-
ly.
Users can track
the different rates
of chemical con-
sumption for individual parts and com-
pare this data to tool life to pinpoint the
actual cost per part for each process in
their facility.
IRMCO • www.irmco.com
WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2021 15
ProdInnovations_MarchApril21SJ.indd 15 3/8/21 7:37 AMDIE SCIENCE
The essential tooling checklist
BY ART HEDRICK
1. Offset one guide enough so that the
die cannot be put together incorrectly.
Usually ¼ in. (6 or 7 mm) is sufficient.
If the die has only two guide pins, make
one guide pin larger than the other.
2. Offset one screw or one dowel
in every component so that the com-
ponent cannot be put on 180 degrees
from normal. This includes pressure
pads, plates, and strippers.
3. When using similar slides, make
them different sizes so they will not go
into the incorrect gibbing. If this is not
possible, add a mechanical feature to
the cam slide, such as a dowel or pin,
that will prohibit the cam from going
into the wrong area on the tool.
4. Whenever possible, use different
body diameters for pierce punches.
This will help prevent pierce punch-
es from being installed in the wrong
retainer.
5. When designing progressive dies,
avoid using a written site stop line as
a representative of the first hit line.
Instead, use a solid mechanical stop to
establish the first hit area on the tool.
Why I can remember 80,000 things
about stamping and dies and forget
Forgetting a few key things when to get bread at the grocery store con-
designing or building a stamping founds me. In any case, I now see the
value of a list.
die can prove to be disastrous. So let’s see …
1. Told them what I was going to tell
them … Check
I
t happens …. especially as we get exactly the reason I encourage you to 2. Explained why it was important …
older. Last week my wife asked me create and use a checklist of items that Check
to go to the grocery store. She asked are critical in this process. 3. Gave them a pretty decent check-
me to get two or three basic things. She list to work from … Check
then asked me if I needed a list and, of Mistake- and 4. Summarized the content … Check
course, I told her no. For heaven’s sake, Error-proofing Tools That’s it!
I could remember just a few things, Sometimes tooling people will refer to Until next time … best of luck! S
right? this as “stupid-proofing.” But keep in
Long story short, I ended up texting mind, very intelligent and experienced Art Hedrick is president and senior con-
her to rediscover the items she wanted. tooling professionals still make hon- sultant of Dieology, 10855 Simpson West
I needed a list after all. est mistakes and put a component on Private, Greenville, MI 48838, 616-894-
Forgetting a few key things when backward from time to time. So make 6855, dieology@pathwaynet.com, www.
designing or building a stamping die sure all of the following are incorporat- dieology.com.
can prove to be disastrous. That is ed into the design and build of the tool:
16 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
DieScience_MarchApril21SJ.indd 16 3/9/21 10:43 AMDIE SCIENCE
Die and Tooling Quality Checklist
Although missing a couple of these things might not be a 7. All dies:
big problem, it’s still a good idea to follow a checklist for ____ Cutting forming joint location/quality
the following items. ____ Easily maintainable die sections
____ No weld unless authorized
1. General die information stamped or stenciled ____ Proper guarding of springs and pinch points
on the die: ____ No altered springs
____ Weight of upper die, lower die, and total ____ Acceptable fasteners/screws/dowels
____ Total tonnage requirement ____ Pry slots and jack screws present and accessible
____ Tool identification number ____ Proper air vents
____ Progression (if applicable) ____ Proper pad guides
____ Feed line/passline height (if applicable) ____ Nonreversible sections
____ Marked metric (if applicable) ____ Adequate die life (cutting sections only)
____ Gas/nitrogen pressure (if applicable) ____ Nitrogen system/installation method/no
preloading present
2. General die appearance: ____ Cutting shear (where applicable)
____ Painted correct color ____ All upper springs fastened to shoe
____ All guards present and painted yellow ____ All springs under pads have spring cams
____ No sharp edges ____ Provisions for proper lubrication methods
____ Manifold gauges clearly marked and accessible
3. Quick die change provisions: ____ Pierce punch spring ejectors
____ Keyways—die locators ____ Correct cutting punch entry
____ Parallel spacing ____ Adequate retainer clearance for shimming
____ Handling holes in die shoes ____ Ball lock punch access (where applicable)
____ Clamp slot height/location/adequate number ____ Button type and installation
____ Transfer bar height correct (if applicable) ____ Fits in designated press
____ Correct shut height per press requirements ____ Correct transfer/pickup height (transfer dies only)
____ Proper attachment of two dies (if applicable) ____ Adequate part locators/gauges
____ Acceptable heeling methods - thrust blocks
4. Tool steel—tooling material: ____ Handling holes for large sections
____ Properly stamped/identified with detail number and ____ Press knockout provisions
tool steel type ____ Parallels doweled to shoe
____ Correct type ____ Adequate scrap relief/ejection
____ Correct hardness ____ Spring rods and cams (where applicable)
____ Radius left in all sections for strength ____ Lubrication methods provided/grease grooves
____ Acceptable thickness ____ All pinch points guarded
____ Acceptable leads on all guide rails and lifters
5. Die finish/polish (where applicable): ____ Die protection provisions supplied and calibrated
____ Acceptable ____ All screws and dowels are tight and secure
6. Progressive/transfer dies: 8. Engineering—CAD specifications:
____ Correct pilot entry ____ Blanking and stripping pressures noted
____ Correct feed rail design—“No hands in die” strip- on the design
starting capability ____ Each station indentfied by numbering and a brief
____ Correct stock lifter description on all design views
____ Acceptable carrier design ____ CAD files/prints provided for all vendors
____ Adequate part ejection ____ Correct file type
____ Pilot spring ejectors ____ All die details drawing clearly dimensioned
____ Pad levelers ____ All tool steel types clearly called out
____ First hit line present—prefer solid stop ____ All recent revisions clearly documented
____ Pitch notch (if applicable) ____ All alterations approved
____ Pilot clearance/button ____ Title block correct
____ Proper feed line height ____ All necessary section views shown
AN FMA PUBLICATION • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2021 17
DieScience_MarchApril21SJ.indd 17 3/8/21 7:31 AMENGINEERING ANGLE
Controlling edge splitting in sheet
metal part production
BY DR. SERGEY GOLOVASHCHENKO
A
pplications of advanced by Comstock et al. Several empirical Process Parameters
high-strength steel and ultra- formulas were developed for each man- The approach described by Stanton et
high-strength steel (UHSS) in ufacturing method of hole fabrication, al and Comstock et al does not take into
the automotive industry are quickly including a formula for achieving the account shearing process parameters,
expanding because of their capacity to best die clearance condition in punch- which change often because of non-
reduce weight, lower raw material con- ing. uniform cutting clearance, sheet metal
sumption, improve fuel economy, and Both publications indicate that the deformation occurring before the cut-
enhance crashworthiness. HER for punched holes is substantial- ting process (prestrain), and a variety
These materials usually undergo ly lower than for reamed holes, which of cutting angles. The effects of these
shearing operations such as blanking, means that the formability of the parameters on 6XXX aluminum alloys
piercing, and trimming (see Figure 1). sheared edge will always be below the have been analyzed in laboratory envi-
In many cases, the sheared surfaces are forming limit diagram. This happens ronments, but knowledge of real cutting
subject to further edge stretching during because of significant plastic deforma- parameters is required to apply these
later stamping and assembly operations. tion during indentation of the cutting results accurately. In stamping, these
Many studies have been performed edges into the blank material, followed parameters often are unknown because
of inaccurate cutting die assembly or
Edge fractures typically occur in flexing of cutting tools during shearing,
blanking, trimming, and punching.
the highest edge strain area in the Measuring the cutting clearance
between the upper and lower shearing
presence of a rough trimmed edge. edges without a blank often is mislead-
ing. This geometric clearance might be
subject to significant changes, as cut-
on material behavior in the traditional by crack propagation, which takes all ting forces can expand it. This typical-
hole expansion test, showing the results available material ductility in a very ly occurs in the cam trimming mecha-
on the hole expansion ratio (HER) for narrow zone of fracture and spreads nism. Cutting conditions also can be
sheet metal blanks with holes punched plastic deformation into the sheet for altered by abrasive die wear, chipped
in lab-controlled conditions. Stanton some portion of the sheet metal’s thick- cutting edges, and adhesion of sheet
et al introduced an empirical formula ness. The indentation zone, which dic- metal particles on the surface of the
that attempted to predict the HER for a tates the level of plastic deformation, cutting tool. All these factors create sig-
number of 6XXX and 5XXX aluminum depends on the height of the burnish nificant uncertainty in real production
alloys as a function of material thickness zone (see Figure 2). The larger the bur- conditions that can vary during the life
and ultimate tensile strength. A similar nish zone, the higher the shear plastic of the trim die and overall production
effort was performed for several steels deformation occurring before fracture. program. Keeping cutting conditions
Figure 1 Figure 2
A typical trimming process is illustrated here. These are the characteristic features of a sheared edge.
18 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
EngineeringAngle_MarchApril21SJ.indd 18 3/8/21 7:30 AMENGINEERING ANGLE
3a. Stretching the sheared edge, no burr 3b. Edge cracking during stretch flanging. 3c. Partial edge cracking from burr side
origination. caused by excessive clearance during
shearing.
3d. Edge cracking from burr side with 3e. Edge splitting with coining deformation 3f. Edge cracking originating in area of
small cutting clearance; burnish zone occu- close to edge crack origination. upset wrinkles.
pies entire thickness.
Figure 3
Shown here are several different types of edge splitting.
under control and avoiding edge split- crack usually initiates from the upper of indentation (burnish zone) occupies
ting can be challenging. cutting edge and then propagates to the most of the blank thickness (see Figure
lower edge, forming the burr around 3d).
Typical Failure Modes it. The final separation during cutting The indication of excessive clear-
The first typical mode of edge split- with excessive clearances occurs when ance between the cutting edges in the
ting is when the edge of the material, the scrap tears off the part in the burr form of burrs might alter to a no-burr
sheared with recommended clearance area, which damages the sheet material. condition when burr is broken off the
providing no burr, still has insufficient Therefore, when further deformation is sheared edge, as described by Golo-
formability for the current die design. applied to the sheet metal in the form of vashchenko et al and Nasheralahkami
In this case, multiple crosshatch cracks edge stretching, edge cracking usually et al. This condition is typical for UHSS
can occur (see Figure 3a). Since there originates from the burr. and results in reduced formability with
is likely no possible improvement in the According to Coryell, edge fractures crack propagating perpendicular to the
cutting process, the solution is to use typically occur in the highest edge strain sheared surface of the blank. This fail-
more formable material or reduce edge area in the presence of a rough trimmed ure mode can be controlled by adjust-
stretching. edge. They often occur during drawing ing the cutting clearance and designing
Another possible failure is one major with blanked windows or from a stretch the trim tools to be well supported to
crack at about 90 degrees to the sheared flange after a rough die trim. This fail- avoid flexing and clearance expansion.
edge surface (see Figure 3b). This fail- ure mode might gradually appear on The next failure mode, coining defor-
ure can be caused by excessive clearance the edge of the blank in the form of mation, is visible on the left side of the
between the cutting edges, insufficient cracks partially propagating through crack in Figure 3e. The material was
clearance, insufficient stiffness of the the thickness. It might occur in cases subjected to local, significant compres-
die, or gradually deteriorated edges. For with excessive clearances (see Figure sion, likely caused by tool misalign-
most materials, this type of crack initi- 3c), where the fracture zone occupies ment. This failure mode can be elimi-
ates in the burr area, where material has most of the edge surface. This failure nated by proper alignment of the tool
the most damage. For cutting condi- mode also might take place in the case and avoiding this local indentation.
tions leading to origination of burrs, the of insufficient clearance, where the zone Finally, the failure mode illustrated in
AN FMA PUBLICATION • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2021 19
EngineeringAngle_MarchApril21SJ.indd 19 3/9/21 10:41 AMENGINEERING ANGLE
Figure 3f likely comes from the draw- controlled by adjusting the draw beads J.J. Coryell, “Edge Fracture in Mixed
ing process, when a wrinkle forms on during production. Sometimes, because Microstructure Steel,” presented at Great
the trim line. During trimming, the of die wear, increased friction or galling Designs in Steel 2016, sponsored by The
wrinkle is smashed, resulting in sig- in draw beads, or variability in produc- American Iron and Steel Institute.
nificant additional deformation of the tion materials, the binder clearance is S. Golovashchenko and R. Sohmshetty,
material. It also may occur during sec- adjusted beyond the typical 10% of the “Evolution of Die Wear and Sheared Edge
ondary trimming or flanging opera- sheet thickness in the draw die. Over- Parameters in Trimming of DP980 Steel,”
tions. Upsetting the wrinkle creates sig- all, this failure mode can be managed presented at Great Designs in Steel 2017,
nificant local deformation of the sheared by the draw bead system to eliminate or sponsored by The American Iron and Steel
edge and likely leads to edge cracking. minimize wrinkles. S Institute.
This failure mode may depend on the S. Nasheralahkami, W. Zhou, and S.
adjustment of the draw bead system Dr. Sergey Golovashchenko is professor Golovashchenko, “Study of Sheared
in the drawing operation. Opening the and director at the Center of Advanced Edge Formability of Ultra-High Strength
flange clearance in drawing might ease Manufacturing and Materials (CAMM), DP980 Sheet Metal Blanks,” Journal of
the material flow into the die cavity Oakland University, 115 Library Drive, Manufacturing Science & Engineering,
and eliminate problems of splitting in Rochester, MI 48309, 248-370-4051, golo- Vol. 141, No. 9 (2019).
drawing, but it also might create new vash@oakland.edu.
wrinkles on the flange, which can be M. Stanton, R. Bhattacharya, I. Dar-
References gue, R. Aylmore, and G. Williams, “Hole
harmful. More study is needed to deter- R.J. Comstock, D.K. Scherrer, and R.D.
mine the acceptable amount of shallow Expansion of Aluminum Alloys for the
Adamczyk, “Hole Expansion in a Variety Automotive Industry,” AIP Conference
wrinkling that would not bring exces- of Sheet Steels,” Journal of Materials Engi-
sive deformation for edge splitting. Proceedings, Vol. 1353 (2011), pp. 1488-
neering and Performance, Vol. 15 (2006), 1493.
Wrinkling on the trim line also can be pp.675-683.
20 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
EngineeringAngle_MarchApril21SJ.indd 20 3/9/21 11:29 AMSupporting manufacturers since 1923!
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Stamping_Journal_Print_Ad_March 2021.indd 1 2/24/2021 12:43:01 PM
EngineeringAngle_MarchApril21SJ.indd 21 3/9/21 9:48 AMDesign for
manufacturability
Bridging the gap between product design and tooling
By Fred Simonson Of course, many parts do not lend and dimensional criteria that are adding
themselves to optimal running con- cost to the part may be unnecessarily
T
he process of stamping parts— ditions for a variety of reasons, and a complex or overdimensioned?
from the initial request for quote good tooling house knows many meth-
(RFQ), through the tooling ods to overcome such challenges, but Function Factors In
design/build process, and finally to those methods typically add cost to the Does the customer company have a
the stamping production—can be a tool and slow the rate at which the tool tooling expert who reviews part designs
long and winding road with a large gap can run. to ensure that they are designed with
between what is designed and what That may be fine and well if the costs tooling feasibility and cost in mind?
can be manufactured. A part designed of the tooling and part production fit Does that expert make sure that
with manufacturability in mind will the budget of the end user. However, tolerances are achievable, and that the
run the smoothest, with the least what if the tooling cost pushes that part tool will run efficiently in production?
amount of downtime caused by tooling out of budget or makes the product Subtle differences in how a part is
design-to-production disconnects. price noncompetitive? Which features dimensioned can make significant dif-
22 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION
ToolDie_Manufacturability_MarApr21SJ.indd 22 3/9/21 11:04 AMTop 4 Design Trip-ups
These “trip-ups” add cost to tool design, build,
and production efficiencies:
1. Excessively tight tolerances on dimensions
not critical to part function
2. Geometric dimensioning and toleranc-
ing (GD&T) datum structuring that is not well
thought out and often is contradicting
3. Form features that stretch or exceed the
physics of the part material
4. Parts that do not have a practical way to be
carried through a tool
customer, it’s discovered that the hole’s
function is simply for hanging the part
on a paint line. Had the part designer
treated that feature for what it was—a
noncritical feature—the part feature
tolerance would have reflected that,
and it would not have been a prob-
lem. The tooling house probably would
have been able to quote the project at a
lower cost. The tool was likely quoted
to account for the difficulty of holding
that feature in print, raising the cost of
the tool.
Tolerances, Callouts That
Are Too Tight
Another example of features that can
add cost unnecessarily relates to toler-
ances. A tool house built a large, rela-
tively complex tool for an automotive
Tier 1 stamper. The part design had
What may appear to be a great design on screen might not be manufacturable in the die. This some rather tight profile callouts on
part’s print had profile tolerances along a tall flange going through a step that gave very little some large flanges. The flange tooling
room for error or material variation. When the part and die were redesigned allowing for triple the designs included a series of step forms
tolerance (marked M), the part ran in production without problems. going through the part, which was to
be stamped from a light-gauge material.
ferences in tooling and production cost. ter yet at the time of RFQ—that can be The tooling manufacturer noticed
The tooling house rarely knows what highly beneficial in wringing out cost some red flags about some of the part
a part’s function is. Nor does it know and smoothing an operation. tolerances and callouts. The print had
the functions of the features within profile tolerances along a tall flange
that part. The tooling manufacturer is Hole Location Creates going through a step that gave very lit-
entirely dependent on the part print to Unnecessary Havoc tle room for error. While a good part
design and build a production tool that For example, let’s say a tooling manu- could probably be made without too
will hold required specifications called facturer is struggling with getting a hole much trouble in tryout, any variation in
out on the part print. While that may be location to check within tolerance on a material condition coming into the tool
how it should be, technically, if a tool- part because of the inherent nature of would spell trouble.
ing house knows a feature’s function the part, combined with a tight block At the time of RFQ, the tooling man-
during the tool tryout process—or bet- tolerance. After discussing it with the ufacturer met with its customer team to
AN FMA PUBLICATION • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2021 23
ToolDie_Manufacturability_MarApr21SJ.indd 23 3/9/21 11:04 AMYou can also read
