Stampingjournal20110506 DL

Unrealistic part Improved robotic Small sensors,
features control big splash
Expertise to help you transform metal into gold www.stampingjournal.com MAY/JUNE 2011
Transfer
tooling
tells all
A PUBLICATION OF THE FABRICATORS &
MANUFACTURERS ASSOCIATION, INTERNATIONAL®
AA PUBLICATION
PUBLICATION OF
OF THE
THE FABRICATORS
FABRICATORS &&
MANUFACTURERS
MANUFACTURERS ASSOCIATION,
ASSOCIATION, INTERNATIONAL
INTERNATIONAL®®
Enter reader service code 111248 at www.ffid.net
An Official Publication of the
Fabricators & Manufacturers Association, International®
Vol. 23 No. 3 maY/JUNE 2011
>> COVER STORY
14 4 steps to transfer press
efficiency
Part-holding tooling often is the snag in a transfer
press stamping operation. Paying attention to tooling
selection pays off. Involving your tooling and automa-
tion supplier upfront; simulating the process; choos-
ing the right tooling framework material; and select-
ing the most suitable end-of-arm tooling can pay in
the long run—and the short run. p. 14
On the cover: Cover image courtesy of Bilsing

Automation North America, Clinton Township, Mich.
>> Features >> departments

4 Meet the Press
18 Making sense of industrial sensors Often a chasm as wide as a sea exists between designers’
Advancements continue to be made in discrete sens- expectations and manufacturability. As addressed in this
ing devices, vision sensors, and advanced motion month’s Die Science column, unrealistic part features that
products. New technologies such as Ethernet; radar; look possible on-screen can be the bane of operators and plant
wireless communications; lasers; and contact-free, floor personnel.
wear-free detection methods are blazing new trails in
6 News & Notes
what some consider to be a commodity product.
8 Product Innovations
Servo-electric-drive press; an integrated tool for developing
20 Automated material handling Q&A optimal flat patterns from complex, 3-D designs.
New press lines use a network to facilitate commu-
nication between the automation equipment and the 9 Stamping Solutions
presses. More control allows more flexibility. Using 10 Die Science
today’s technology, stampers can be more aware of Art Hedrick’s column in this issue explores ways to resolve
what is happening on the line in terms of uptime, problems such as hole position tolerance and flatness in Part
cycle time, bottlenecks, and so forth. II of “Attempting to defy the laws of physics: Unrealistic part
features.”
26 Forming & Fabricating® Press Feed 12 R&D Update
Buyers’ Guide© Researchers at The Ohio State University delve into “Deter-
Here is an opportunity to review a side-by-side com- mining the flow stress curve with yield and ultimate tensile
parison of different OEMs’ press feed equipment and strengths, Part I: Important data from the tensile test.”
their features. 24 Automotive Intelligence
In “Lower-tier suppliers and the automotive recovery: Bottle-
neck ahead?” Bernard Swiecki warns that the smaller pool of
automotive suppliers that survived the recent economic crisis
will be challenged to produce components for the 15-million-
car demand forecast for 2011.
28 Product News
33 Classified Advertising
33 Advertisers’ Index
34 Ask the Expert
Dennis Cattell answers “Do die repairs require full lockout/
tagout? that OSHA’s minor servicing exception cannot be used
as an excuse not to comply with lockout/tagout standards.
an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 3

MEET THE PRESS
www.stampingjournal.com
7 & 7: Requests from the stamping journal staff

President & CEO, FMA Gerald M. Shankel
shop floor to the design Group Publisher

Editor-in-Chief
Stamping Journal Editor
Edward Youdell
Dan Davis
Kate Bachman
room—and vice versa

Senior Editor Tim Heston
TPJ Editor Eric Lundin
Senior Copy Editor Teresa Chartos
Closing the manufacturability chasm

Associate Editor Amanda Carlson
Contributing Editor Amy Nickel
A
Graphic Designers Margaret Clark, Janell Drolsum,
design engineer walks into a bar and says to the bartender,
Publishing Coordinator
Mary Mincemoyer, Jennifer Paulson
Jean Thompson
“Make me a drink. Use a highball glass that holds 12 fluid Director of Circulation
Web Content Manager
Kim Clothier
Vicki Bell
ounces (350 ml) and input 3 ounces (85 ml) filtered cubed Multimedia Specialist Sherry Young
Senior Web Developer Jason Bartholme
ice. Pour in 3 ounces Seagram’s Seven Crown blended whisky. Add Web Developer Johanna Albee
6 ounces (170 ml) 7UP. Stir for 8 seconds. Garnish with a 1-inch stamping journal editorial
advisory board
lemon wedge, seeds removed.” Tom Bell, Bohler Uddeholm Corp. Art Hedrick, Dieology
A production manager walks into the bar and tells the bartender, Bruce Braker, Tooling & Mfg. Brad Rine, Honda of America
Association (TMA) Mary E. Schacht, E.C.
Kate Bachman, “Make me a drink. Make sure it wets my whistle, cools my brow, Jerry Busse, Rockford Toolcraft Inc. Styberg Engineering Co., Inc.
STAMPING Journal Editor Michael Chester, Buhrke Industries Inc. Jim Schwartz
gives me a buzz, and goes down easy.” Mark Fansler, Thomas Built Buses, Inc. Eagle Wings Industries, Inc.
(Ret.) Zeev Zimerman,
Let’s face it, sometimes design engineers and stamping floor per- Steven E. Gruver, Orchid International Bethlehem Steel
sonnel just don’t speak the same language or think the same. Advertising Sales
If I hear a common refrain from shop floor operators and pro- Associate Publisher

Jim Gorzek • 815-227-8269
jimg@thefabricator.com
duction managers, it is this: Too many designs make their way Senior Account Representatives
Michigan/Northeast Sean Smith • 815-227-8265
to the plant floor that are not manufacturable. Production folks seans@thefabricator.com
describe impossible hole positioning and fantastical tolerances— Indiana/Ohio/

Southeast/International
Mike Lacny • 815-227-8264
mikel@thefabricator.com
usually accompanied by rolling eyes and shaking heads: Tennessee/Alabama/ Tony Arnone • 815-227-8263
“Some designers are right out of engineering school and have Mississippi/ West tony@thefabricator.com
Minnesota/Iowa/ Amy Hudson • 815-227-8237

no practical knowledge of forming processes. They just rely on a
Let’s face it, sheet metal software package or a CAD system. They have no idea
Illinois/Wisconsin/Canada amyh@thefabricator.com
Classified Advertising Patty D’Amico • 815-227-8278

patriciad@thefabricator.com
sometimes of what is manufacturable and what is not.” Director of Accounting Bob Young
7 Pleas From Production to Designers: Accounts Receivable/ Mary Simons
design 1. Forget perfect. Design what is achievable on Earth.

Credit Coordinator
How to Contact Us

2. Pay attention to punch-to-die clearances, and make sure they

engineers and can be done in real life.
833 Featherstone Rd., Rockford, IL 61107
Phone 815-399-8700 • Fax 815-484-7700
E-mail info@thefabricator.com
3. Know the material’s metallurgical capabilities and limits. Web site www.stampingjournal.com
stamping floor 4. Think about what happens to hole position after the metal Statement of Policy
The STAMPING Journal’s objective is to disseminate new and
personnel just undergoes forming. complete information relating to the metal stamping industry. The
Callout 5. Just because a radius can be drawn in a program doesn’t mean main editorial text consists of articles and news releases designed to
assist owners, managers, manufacturing engineers, supervisors and
don’t speak the it can be formed on a part. foremen in the evaluation of new methods and techniques. It is an
official publication of the Fabricators & Manufacturers Association,
6. Understand the relationship between hole size and material International. The policy of the publisher and this journal is to be
nonpartisan, favoring no one product or company. The representa-
same language thickness. tions of facts and opinions expressed in the articles are those of the
author and are not necessarily endorsed by the publisher and this
7. Involve shop floor personnel upfront in your design process journal. By including information on new products, new literature,
or think the to ensure that what you envision can be accomplished.

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 acknowl-
Design engineers have no shortages of frustration either.
same way.
edge that on occasion there may be oversights or errors; the editors
regret such oversights and re-emphasize their policy to be impartial
7 Pleas From Designers to Production: at all times. The Publisher reserves the right to refuse advertising
it deems inappropriate for publication in STAMPING Journal®,
1. Try. including ads for classes of products and services not considered of
significant interest to the readership. (ISSN 1091-2460) STAMPING
2. Try again. Journal is a trademark of FMA Communications Inc. All rights
reserved. Publications of FMA Communications Inc., maintain a
3. Suggest an alternative. policy of keeping editorial and advertising separate to ensure edito-
rial integrity that most benefits our readership. Editorial content,
4. There are going to be changes. Live with it. including feature articles and press releases, is determined solely
by the publisher. Editorial content cannot be purchased, nor can it
5. It’s not always about speed; it’s about getting good parts. be used as a benefit of advertising dollars spent. Editorial is free-
6. Have you checked the tooling, press, feeder, lubricant, and of-charge, subject to space availability, and open to all interested
parties that submit items meeting our editorial style and format as
material before blaming the design? determined by the publisher. Standard Rate & Data Service lists our
advertising rates in Section 88. Consult SRDS or our current rate
7. Work with me. We’re all in this together.S card for full rates and data.
Note: Some photographs printed in this publication may be taken
with safety equipment removed for photographic purposes. However,
in actual operation, it is recommended that correct safety procedures
and equipment be utilized.
Got thoughts? kateb@thefabricator.com

4 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
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NEWS & Notes
> > E&E adds 1,500-ton press • Dayton acquires Lane Punch • Magna opens in Mexico < <
Atlas Technologies announces engineering after serving the compa- matic storage and retrieval systems,
management changes ny for 17 years as a mechanical and conventional and robotic stacking
applications engineer. and destacking systems, and in-press
Atlas Technologies Inc., Fenton, Robert Stonier has rejoined the transfer systems.
Mich., has changed its management company as project manager for a
structure. large order recently obtained for
William Rogner has returned to a tandem press automation line. E&E Mfg. expands
the company as the interim general Charles Rheingans has returned to stamping capacity
manager, joining veteran manag- the company to serve as regional
ers Randy Austin, vice president of sales manager to China and to man- E&E Mfg. of Tennessee LLC has
applications, and Louis Weigele, age stateside projects. Lesa Jemison announced plans to add a 1,500-ton
human resources and purchasing returned as the director of marketing metal stamping press to its plant in
manager. and e-commerce. Athens, Tenn. The press will be used
Kim Nation has been promoted Atlas Technologies offers turnkey to produce stampings and welded
to controller after serving the com- stamping and fabricating systems, products.
pany as assistant controller for eight heavy plate and bar steel process- The company reports that it will
years. Brenda Crampton has been ing equipment, robotic integration, invest $6 million in this capacity
promoted to director of mechanical quick die change equipment, auto- expansion.


NEWS & NOTES
Coe Press Equipment ships Magna to open new stamping Cosma Intl., will employ 700 peo-
press feed line to John Deere plant in Mexico ple, according to the manufacturer.
The new location will provide
Coe Press Equip- Auto supplier Magna has announced stamped and welded assemblies to
ment, Sterling plans to open a new stamping plant automakers worldwide.
Heights, Mich., in San Luis Potosi, Mexico. The Source: www.autoevolution.com
has shipped a 300,000-sq.-ft. facility, a division of
new feeding line
to John Deere
Horicon Works
in Wisconsin for the manufacture of
lawn and garden tractors and lawn
mowers. The new coil feed line can
handle coil widths up to 18 in. and
coil weights to 10,000 lbs. It can
process steel up to 0.250 in. thick
by 8 in. wide at 50,000-PSI yield
strength, attaining roll speeds of 80
FPM.
The line features a ServoMaster
series 4-in.-dia. roll feed with motor-
ized passline height adjustment and
end-of-stock electric-eye shutoff; an
adjustable threading table; and a
350 series power straightener with
15-HP, AC digital control, variable-
speed drive, and an automatic lubri-
cation system.
Dayton Progress Corp.

acquires Lane Punch
business, assets
Dayton Progress Corp., Dayton,

Ohio, has acquired the business and
assets of Lane Punch Corp., a manu-
facturer of metal stamping tools with
locations in Michigan and North
Carolina. Dayton Progress will trans-
fer all production from the two Lane
plants to Dayton Progress factories
in Ohio, Canada, Mexico, Europe,
and Asia, nearer to the customers of
Lane.
Dayton Progress is a manufacturer
of tools and accessories for the metal
stamping and metal forming indus-
tries, with 10 factories in North
America, Europe, and Asia.

PRODUCT INNOVATIONS
Servo-electric-drive
presses perform variety of sheet metal operations Software integrates flat-
pattern development into
Amada offers the the energy accumulated during SolidWorks
multifunctional deceleration and reuses this when
SDE press, which it accelerates again. It is neces-
the company sary to supply power only when
reports can replace the machine is being used for
several dedicated production.
presses for stamp- Setup and adjustment informa-
ing, drawing, and tion can be called up at the touch
forming. of a button. The program setting for
The machine the current tool is performed inter-
employs a servo- actively in five different modes, and
electric drive, the controller can save up to 399
eliminating the programs or tools. It is possible to Forming Technologies Inc. has
need for hydrau- program stops at any point in the released BlankWorks v4.3 soft-
lic system main- stroke curve and reverse the stroke ware, which provides SolidWorks®
tenance and sev- at these points if required. 2011 users with an integrated tool
eral mechanical Amada America Inc., 7025 Fire- for developing optimal flat patterns
components, such as the flywheel stone Blvd., Buena Park, CA 90621, from complex, 3-D designs.
and belt drive. The system stores 714-739-2111, www.amada.com In progressive-die design appli-
cations, users can develop flanges
and blank shapes for stampings in
less than a minute, according to the
developer.
New features include flange/blank
synchronization with SolidWorks
geometry, blank edge smoothing to
generate tangent continuous arc, and
line geometry to enhance the trans-
lation to the manufacturing process.
The software also provides a con-
tour plot indicating the thicken-
ing and thinning resulting from the
forming process. It accounts for
material stretch and deformation as
well as bending and can flatten any
SolidWorks geometry. This tool can
also be used to assess the feasibility
of a part for manufacturing.
Forming Technologies Inc., 3370
S. Service Road, Burlington, ON,
Canada L7N 3M6, 905-340-3370,
sales@forming.com, www.forming.
com

STAMPING SOLUTIONS
Servo press increases output for

windshield wiper component-maker
Situation program different feed lengths. phase and fast resolution of malfunc-
Like many automotive parts sup- The coil line offers an integrated tions.
pliers, Belgian company Penne has control architecture and visualiza- Schuler Inc., 7145 Commerce Blvd.,
seen its industry become increasingly tion system for all components. For Canton, MI 48187, 734-207-7200,
competitive. Penne, this means a simplified tryout www.schulerinc.com
Remaining suc-
cessful and via-
ble in this chal-
lenging market
means reducing
process costs
while at the
same time meet-
ing increased
quality require-
ments.
When the
company needed to produce compo-
nents for its next generation of wind-
shield wipers, it looked into servo
technology.
Resolution
Penne purchased a servo press with
a coil line and roll feed from Schuler
Automation. The PSE2-315 blanking
and forming press, specifically devel-
oped for flexible use in part supply
companies, delivers 100 SPM and a
press force of 350 tons. Its bed mea-
sures 120 by 50 in.
Penne’s output on the servo press
is higher than on conventional
mechanical presses. In addition, the
ability to program the slide speed and
movement individually helps ensure
long die service life and optimum
part quality. These are key factors in
the production of delicate yet highly
stressed windshield wiper parts.
The one-sided fanning and decoil-
ing unit is designed for coil weighing
up to 6 tons, with external diameters
of 30 to 70 in. and widths of 12 to
30 in. The system also includes a lift-
ing platform, a straightening machine
with six rollers, a threading aid, and a
coil loop bridge. The roll feed’s perfo-
ration control unit enables Penne to Enter reader service code 100734 at www.ffid.net

DIE SCIENCE
Attempting to defy the etry (see Figure 1).

When the pad is fully engaged, the
laws of physics, Part II pierce holes get put in the part in the
desired location. However, once the
pad is removed, the part will return
Unrealistic part features to the original shape that came out
By Art Hedrick of the forming die, and position of
the pierced holes will move with the
Editor’s Note: This is Part II of a two-part article apart in the part. However, this is surfaces of the part.
on part tolerancing. Part I, which appeared in the not true, especially if the parts have So why not fit the punch and the
March/April 2011 issue, discussed the effects of shape to them. pad to the part that is coming out of
variations in the incoming metal and the impor- Remember, the incoming mate- the forming die? While this is some-
tance of consistent strain levels. rial is not perfectly consistent. This times attempted, the inconsistency
inconsistency in material, as well of the formed part makes it hard
I
t is almost unrealistic to expect as other factors, results in different to determine just what the shape
some part features to remain with- springback values for each part. should be.
in a small tolerancing zone. In a nutshell, each part made has Basically, when you specify a tight
a slightly different shape. While this positional tolerance on two holes
Hole Position difference might be well within the distanced far apart on a formed part,
Hole position tolerance is a big one. form or profile of the part’s surface you are asking for the same tolerance
In fact, I am very confident that as I tolerance, keep in mind that as a on the shape of the part. Good luck
am writing this article, within a 500- rule, positional tolerances of features with that one!
Flatness
Specifying a flatness tolerance of 0.002 Of all the geometric tolerances that
in. total indicator reading (TIR) over the are difficult to achieve, flatness is
one of the hardest. Many people
surface of a 0.010-in.-thick stainless steel believe that dies are responsible for
part flatness. While dies sometimes
part that is 2 by 4 in. is insanity. can improve or diminish the flatness
of a part, their main purpose is to
mile radius at least 500 QC inspec- such as pierced holes typically are retain a given flatness in the incom-
tors are complaining about the dies held to much tighter tolerances. ing material.
being unable to hold a certain posi- For the holes to be pierced in the Part flatness is more a product of
tional tolerance on the pierced holes. part, the part must nest or fit onto a the coil straightener and tension lev-
To understand why it is sometimes punch that matches the profile or the eler, and it is affected by the severity
very difficult to achieve and main- shape of the part. This punch usually of the steel cutting deformation, the
tain certain positional tolerances, is cut to the exact profile or shape sheet material’s mechanical proper-
you need to understand the entire of the designed part. Even though ties, incoming material or coil flat-
process and all of its variables. One the punch is cut very accurately, it’s ness, metal thickness, and residual
of the least-understood concepts is unlikely the part will fit perfectly stress created in prior operations.
the catalyst for this question: If all of onto the punch—and every part will For example, specifying a flatness
the holes that have a small tolerance fit differently on the punch. tolerance of 0.002 in. total indica-
are pierced in the part in a single A spring- or nitrogen-loaded pres- tor reading (TIR) over the surface of
operation, why don’t they maintain sure pad, cut to fit the designed a 0.010-in.-thick stainless steel part
the same positional relationship with shape of the part, is used to hold the that is 2 by 4 in. is insanity. Keep in
each other? part tightly to the punch. When this mind that the coil this part is made
For those who don’t understand pad contacts the part, it forces the from is wound over a mandrel and
the variables, it would seem logical part to take the ideal shape by push- contains coil set. The amount of
that two holes exactly 200 mm apart ing, twisting, and bending part sur- coil set changes with respect to how
in the die would measure 200 mm faces back to their intended geom- tightly the coil is wound. To remove

DIE SCIENCE
the coil set, the material must be

strained using a tension leveler and
straightener.
To achieve a critical flatness char-
acteristic, most die designers try to
keep the part flat during cutting and
also employ methods such as pres-
sure blanking, compound blanking,
cut-and-carry, fineblanking, and
GRIP®flow.
Achieving certain tolerances can
be very difficult. Only through a
comprehensive understanding of the
stamping process can you dimension
and tolerance your parts accurately.
Until next time … Best of luck!S
Art Hedrick is president and senior consultant of

Figure 1
Dieology, 8730 10 Mile Road S.E., Rockford, MI
When the pressure pad contacts the part, it forces the part to take the ideal shape. 49341, 616-894-6855, dieology@pathwaynet.
com, www.dieology.com.

R&D UPDATE
Determining the flow the flow stress curve gives the value
of Y.
stress curve with •Ultimate tensile
(UTS) is the maximum engineering
strength
yield and ultimate tensile stress in a tensile test and signifies the
end of uniform elongation and the
strengths, start of localized necking.

•Elastic modulus (E) (also
known as Young’s modulus) is the
Part I slope of the elastic part of an engi-
neering stress-strain curve.
Important data from the tensile test •e0 is the elongation at Y.
•Uniform elongation, eu, is the
By Nimet Kardes Sever, Changhyok Choi, Xi Yang, and Taylan Altan
elongation at the maximum load.
•Total elongation, et (also known
Editor’s Note: Part II of this article will appear in specimen as elongation at break), is the elonga-
the July/August 2011 issue. A0 = original cross-sectional area of tion of the original gauge length of a
the specimen tensile specimen at fracture, includ-
M
aterial suppliers often pro- l0 = original gauge length ing both uniform (eu) and postuni-
vide the yield stress and Δl = elongation of l0 during the test form elongations.
ultimate tensile strength for The F versus Δl data is used to •Area reduction, Ar, is the per-
sheet materials. They don’t, however, obtain the engineering stress-strain centage of reduction in the area,
always provide the true stress-true curve (see Figure 2), which helps calculated by cross-sectional area at
strain (flow stress) curve. This curve determine several basic mechanical fracture, Af, and initial cross-sectional
is one of the most important vari- material properties: area, A0:
ables for calculating input data for •Yield stress (Y) indicates the A0 − Af
the finite element (FE) and analytical start of plastic deformation. Y is Ar= × 100% (Eq. 3)
A0
methods used to predict metal flow determined approximately by draw-
and defects. ing a parallel line to the linear elastic The total elongation, et, at fracture
The flow stress curve, which region of the flow stress curve from and the total area of reduction at frac-
reflects the sheet material’s elastic 0.2 percent engineering strain. The ture, Ar, are considered to be indica-
and plastic properties, typically is intersection of this parallel line with tions of material ductility. However,
obtained from a tensile test or bulge
test.1 In a tensile test, a standard-
size specimen is cut out from the
sheet metal and pulled slowly until it
breaks. An extensometer is attached
to the specimen to measure the elon- Fracture
gation over an original gauge length,
l0. Throughout the test, the load
Force (F)
applied and the elongation of gauge Uniform

length are recorded in real time (see Plastic
Figure 1). Deformation
The engineering stress, σe, and the Nonuniform
engineering strain, e, are calculated Plastic
Uniform Elongation, lU Deformation
as:
Total Elongation at Fracture, lF
F ∆l
σe= A (Eq. 1) e = l (Eq. 2)
0 0
Elongation (∆l)
where: Figure 1
F = tensile force applied to the
The force-elongation curve is obtained from a tensile test.

R&D UPDATE
Elastic Plastic
P2
Stress
the uniform elongation, eu, better represents the material’s UTS
Y
ductility or formability in uniaxial deformation, because P1 Fracture
Y
after necking (when uniform elongation is exhausted),
the material can be considered to have failed.
Offset tan-1 E
The stress and strain definitions in Equations 1 and 2 O eo eu et Strain (for lo = 1)
are based on the original cross-sectional area of the ten- lo l
sile specimen, so they are known as engineering stress
Ao
and strain. True normal stress, σ, is based on the instan- le
taneous cross-sectional area, Ai:
Uniform Elongation
F lu
σ= (Eq. 4)
Ai Neck
True stress values are more accurate measures of stress Postuniform Elongation
Total Elongation
than engineering values for large deformations.2 True lt
stress can be calculated as:
Af
F F Ao A l
σ= = = σe o = σe i = σe (1 + e) (Eq. 5)
Figure 2
Ai Ai Ao Ai lo
Similarly, true strain calculation considers the instanta- The engineering stress-strain curve helps determine several
neous gauge length of the specimen, li = Δl + l0, instead of basic mechanical material properties.2
the initial length, l0: b′ σe vs. ε
ε = ln (1 + e)
dl yields l σ = σe (1 + e)
dε = → ε = ln = ln (1 + e) (Eq. 6) a′
l lo
Stress
a b
A flow stress curve does not reach a maximum, as σe vs. e
an engineering stress-strain curve does (see Figure 3),
because by definition it can be drawn up to the strain
value corresponding to the start of necking. For instance,
Equations 5 and 6 are valid in the range of uniform elon-
gation, eu.
Figure 4 shows the flow stress curves for a draw-
quality steel (AKDQ), an aluminum alloy (Al 5754), Strain
and a high-strength steel (DP600). Force and elongation Figure 3
are the measured values (Figure 1), while the engineer-
ing stress-strain curves (Figure 2) and flow stress curves A flow stress curve does not reach a maximum, as an engi-
(Figure 3) are calculated using the previous equations.S neering stress-strain curve does, because by definition it can
be drawn up to the strain value corresponding to the start of
Nimet Kardes Sever and Xi Yang are graduate research associates, Dr. Chan- necking.
3
ghyok Choi is postdoctoral researcher, and Taylan Altan is professor and 140
director of the Center for Precision Forming (CPF), The Ohio State Univer- 120 DP600 − t = 0.0236
True Stress (KSI)
sity, 339 Baker Systems, 1971 Neil Ave., Columbus, OH 43210-1271, 614- 100
292-9267, www.cpforming.org. 80
60 AKDQ Steel − t = 0.0327
Notes 40 AI5754-O − t = 0.052
1. G. Ngaile and T. Altan, “Determining the flow stress curve for sheet 20
materials: Capabilities of the viscous pressure bulge test,” STAMPING Jour- 0
nal®, November/December 2000, p. 32. 0 0.05 0.1 0.15 0.2 0.25
True Strain (in./in.)
2. S. Kalpakjian and S. Schmid, Manufacturing Processes for Engineer-
ing Materials, 5th ed. (Upper Saddle River, N.J.: Pearson Education, 2008). Figure 4
3. W.F. Hosford and R.M. Caddell, Metal Forming: Mechanics and
Shown here are the flow stress curves for a draw-quality steel
Metallurgy, 3rd ed. (Cambridge, U.K.: Cambridge University Press, 2007).
(AKDQ), an aluminum alloy (Al5754), and a high-strength steel
(DP600).
4
steps
By Benjamin Pauzus Jr.
G
iven today’s focus on produc-
to press
tivity and competitive pricing,
it’s no surprise that the goal of
stamping operations is to achieve the
highest net yields at the lowest cost.
transfer
More good parts out the door trans-
lates into more profit. And given that
press lines are at the front of most
efficiency
other assembly operations, a lag in
the pressroom can drag the rest of
the operation downhill.
No company can afford to have
Paying attention to tooling selection pays off expensive press line equipment run-
ning at less than its peak produc-
tion rate. Ironically, the automation’s
part-holding tooling—a fraction of
the total press line cost—often is the
reason that stamping operations do
not run at full potential.
Taking the correct approach to
tooling up the automation on a press
line can make all the difference.
1. Get Your Supplier
Involved
First and most important, involve
your tooling and automation sup-
plier early in the process—during
die design. At this stage the sup-
plier can provide useful and neces-
sary insight, so that obstacles and
opportunities can be realized before
implementation.
Involving your automation equip-
ment supplier at this point will
greatly reduce the amount of time it
takes to launch production and can
cut costs substantially.
2. Simulate the Process

It really pays to simulate the proc-
esses virtually. This is particularly
true for triaxis transfer press lines,
in which press speed must be opti-
mized for multiple motion paths,
without any interferences. Typically,
you propose the process and provide
Because of the sweeping trajectories in triaxis transfer press part handling, the the supplier with the part data. The
workpiece typically must be secured with pneumatic grippers and shovels rather than die designer is responsible for devel-
suction cups.

required to hold the sheet metal.
Larger tooling can get heavy and
cause a vibration or harmonics issue,
interfering with the robot’s ability
to settle quickly and accurately into
position.
Carbon fiber (Cf) frame compo-
nents can help to prevent vibration
(see Figure 2). A Cf frame can weigh
up to 50 percent less than alumi-
num while exhibiting less deflection.
It also enables faster motion paths
and quicker settling of the robot. In
some cases, stampers have achieved
Figure 1
productivity increases of up to 20
Simulating the press handling operations in the virtual world helps to eliminate percent after equipping robots with
potential collisions and optimize the motion path for increased productivity. Cf booms.
4. Select the Most Suitable
oping the die around those curves. work as light as possible, yet durable End-of-arm Tooling
With simulation software, you can enough for the application at hand. Your choice of end-of-arm tooling
determine the production rate of any Triaxis press tooling framework will be influenced by the press oper-
line by proposing the best trajectory typically is made of steel, while tan- ation; the trajectory and weight lim-
for the operation (see Figure 1). You dem lines often employ aluminum its of the automation best determine
also can identify potential collisions extrusions for the framework. The how to secure the workpiece.
in the virtual world, eliminating aluminum provides long life, low Vacuum Cups. For tandem press
retooling or reprogramming late in maintenance, and repeatability of operations, which typically involve
the production cycle. the robot motion. However, as part an up-and-down motion or a back-
Uncovering potential collisions size increases, so does the amount and-forth motion, suction cups are a
with a die in a stamping press before of tooling, as more suction cups are good choice, as it is easy to create a
production starts allows the diemak-
er to modify the design before pro-
duction, saving hours of work (and
downtime) later to mill the die down
to size.
3. Choose the Right
Tooling Framework
Material
The next decision you’ll need to
make involves the tooling frame-
work. Components such as brackets,
clamps, and connectors are attached
to this framework to secure the suc-
tion cups, grippers, shovels, and
magnets that are used to handle
workpieces.
The material for the tool frame is
Figure 2
an important consideration. With a
focus on press strokes per minute, Press operations can benefit from carbon fiber booms, which reduce the frame
the goal is to make the tool frame- weight up to 50 percent compared to steel and aluminum tubing.

vacuum to hold the part (see Figure and-down motions, such as destack- to the center. This provides more
3). The cups come in several shapes, ers. With sweeping approaches to support and prevents the vacuum
cleat designs, and materials. the part it is better to use a flat-style from drawing or dimpling the panel.
Bell-shaped cups typically can’t be cup, which can work with flat parts For thinner panels, the cleat design
used for applications that involve a that are smooth or slightly textured. should be more evenly distributed
trajectory that dives into the part, For thicker sheet metals, choose across the whole surface of the cup,
but they are suitable for straight up- a cup with a cleated pattern close dispersing the suction equally to pre-
vent unusual gripping or dimpling.
Bellows cups are flexible and so
can accommodate uneven and mod-
erately contoured parts while hold-
ing during acceleration and decel-
eration. They are suitable for light oil
Demonstrating Precision Parallelism Control and duty. Traction cups are less flexi-
bile on uneven or contoured parts,
and Sheet Hydroforming at IMTS and FABTECH but secure the part better during
acceleration and deceleration. They
are suitable for destackers and feed-
Active Leveling Control ers systems. Flatfoot cups have the
best shear holding force during part
acceleration and deceleration. They
can be used on Class A surfaces that
are oily or sensitive to dimpling.
The goal is to use the minimum
number of cups per operation. Cups
typically are spaced 9 to 12 inches
apart for material handling in blank-
ing operations. Use this formula to
calculate how much vacuum you
will need to lift the panel:
Lifting capacity = 0.4912 × C × P
F(4)
Triform Sheet Hydroforming where:
C = area of vacuum pad surface (in
square inches)
P = amount of vacuum (in inches
of mercury)
F = safety factor
Grippers and Shovels. Triaxis
transfer presses typically employ
multiaxis transfer systems, which
often use a sweeping motion to
approach the part and secure it for
material handling. In addition, the
shapes and sizes of parts in these
applications usually do not lend
“The Perfect Press For You” themselves well to vacuum cups. For
these applications, part grippers are
www.beckwoodpress.com most suitable.
St. Louis, MO, USA| 800-737-0111 In some transfer press situations,
info@beckwoodpress.com the part can be moved at an optimum

they are limited in use to sheet metal
components that have some stability.
Typically, the first operation on any
transfer press line requires grippers
because the part is flexible and weak.
That first stamping operation gives the
Your Quality Tempered Source
part some shape and stability, allowing
the use of shovels or a combination of The Shortest Lead time in the
shovels and grippers. Metal Industry
Your automation supplier’s respon-
sibility is to help you get the press In House Tempering/Rolling:
Figure 3 line optimized through the imple- • 1/8 Hard • 1/4 Hard
mentation of the right tooling and • 1/2 Hard • 3/4 Hard
This vacuum cup has a cleat-type tread components. Working with your • Full Hard • Extra Full Hard
design that offers high absorption of
transverse forces and helps to disperse oils
supplier early in the process to make In House Quality Laboratory
the most suitable choices for your
from the sheet metal surface to enhance the
application.S
ISO Certified
gripping capability.
Ben Pauzus is general manager of Bilsing Automa-
rate of speed using shovels instead of tion North America, 22287 Starks Drive, Clinton
grippers. Shovels cost less and require Township, MI 48036, 586-463-0686, www.bilsing-
less maintenance than grippers, but automation.com.
Locations:
Sterling Heights, MI
800-334-7509 • Fax: 586-731-0729
tctmi@tctstainless.com
Lebanon, TN
800-877-8366 • Fax: 615-449-6079
tcttn@tctstainless.com
Dallas, TX
877-472-2422 • Fax: 214-348-1092
Enter reader service code 504648 at www.ffid.net bgreen@tctstainless.com
an fma publication • STAMPING JOURNAL Enter reader service code 507212 at www.ffid.net 17
Making sense of
are smaller, faster, and higher-per-
forming, but that help solve previ-
ously unsolvable problems.
Common Sensor Styles
industrial sensors
Advancements continue to be made
in discrete sensing devices, vision
sensors, and advanced motion prod-
ucts. For example, industrial Ether-
net systems provide cost-effective
How these common devices can make a big impact

communication options that still
allow for deterministic response
times.
Sensor manufacturers are incorpo-
rating many new technologies such
as Ethernet, radar technology, wire-
less communications, and lasers into
their devices. A number of object-
detection and proximitylike sensors
are being used in industry to address
common problems.
movement sensors. Detecting
motion, or lack of it, is not new;
however, a new class of device pro-
vides a contact-free, wear-free detec-
tion method for simple motion and
feed applications.
Movement sensors, or noncontact
motion sensors, use a laser to detect
whether an object placed in the sen-
sor’s field of view is moving. For feed
applications, this means that mate-
rial can be measured at any position
along the process without contact.
These self-contained laser devices
are virtually material-independent
and immune to debris and contami-
Sensors are not all the same, and sensor manufacturers’ continuous investment and
ingenuity have resulted in new devices that not only are smaller, faster, and higher-
nants. Advanced versions can incor-
performing, but that help solve previously unsolvable problems. porate a pixel-style camera to include
direction outputs or incremental out-
puts for speed, distance, and velocity.
By matthew scott spread, the technical personnel angle sensors. Also known
and managers who take the time to as L-shaped photoelectric sensors,
W
ho cares about industrial sen- understand today’s industrial sensors angle sensors typically are available
sors? They are the proverbial can advance their companies’ capa- with visible red light, infrared, or
“commodity products” in the bilities while generating extraordi- laser optics. They come in a number
factory automation and machine- nary value for their organizations. of shapes, sizes, and configurations
building industries. Worse yet, they Sensors are not all the same, and to operate at a safe distance from
are boring, simple, and all the same. sensor manufacturers’ continuous any material or stamping activity (see
Right? investment and ingenuity have Figure 1).
While these perceptions are wide- resulted in new devices that not only Versions with high-powered optics
18 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STaMPInG JOuRnaL • an fma publication

and contamination-detection fea- area where parts need to be detected
tures can work in the presence of or counted, it will register a part’s
heavy contamination such as metal initial contact and ignore subsequent
shavings and grease. A flashing LED contact with the same part, result-
indicates when the device is seeing ing in accurate counting. The fully
significant debris. Infrared versions enclosed devices on the market today
are especially tolerant of environ- can handle up to 100 parts per sec-
ments with heavy pollution, dust, or ond. Timing and operation typically
debris.
Angle sensors can operate for
years without adjustment or While contact sensors aren’t Figure 2
replacement.
Contact SA new class of necessarily new for part Contact sensors can detect vibration
sensor provides an alternative meth-
od for part counting, part ejection, counting, this technology also patterns to identify machine wear and
tear, bearing problems, and empty
and even vibration-related applica- parts bins.
tions. These ultracompact sensors
can detect vibration patterns.
are based on piezoelectricity that ing through dirt and heavy coolant.
detects when any contact is made can be adjusted on the devices using For the feed application, the die
with the sensor, including impulses. potentiometers or self-teach buttons. incorporates a noncontact movement
In essence, these devices know when While contact sensors aren’t nec- sensor with a small beam spot to pro-
something “hits” them, and they reg- essarily new for part counting, this vide accurate sensing away from the
ister that hit by measuring frequency technology also can detect vibration target. The movement sensor works
and amplitude. patterns. The sensor can be tuned to across all desired materials, regard-
When the sensor is mounted in an operate normally at a standard oper- less of the reflectivity.
ating frequency so that when the fre- Ultra’s die also employs a con-
quency increases, the sensor triggers tact and vibration sensor to sense a
its output (see Figure 2). This meth- change in the vibration of the tooling
od can be used to detect machine itself. Configured to a low vibration
wear and tear, bearing problems, and pattern, the sensor can detect pos-
even an empty parts bin or hopper. sible mechanical failures early on to
help prevent catastrophic die crash-
Sensors in the Transfer Die: es. The company also can use vibra-
Case Example tion sensing to generate a preventive
Ultra Tool & Manufacturing, maintenance schedule based on real-
Menomonee Falls, Wis., makes tool- world equipment operation.
ing and automation products. Its lat- Many traditional and emerging-
est transfer system reduces material technology sensors are available
usage, driving down piece-part costs to help stamping companies solve
and streamlining the overall stamp- their application challenges. Stay-
ing process. The transfer die incorpo- ing knowledgeable about these
rates 28 proximity sensors to protect devices is key for stampers to ensure
and monitor the press. They provide their equipment, systems, and
the repeatability that the company businesses remain innovative and
needs to guarantee operation with competitive.S
minimal hysteresis.
Figure 1
The transfer die also incorporates a Matthew Scott, PE, CMA, MBA, is director of
Angle sensors come in a number of laser angle sensor that provides non- operations and strategic development with TR
shapes, sizes, and configurations to contact detection of rotating targets. Electronic North America, 200 E. Big Beaver
operate at a safe distance from any This high-powered sensor can oper- Road, Troy, MI 48083, 800-709-3300, mscott@
material or stamping activity. ate in extreme environments, shoot- trelectronic.com, www.trelectronic.com.

Automated
material
handling
Q&A
More control allows
more flexibility
Editor’s Note: This question-and-answer article Figure 1

probes new automation technology with Enrique
Robots may be equipped with an interface between the robot and operator, such as
Pano, ABB Robotics press automation manager.
ABB’s StampWare, that has a teach pendant and a color touchscreen that interacts
Q
with the robot to simplify the programming of new parts and paths.
: what automated mate-
rial handling challenges do accessed. Using today’s technology, tromechanical position switches to
stampers currently face? stampers can be more aware of what increase control and flexibility and
a: Stampers have always been is happening on the line in terms of reduce maintenance. All of a robot’s
pressured to improve material han- uptime, cycle time, bottlenecks, and axes can be supervised through this
dling while reducing costs to stay so forth. This makes it easier to opti- software and can be used to define
competitive—with safety always at mize production and reduce down- complex working envelopes for a
the forefront. time. robot.
What has changed is the business Q: what is new? New control software sets speed
environment. There is more uncer- a: Key factors for robots used in at a defined pace so that an operator
tainty. Design changes are happening press automation are torque and can work within the proximity of the
faster, and every player has to be pre- acceleration. Current-generation robot. It supervises the speed of all
pared for them. robots include enhanced motion robot parts, including the tool-center
Because of this, cost-effective control to improve path accuracy point and individual axes.
systems and shorter paybacks are and shorten cycle times. New soft- New software provides a simpli-
required to justify an investment. ware- and electronics-based safety fied interface between the robot and
Other factors like flexibility, ease of features are available to ensure safe operator (see Figure 1). A robot
use, and energy efficiency are equally and predictable robot motion with- teach pendant is equipped with a
important. in a flexible operation and replaces color touchscreen that interacts with
Q: How is current-generation electromechanical position switches. the robot graphically to simplify
equipment addressing these chal- For example, recent proprietary the programming of new parts and
lenges? software can define a detailed 3-D paths. This way an operator doesn’t
a: Robotic automation can pro- work zone to optimize cell size and have to be a programming expert,
vide more flexibility than hard (non- simplify safeguarding to protect both which can reduce the cost of training
robotic) automation. operators and machinery. It restricts and programming time.
New press lines use a network to robotic motion to either inside or Another new development is
facilitate communication between outside of a defined zone. It also a flexible crossbar, installed at
the automation equipment and the restricts tool orientation. the robot’s wrist to provide addi-
presses. More information is being The new software replaces elec- tional linear motion for the part
20 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STaMPInG JOuRnaL • an fma publication

as it moves from press to press or
between any other two points, such
as in destacking (see Figure 2). The
device’s servomotor is controlled
by the robot controller as an addi-
tional axis, which allows full motion
control.
Moving parts linearly (without
a 180-degree rotation of the dies)
offers the potential to condense
lines, as well as to accelerate cycle
times. Automatic tool changes can
be installed the same way as with
standard six-axis robots.
Q: what are some current criti-
cal developments you’re seeing?
a: A new technology that Figure 2
improves cycle time and part quality
A flexible crossbar can be installed at the robot’s wrist to provide additional linear
is the installation of a servomotor on motion of the part as it moves from press to press or between any other two points,
mechanical presses (new or retrofit). such as in destacking applications. The device’s servomotor is controlled by the
The idea is to have the servomotor robot controller as an additional axis, which allows full motion control.
an fma publication • STaMPInG JOuRnaL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 21

control and speed the slide motion but use the energy of
the existing flywheel, engaging the clutch at synchronized
speed just before the press draws the part. The benefits of
this hybrid working mode are increased productivity (better
cycle time); improved synchronization between presses and
automation; improved quality (pressing at lower speed with
same productivity); reduced maintenance (brake is not used,
synchronized clutching, smooth press start and stop); and
reduced peak power and energy consumption (no changes
in installation).
Throughput requirements are always increasing. At the
same time, stampers need highly flexible systems that enable
them to change over production quickly with minimal labor.
Vision systems are becoming more widely used for part cen-
tering, inspection, and quality control. These systems gener-
ally are highly flexible.
The market for robotic automation has grown in the past
five years. Stampers are increasingly looking to a single
source to integrate concept development, system engineer-
ing, project execution, physical installation, start-up, and
production support. Also, having one responsible supplier
reduces project risk and complexity.S
Enrique Pano is press automation manager, ABB Inc., 201 Westcreek Blvd.,
Brampton, ON, Canada L6T 5S6. 905-460-3347, enrique.pano@ca.abb.com,
www.abb.com/robotics.

Enter reader service code
145521 at www.ffid.net
AUTOMOTIVE INTELLIGENCE
Lower-tier suppliers and the This conversation yielded another

critical perspective: This supplier,
automotive recovery because it is doing well financially,
had entertained four visits from
banks offering loans in the two
Bottleneck ahead? weeks before the interview. Despite
reports to the contrary, ample credit
By Bernard Swiecki appears to be available to lower-tier
suppliers—but it’s available only
A
s the automotive sales and though many industry observers are for the firms that need it least. This
production recovery con- pleasantly surprised that fewer sup- discrepancy threatens the suppliers
tinues, concerns are being pliers disappeared than they had who currently may not be doing well
raised within the industry about the expected, the problem is not just in financially but would be saved by
risk of production disruptions caused the number of firms—it’s also that increased production orders if they
by lower-tier suppliers’ inability to the surviving firms are smaller and could only get the loans necessary to
fulfill more orders from their custom- their capability to add capacity has fulfill them.
ers. At the moment only a few pro- been reduced. These “on-the-bubble” firms face
duction interruptions have cascaded an even greater risk: During con-
versations with Tier 1 purchasing
executives, several expressed concern
In trying to prevent production about new business gradually con-
solidating among the healthiest low-
disruptions, the industry may create er-tier suppliers, which would bring
down many of the less healthy firms.
a new way of causing them. It’s a scenario rich in irony. Out of
fear of production disruptions, OEMs
and Tier 1 suppliers prefer sourcing
more business from lower-tier sup-
from the lower tiers to automaker In Suppliers’ Own Words pliers with healthier balance sheets.
assembly plants, but as sales and The Center for Automotive Research The remaining, less healthy suppli-
production forecasts become increas- (CAR) recently has been interviewing ers still hold multiple contracts and
ingly optimistic, the apprehension executives from Tier 1 suppliers, as have the capacity to disrupt multiple
has been rising. well as some from lower tiers, about supply chains if they fail as a result
In 2010, 11.6 million vehicles were these issues. The feedback has been of these changes. In trying to prevent
sold in the U.S. Such volumes are so remarkably revealing. production disruptions, the indus-
far below the 16 and 17 million unit One CEO of a lower-tier supplier try may create a new way of causing
levels seen as recently as 2007 that it put it succinctly: In his opinion, if an them.
seems suppliers should have no trou- OEM experiences a production dis-
ble meeting the parts requirements of ruption as a result of a lower-tier sup- Increasing Sophistication
today’s smaller market. After all, even plier being unable to satisfy an order, in Supplier Relations
when the industry was selling 17 mil- it is most likely the OEM’s fault. His The good news, however, is that
lion units annually, it was suffering logic is that if the OEM were offering purchasing departments at OEMs
from an immense overcapacity prob- a reasonable price and terms on the and Tier 1 suppliers are increasingly
lem that prevented many of its stake- contract, suppliers would be willing savvy and aware of these risks.
holders from being profitable even to add capacity, and just as impor- Across the board, purchasing
amidst booming sales. Current sales tant, banks would be willing to pro- executives have expressed a renewed
and production levels, therefore, vide the financing necessary to put concern about total lifetime cost and
should not be a problem—right? it in place. In his opinion, no crisis quality, as opposed to simply focusing
It’s not quite that simple, of course. needs to take place if the industry on piece price. They also have stated
The recent economic crisis drove can maintain the proper relationships that purchasing managers are being
many suppliers out of business. Even and business terms. evaluated more on these parameters,

AUTOMOTIVE INTELLIGENCE
as opposed to the price markdowns common. Today many forecasters orders to handle is a relatively rare
that previously motivated them. are mentioning numbers closer to 15 experience.
Suppliers also are incorporating million units this year and a contin- It appears the trick will be bal-
quality and engineering staff in pur- ued rise in the years following. ancing market forces with pricing
chasing teams more frequently. This If there were concerns about low- sanity and getting the banks to play
gives lower-tier suppliers a better er-tier suppliers meeting shipment along. Increasingly, it will take many
opportunity to pitch their product orders in a 12-million-unit market, stakeholders in the industry working
and its total benefits, including qual- alarm bells should be going off when together to achieve such a goal, as
ity and durability, and is another forecasts of 15 million units start opposed to executing a given strategy
means of focusing the decision on appearing. Clearly, it is critical for at a single firm.
factors other than piece price. the automotive industry to solve this For the small suppliers who have
issue if it is to take full advantage of weathered the storm of the last three
The Stakes Are Rising the long-awaited sales recovery it is years, it appears success and prosper-
For the industry as a whole, these finally enjoying. ity are just around the corner—if too
changes cannot come soon enough. much success doesn’t prove as harm-
The industry’s volume recovery is not Looking Ahead ful as its absence did.S
only continuing, but accelerating. Many industry observers describe
Forecasters are routinely increasing this as a good problem to have. Bernard Swiecki is director, market analysis, at
their forecasts for 2011 light-vehicle After all, in an industry that was for the Center for Automotive Research, 1000 Victors
sales. Only a few months ago, predic- decades associated with overcapac- Way, Suite 200, Ann Arbor, MI 48108, 734-929-
TestimonialAd-SJ708R:Layout
tions around 12 million units1were 6/24/08
ity, the2:44 PM of
prospect Page 1 too many
having 0484, bswiecki@cargroup.org, www.cargroup.org.
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2011 Press Feed Buyers’ Guide©
Feed Drive
Mechanical Slide
Motor-driven Slide
Push-Pull (Roll)
Hydraulic Slide
Zig-Zag (Roll)
Max.
Double (Roll)
Single (Roll)
Hitch Slide
Max. Feed Thickness
Pneumatic
DC Servo
AC Servo
Air SliDe
Press Min.-Max. Length at Full
Gripper
Speed Stock Width Range Width
Cam
Model Other (SPM) (Inches) (Inches) (Inches)
ARKU Coil-Systems, Cincinnati, OH Enter code 991833 at www.ffid.net
ServoMaster Series 3 3 3 3 3 350 41.34 0-999 .240
PowerMaster Series 3 3 3 3 3 250 43.31 0-999 .390
PowerMaster 1300 Wide-Strip Feed 3 3 3 3 3 120 3.94-51.18 0-999 .240
CompactFeed 50 Feeder/Straightener 3 3 3 3 3 3 3 3 3 3 3 3 3 3 100 1.18-59.06 0-999 .240
CompactFeed 65 Feeder/Straightener 3 3 3 3 3 3 3 3 3 3 3 3 3 3 100 1.18-59.06 0-999 .310
CompactFeed 80L Feeder/Straightener 3 3 3 3 3 3 3 3 3 3 3 3 3 3 100 1.18-59.06 0-999 .310
CompactFeed 80S Feeder/Straightener 3 3 3 3 3 3 3 3 3 3 3 3 3 3 100 1.18-59.06 0-999 .590
Coe Press Equipment, Sterling Heights, MI Enter code 111347 at www.ffid.net
ServoMaster CPRF-SM1 Series 3 3 3 3 300 1-30 0-999 .156
Heavy Duty CPRF-500 Series 3 3 3 3 150 1-60 0-999 .310
SpaceMaster Compact Coil 3 3 150 1-52 0-999 .187
Line Series 2
SpaceMaster Compact Coil 3 3 150 1-64 0-999 .250
Line Series 3
CoilMate/Dickerman, Clinton, ME Enter code 995664 at www.ffid.net
SMLT Series 3 3 600 1-4 0-999 .062
SMIV Series 3 3 450 1-12 0-999 .125
SMXSE Series 3 3 3 3 3 450 1-36 0-999 .187
ECONO PAL 3 3 450 1-4 0-999 .062
ECONO PAK 3 3 450 1-12 0-999 .062
RC HITCH FEED 3 250 1-2 2 .031
SMLT HS Series 3 3 1,400 1-4 0-999 .032
DDR HS Series 3 450 1-24 4 .090
DDR XH Series 3 800 1-5 2 .065
DDR G Series 3 200 1-24 14 .125
Cooper-Weymouth, Peterson - Member of the Formtek Group, Clinton, ME Enter code 423540 at www.ffid.net
SMXH Series 3 3 3 3 280 12-48 0-999 .250
SMXH6 Series 3 3 3 260 12-60 0-999 .375
SMXH8 Series 3 3 240 12-60 0-999 .500
SMXSE4 Series 3 3 240 12-84 0-999 .375
SMX BSF Series 3 3 180 6-24 0-999 .125
SMX CSF Series 3 3 180 6-30 0-999 .187
SMX DSF Series 3 3 160 30-84 0-999 .156
SMX 3.5SF Series 3 3 140 12-30 0-999 .312
SMX 64 SF Series 3 3 140 12-84 0-999 .375
SMX HD64SF Series 3 3 120 12-84 0-999 .500
The information presented was provided by the manufacturers. For additional information, use the corresponding advertising code at www.ffid.net or the links in
this online buyers’ guide at www.thefabricator.com. ©Copyright 2011 by FMA Communications Inc. Reproduction in full or in part without written permission of
the publisher is prohibited.

2011 Press Feed Buyers’ Guide©
Feed Drive
Mechanical Slide
Motor-driven Slide
Push-Pull (Roll)
Hydraulic Slide
Zig-Zag (Roll)
Max.
Double (Roll)
Single (Roll)
Hitch Slide
Max. Feed Thickness
Pneumatic
DC Servo
AC Servo
Air Slide
Press Min.-Max. Length at Full
Gripper
Speed Stock Width Range Width
Cam
Model Other (SPM) (Inches) (Inches) (Inches)
Linear Transfer Automation, Barrie, ON Canada Enter code 390404 at www.ffid.net
LTS-1000 FR 50 144
LTS-1000 W 80 144
LTS-2000 FR 40 180
LTS-2000 W 40 180
LTS-3000 FR 35 220
LTS-3000 W 35
LTS TITAN W
LTS TITAN FR
LTS Md-Class
Mecon Industries, Toronto, ON Canada Enter code 100151 at www.ffid.net
200F 3 3 3 3 3 300 0-24 0-999 .005-.100
250F 3 3 3 3 3 250 0-36 0-999 .125
325F 3 3 3 3 3 250 0-48 0-999 .020-.150
400F 3 3 3 3 3 300 0-60 0-999 .025-.225
500F 3 3 3 3 3 200 0-84 0-999 .350
600F 3 3 3 3 3 200 0-84 0-999 .500
325 FS 3 3 3 3 3 3 3 120 0-48 0-999 .135
400 FS 2011 Press Feed 3 Buyers’ Guide
3 3 3
©
3 3 3 120 0-84 0-999 .200
500 FS 3 3 3 3 3 3 3 100 0-84 0-999 .320
600 FS 3 3 3 3 3 3 3 100 0-84 0-999 Var.
Perfecto Industries Inc., Piqua, OH Enter code 109635 at www.ffid.net
STCFCU12-72 Cambox Feed 3 400 1-84 1-12 .25
FES300 3 3 3 3 400 1-48 1-999 .090
FES400 3 3 3 3 400 1-48 1-999 .125
FES500 3 3 3 3 400 1-60 1-999 .188
FES600 3 3 3 3 300 1-72 1-999 .25
FES700 3 3 3 3 250 1-72 1-999 .375
Plumb Products LLC, Woodbury, CT Enter code 750652 at www.ffid.net
Pressmate PI-1 3 3 3 3 Chain 250 2.187 1.125 .08
Pressmate PG-2 3 3 3 3 Chain 200 2.187 1.125 .08
Pressmate PC-5 3 3 3 3 Chain 150 5.187 2.500 .08
Pressmate PC-6 3 3 3 3 Chain 150 6.187 3.0 .08
Pressmate PX-7 3 3 3 3 Chain 100 7.187 3.5 .08
Pressmate PX-8 3 3 3 3 Chain 100 8.187 4.0 .08
Pressmate PL-9 3 3 3 3 Chain 75 9.187 4.5 .08
Pressmate PL-10 3 3 3 3 Chain 75 10.187 5.0 .08
Rowe - Member of the Formtek Group, Clinton, ME Enter code 995662 at www.ffid.net
PM-EAC-073 Series 3 3 3 3 3 280 1-50 0-999 .187
PM-DOM3-123 Series 3 3 240 1-50 0-999 .250
PM-EAC-163 Series 3 3 3 3 3 240 1-50 0-999 .275
SFAC4 Series 3 3 140 1-72 0-999 .190
SFAC6 Series 3 3 140 1-72 0-999 .235
SFAC9 Series 3 3 3 120 1-72 0-999 .312
PM-LT3 Series 3 3 3 3 3 3 450 1-36 0-999 .187
DOM3-123 Series 3 3 240 1-84 0-999 .250
DOM3-163 Series 3 3 220 1-84 0-999 .28

PRODUCT NEWS
Modular skid conveyor reduce maintenance. monorail systems or eccentric lift-

The conveyor can respond to ing tables. The shuttle raises, low-
The Eisenmann VarioLoc™ modu- varying plant production through- ers, and transports skids and bodies
lar skid conveyor system has been puts. It can be converted to skidless moving along a rail installed at floor
designed to use a reduced number transport of vehicle bodies. level. Fixtures at each side of the rail
of mechanical and control compo- The conveyor combines several support the skids and bodies.
nents to help improve flexibility and types of systems, such as inverted The shuttle’s travel and lift
sequences are monitored by a vehi-
cle controller. Bar codes on the rail
and a reader on the shuttle help
ensure reliable position detection.
Eisenmann Corp. • 815-455-4100 •
www.eisenmann.com/usa
Laser splicing system
Joining Tech-
nologies Inc.
has intro-
duced the
Infinite Web®
355 laser cut-
ting and weld-
ing system for
splicing iron
and nickel-based strip alloys. This
all-in-one coil joiner incorporates
laser welding and cutting with a
single head.
The system automatically pre-
pares the coil ends and welds them
together in less than three minutes,
according to the manufacturer. The
mobile, stand-alone system requires
one electrical input and minimal
operator involvement. The industri-
al PC-based control system features
a touchscreen interface, canned pro-
grams for selected alloys, and pro-
prietary self-diagnostics.
Designed to handle material
thicknesses from 0.002 to 0.05 in.,
the joiner uses coaxial optics to ver-
ify proper positioning and provide
accurate splices. Both cutting and
welding operations are automatic
and noncontact.
Joining Technologies Inc. • 800-
266-1966 • www.joiningtech.com

PRODUCT NEWS
Die table ing presses, have shorter changeover extremely long production time.
times and a longer production time. Each traverse spooler is equipped
When the strip is welded together, with an oiling device to oil the strips
a large coil with a diameter of up to and protect their surfaces during
8.2 ft. can be wound at the recoiler. further processing.
This large coil then is transported Burghardt + Schmidt GmbH • 49-
to the decoiler again, allowing an 7232-3661-0 • www.b-s-germany.de
Serapid Inc. has designed and built a

die table for an auto parts supplier to
help speed the exchange of dies.
The die table has a 12-ton capacity
for dies measuring up to 54 by 120
in. The dies travel at a speed of 10
FPM about 110 in. in and out of the
press. A pair of engineered bolster
extensions hinged at the die table
provide a retractable, 42-in. bridge
so the area immediately adjacent to
the press can be kept clear during
production.
The unit uses the company’s Roll-
Beam telescopic push-pull actuator
to push the die across the hinged bol-
ster extension and up to 12 in. onto
the bolster. The actuator is capable
of pushing into an area and then
retracting fully out of the area.
Serapid Inc. • 800-663-4514 •www.
serapid.us
Precision slitting line
Burghardt + Schmidt has developed

for a customer a precision slitting
line for stainless steel with 12 tra-
verse spoolers.
Up to 12 strips can be cut off the
original strip and wound oscillated
onto the 12 traverse spoolers. The
remaining strip can be rewound
onto a recoiler.
With the use of an integrated
laser welding device, the strips can
be welded together in such a way
that a long, continuous strip line is
produced for oscillated coiling. As
a result, the machines that follow,
such as cutting devices and stamp-

PRODUCT NEWS
Industrial automation products array sensors; iVu Plus integrated pany vision sensors; and the AG4
touchscreen image sensors and iVu laser scanner and EZ-SCREEN® low-
Banner Eng. has published its 2011 Plus image sensors with remote dis- profile safety light screens.
product catalog in print and interac- play; SureCross™ wireless network The print catalog includes more
tive online versions. devices and FlexPower™ power than 860 pages of product features,
Included in the catalog are pho- supplies; EZ-LIGHT™ lighting, task application images, model numbers,
toelectric, fiber-optic, special-pur- lights, high-brightness models of and accessories. Offering the same
pose, ultrasonic, and measuring existing lights, and lights to accom- organization style and content as
the print version, the interactive
online catalog also features a search
tool to help users find products
and details.
Illustrations show how the indus-
trial automation products can be
applied in a number of applications,
with page references that guide
users to additional information on
each product demonstrated. Also
included are more than 100 pages
of accessories, including mounting
brackets, cordsets, retroreflectors,
and enclosures. The online version
provides links throughout the prod-
uct sections.
Banner Eng. • 888-373-6767 •
www.bannerengineering.com
Small-part deburring machine
The CrossMas-
ter DD double-
disk deburring
machine, offered
by AM Machin-
ery Sales, han-
dles parts as
small as the size
of a quarter. The
t h ro u g h - f e e d
machine was designed specifically for
small parts to eliminate hand deburr-
ing or vibratory operations.
The machine can process both fer-
rous and nonferrous material with-
out magnetic or vacuum tables. It is
available in 6- and 12-in. widths.
AM Machinery Sales • 215-293-
0333 • www.ammachinerysales.com

PRODUCT NEWS
Synthetic stamping lubricant essing systems. During routine work process, an alarm will sound,
operation, data from all cameras, and the system will be slowed down
ideally also fastened to the gripping automatically or stopped.
arms of the robots, is recorded in Fraunhofer • 49-89-1205-1399 •
real time, analyzed, and evaluated. www.fraunhofer.de
If a collision is imminent during the
Reliability. Service. Value.

Tower Oil & Technology Co. has
introduced Saf-T-Vanish, a synthetic,
Clearly COE Press Equipment
VOC-free stamping lubricant.
The lubricant contains no haz-
ardous ingredients, uses renewable
resources, and is totally biodegrad-
able. Drying time typically is twice
as fast as solvent-based fluids, the
company states. The lubricant does
not contain typical EP additives and
has a high lubricity factor.
The product provides corrosion
protection and is safe to use with all
metals.
Tower Oil & Technology Co. • 888-
521-1445 • www.toweroil.com
Safety monitoring system

When you want a no-nonsense, coil feeding
Fraunhofer has introduced a new
equipment partner you can count on, it’s
prototype for safety monitoring in
industrial workplaces. The intel- clearly COE Press Equipment. With a heritage
ligent monitoring system makes of reliability since 1976, North American stampers,
it possible to predict dangerous fabricators and manufacturers have depended
situations between humans and upon COE for productivity-enhancing solutions that improve
machines. their bottom line. A single source supplier, COE delivers
The system includes the Sim4Save
best-in-class machinery, on-site engineering and manufacturing,
configuration tool, an in-house
development of the Fraunhofer 24/7 support, and unparalleled service. Simplify your life and
Institute for Digital Media Technol- improve your operations. COE is clearly the one-stop shop for
ogy (IDMT). This tool simulates a all your coil feeding needs.
3-D model of the production hall
and tells the user how many cameras • On-site Service & Support
are required to monitor all safety-rel-
• Fully Integrated Systems COE Press Equipment
evant areas, eliminating blind spots
and dark corners. • Roll Feeds Tel (586) 979-4400
The monitoring system also • Coil Reels Email info@cpec.com
includes a communication platform, • Straighteners www.cpec.com
connected hardware, and preproc- Enter reader service code 111347 at www.ffid.net

PRODUCT NEWS
Spanish-language gas spring Portable lubrication system a forklift in the bed of a heavy-duty
brochures pickup truck. It includes two 50-gal.
and two 25-gal. steel containers
Hyson Products, a business of with PVC sight gauges. Air-operated
Barnes Group Inc., has issued piston pumps on the top of each
three of its gas spring brochures in container provide a 5-to-1 pump-
Spanish. ing ratio, while filters on the side of
The brochures feature the Tanker® each container remove dirt or small
S&T series gas springs, which offer particulates.
high force in short heights and pat- A ball valve manifold attached to
ented dynamic lubrication; the T3 the compressor in the center of the
series, with 12 models in contact A new mobile lubrication system system allows users to turn on one,
forces from 380 to 45,000 lbs. and from The IFH Group provides stor- two, or four of the pumps at any
diameters from 0.75 to almost 8 in.; age and dispensing of lubricants, given time. At the dispensing end,
and the T4 line of heavy-duty gas cutting oils, bearing oils, hydrau- the system provides retractable hose
springs, with five models in contact lic fluids, transmission fluids, and reels with metered dispensing con-
forces from 2,075 to 21,375 lbs. engine oils for plants requiring trol handles to show how much fluid
and full stroke forces from 3,350 to lubrication maintenance at multiple has been dispensed.
33,300 lbs. locations over a large area. The IFH Group • 800-435-7003 •
Hyson Products • 440-526-5900 • The new system is delivered on a www.ifhgroup.com
www.hysonproducts.com pallet that allows it to be placed by
Cleaner concentrate
Metal Market

3 ( 1 , 1 6 8 / $ 5
& < / , 1 ' ( 5 & 2
Cimcool Fluid Technology offers
CIMCLEAN® 30 for eliminating
shop waste, metal swarf, oil, mold,
and bacteria in manufacturing envi-
ronments.
The general-purpose cleaner con-
centrate removes biofilms, dirt, grit,
chip deposits, insoluble soaps, and
oils from central systems and indi-
vidual machine sumps and con-
tains corrosion inhibitors to protect
machines and parts from rusting
during the cleaning process. Avail-
able in mildly alkaline or highly
alkaline solutions, the cleaner can
be used in washer, spray, dip-tank,
and ultrasonic applications.
Cimcool Fluid Technology • 888-
246-2665 • www.cimcool.com
Enter reader service code 473163 at www.ffid.net Enter reader service code 128643 at www.ffid.net

CLASSIFIED ADVERTISING ADVERTISERS’ INDEX
tungsten carbide new machinery Enter Reader Service Code at

preforms for sale www.ffid.net
RS
Code Page
777007 Accurate Die Design . . . . . . . . . 11
842576 Agathon Machine Tools . . . . . . . 21
203-730-8741
240054 Aida - America . . . . . . . . . . . . . . . 7
www.aida-america.com
155146 Beckwood Press . . . . . . . . . . . . . 16
www.beckwoodpress.com
business
111347 Coe Press / Sesco Products . . . . 31
opportunities 586-979-4400
465486 Eriez Magnetics . . . . . . . . . . . . . 25

Available in all regions www.eriez.com
Metal stamping companies, $1-$40 FABTECH® . . . . . . . . . . . . . . . . . . . 5
million sales. Also, companies in metal www.fabtechexpo.com
fabricating, machining, powdered
metal, foundries. 111248 Feed Lease . . . . . . . . . . . . . . . . . . 2
Will@SahleinAssoc.com 888-510-4222
Ph: 781-259-0614 100734 Formtek Maine . . . . . . . . . . . . . . . 9
800-247-COIL
112922 Industrial Magnetics . . . . . . . . . . . 6

www.magnetics.com
PRODUCTS FOR SALE 459021 JW Winco . . . . . . . . . . . . . . . . . . . 6

504648 Lubrizol . . . . . . . . . . . . . . . . . . . . 17
Markingpendepot.com 486285 Numberall Stamp & Tool . . . . . . 22
Paint Markers, $1.10* www.numberall.com
China Markers, .50** 473163 Peninsula . . . . . . . . . . . . . . . . . . . 32
Artline, Dixon, Dykem, www.peninsularcylinders.com
Markal, Sharpie, Unipaint
263137 PHD . . . . . . . . . . . . . . . . . . . . . . . 11
The World’s Largest www.phdinc.com
750652 Pressmate/Plumb Products . . . . . 8
Selection Of Markers! www.plumbproductsllc.com
*MPD 15, 576+
261649 Schuler . . . . . . . . . . . . . . . . . . . . 29
Markal, 72+ www.schulergroup.com
Call 888-906-9370 128643 Tamer Industries . . . . . . . . . . . . . 32
800-882-6348
141876 Tapeswitch . . . . . . . . . . . . . . . . . 21
www.tapeswitch.com
STAMPING Journal® (ISSN 1091-2460) is 507212 TCT Stainless Steel . . . . . . . . . . . 17

published bimonthly by FMA Communica- www.tctstainless.com
tions Inc., 833 Featherstone Rd., Rockford,
772286 The Shed-it . . . . . . . . . . . . . . . . . 35
IL 61107-6302. STAMPING Journal is circu- www.shed-it.com
lated free upon request to those who qualify
and who are involved in metal stamping. 868526 TR Electronic . . . . . . . . . . . . . . . . 22
Subscription to all others is $65.00 per year. www.trelectronic.com
Foreign subscription is $95.00 per year.
170574 Unist . . . . . . . . . . . . . . . . . . . . . . 30
Periodical postage paid at Rockford, IL and www.unist.com
additional mailing offices. Postmaster: Send
address changes to: STAMPING Journal, 833 Publications Mail Agreement No. 12345678 458793 Vibro Industries . . . . . . . . . . . . . 28
Featherstone Rd., Rockford, IL 61107-6302. (41467014) 517-527-2094
Return Undeliverable Canadian Addresses to:
Copyright 2011 by FMA Communications
PITNEY BOWES INTL MAIL SVCS 145521 Wayne Trail Technologies . . . . . 23
Inc. Reproduction in whole or in part with- STATION A, P.O. BOX 54 www.waynetrail.com
out written permission of the publisher is WINDSOR ON N9A 6J5
prohibited. E-mail: returnsil@imex.pb.com
462891 Wilson Tool International . . . . . . 36
www.wilsontool.com

ASK THE EXPERT
Do die repairs require full

lockout/tagout?
By Dennis Cattell
Editor’s Note: Regular readers of this column safety block chain is connected only
might recognize that Mr. Cattell answered a to the air supply. That is unaccept-
similar question in the May/June 2010 issue of able because the main motor and fly-
STAMPING Journal. Since this question reflects a wheel still can be running. You must
common concern among stampers—and is asked have an electrical interlock to stop all
of Mr. Cattell quite frequently in his work—we felt motors that can cause movement of
it would be beneficial to address the issue again. both the press and feed. Figure 1
Q: Are we required to perform The objective is to break the elec-
full lockout/tagout (LOTO) on a trical circuit to the main motor and In this pneumatic die safety block, the
press when we need to repair only feed drive so it cannot run when the safety block chain is connected only
the dies? The electrical compo- safety blocks are put in the die area. to the air supply, the main motor and
nents of our continuously running This can be accomplished by con- flywheel still can be running.
employee make any adjustments or

Anytime you need to put your
service within the point of operation
hands in the die area of a press or (die space area) or other hazardous
you need to work on the die, you area without taking proper protec-
tion measures that meet OSHA and
must comply with the OSHA regu-
ANSI requirements.
Dennis Cattell lations. There are no exceptions. The minor servicing exception for
Tom Vacca
normal and repetitive tasks requires
presses are failing prematurely necting a dummy plug to each safety that safety procedures be docu-
because we power down the press- block with a metal chain. Remov- mented for each process. It must be
es so often to perform full LOTO. ing the plug from the socket breaks authorized by your company and
Can we just use die safety (opens) the circuit. safety department, with training
blocks? Do the safety blocks and You can keep the panel view live given before the implementation of
electrical interlock alone provide with a circuit revision. This will help the process. The written procedures
adequate protection every time you with control component failure. must meet OSHA’s 1910.147 regula-
that we need to put our hands in Although the plug is removed, tions and be proven effective protec-
the die area? the flywheel might coast for a short tion for all employees.
How does OSHA’s minor servic- time. You’ll need to check the main Regardless of how troublesome
ing exception fit into our stamping motor and flywheel to ensure they’ve these procedures might be, you and
plant? stopped. If the flywheel continues to your company are responsible—and
A: OSHA’s minor servicing excep- turn, it will generate enough energy liable—for protecting the people in
tion—and, in your case, failure of to crush the safety block if the press your press shop.
press controls through constant shut- engages. Training programs on this subject
down—cannot be used as an excuse The lockout procedure is not are available through the FMA.S
not to comply with OSHA’s 1910.147 required by OSHA for minor adjust- Has a shop floor stamping or tool
LOTO standards. Anytime you need ments or service activities if they are and die question stumped you? Send
to put your hands in the die area of a part of normal production or if the your questions to kateb@thefabrica-
press or you need to work on the die, unexpected energization or start-up tor.com to be answered by Thomas
you must follow the OSHA regula- of the equipment would not affect Vacca, director of tooling and design
tions. There are no exceptions. the employee’s safety and appropri- engineering at Micro Stamping
In the photo of your pneumatic ate protection of the employees is Corp., or by industry veteran and
die safety block (see Figure 1), the provided. At no time should the press expert Dennis Cattell.

Trade business as usual for a
business that’s more successful.
Switch to The Shed-It
A revolutionary new ejector system

that delivers more of what you want.
• More productivity
• Generates proﬁts
• 100,000,000 press strokes
• Zero failures
• Eliminates ejector failures
• Long-lasting ejector system
Failed ejectors.
Short production runs.
PIERCE PUNCHES FOR PROGRESSIVE DIES
Dies that need constant repair.
For years, the tool and die industry has
had to face challenges like these on a
daily basis. Now there’s no longer a need SHED-IT
to tolerate these ejector failures. Now you
can eliminate them. With the Shed-It, a SHED-IT PROTRUDE
revolutionary new ejector system, you’ll .050/.080 BEYOND PUNCH
KNOCK OUT FOR
have more productivity, more reliability, COMPOUND DIE
more press strokes without failure and
more of what you really want. Profits!
Make the switch to the Shed-It

Limited only by imagination. Call: 978-465-6100
Enter reader service code 772286 at www.ffid.net info@shed-it.com • www.Shed-It.com
Crystal Engineering_Shed-It_fullpg_AD_May_June_2011

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Unrealistic part Improved robotic Small sensors,

features control big splash

On the cover: Cover image courtesy of Bilsing

>> Features >> departments

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 3

7 & 7: Requests from the stamping journal staff

shop floor to the design Group Publisher

room—and vice versa

Closing the manufacturability chasm

describe impossible hole positioning and fantastical tolerances— Indiana/Ohio/

Minnesota/Iowa/ Amy Hudson • 815-227-8237

Classified Advertising Patty D’Amico • 815-227-8278

7 Pleas From Production to Designers: Accounts Receivable/ Mary Simons

design 1. Forget perfect. Design what is achievable on Earth.

2. Pay attention to punch-to-die clearances, and make sure they

or think the to ensure that what you envision can be accomplished.

Got thoughts? kateb@thefabricator.com

IT’S ALL HERE. Discover the most

November 14-17, 2011 | McCormick Place | Chicago, IL

Enter reader service code 459021 at www.ffid.net

6 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

Dayton Progress Corp.

Dayton Progress Corp., Dayton,

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 7

Enter reader service code 750652 at www.ffid.net

Servo press increases output for

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 9

Attempting to defy the etry (see Figure 1).

10 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

the coil set, the material must be

Art Hedrick is president and senior consultant of

Enter reader service code 263137 at www.ffid.net

Enter reader service code 777007 at www.ffid.net

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 11

strengths, start of localized necking.

applied and the elongation of gauge Uniform

12 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

2. Simulate the Process

14 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 15

16 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

Common Sensor Styles

How these common devices can make a big impact

18 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STaMPInG JOuRnaL • an fma publication

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 19

Editor’s Note: This question-and-answer article Figure 1

20 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STaMPInG JOuRnaL • an fma publication

Enter reader service code 141876 at www.ffid.net

Enter reader service code 842576 at www.ffid.net

an fma publication • STaMPInG JOuRnaL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 21

Enter reader service code 868526 at www.ffid.net

Lower-tier suppliers and the This conversation yielded another

24 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 25

26 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 27

Modular skid conveyor reduce maintenance. monorail systems or eccentric lift-

Laser splicing system

28 MAY/JUNE 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

Serapid Inc. has designed and built a

Precision slitting line

Burghardt + Schmidt has developed

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MAY/JUNE 2011 29