Deep-drawing Mechanical Press

Coil feed retrofit?

contact angle Buyers’ Guide©

Expertise to help you transform metal into gold www.stampingjournal.com March/april

March/April 2011

Closing communication gaps

for better dies

A PUBLICATION OF THE FABRICATORS &

MANUFACTURERS ASSOCIATION, INTERNATIONAL®

AA PUBLICATION
PUBLICATION OF
OF THE
THE FABRICATORS
FABRICATORS &&
MANUFACTURERS
MANUFACTURERS ASSOCIATION,
ASSOCIATION, INTERNATIONAL
INTERNATIONAL®®
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 An Official Publication of the
Fabricators & Manufacturers Association, International®
>> COVER STORY
16 5 ways to empower die
designers for better die results:
How effective design leads to
an improved bottom line
By improving communication, supplying critical
requirements upfront, creating die standards, using
advanced software, and powering up equipment, die
designers can get better dies to their customers faster.
On the cover: Cover image courtesy of 3-D Solu-
tions Design Service, Rockford, Mich.
>> Features
14 The importance of the contact angle
in deep drawing
Drawn parts with very precise circularity, roundness,
and straightness, as well as no score marks, are in
strong demand in the automotive, medical, and elec-
tronics industries. Read how to prevent problems with
cylindrical parts via the contact angle.
18 Coil processing equipment—
new or retrofit?
If existing coil feeding equipment is malfunctioning,
or if productivity needs a boost, stampers can achieve
measurable gains through coil handling and feeding
equipment upgrades, including servo drives, variable-
speed controls, and operator interfaces. Moderniza-
tion without a big price tag is possible.
26 Forming & Fabricating® Mechanical
Press Buyers’ Guide©
For a side-by-side comparison of several press brands,
don’t miss this.
30 Ask the Expert
Tom Vacca responds to “Which springs are best for
forming HSLA down and drawing up.”
an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM March/april 2011
Vol. 23 No. 2 march/april 2011
p. 16
>> departments
4 Meet the Press
The U.S. economy is bouncing back; manufacturing is
on a consistent upswing; and the automotive segment is
rebounding. It appears that stampers can heave a sigh of
relief at last. Pop the cork and clip the cigars, Editor Kate
Bachman prods.
5 Readers Respond
One reader welcomes the good economic news but thinks
the U.S. needs to make more energy-efficient cars;
another says that while renewable energy is a market
opportunity, America is behind on producing it; a reader
thinks schooled engineers need practical manufacturing
experience; another sees a conflict with the dual role of
the U.S.’s “banker.”
7 News & Notes
8 Product Innovations
9 Stamping Solutions
10 Die Science
Art Hedrick’s column in this issue delves into variables
that make part tolerancing a pipe dream in Part I of
“Attempting to defy the laws of physics.”
12 R&D Update
In an update to previous articles on the topic of simula-
tion of the hot-stamping process, researchers at The Ohio
State University disclose recent advances. Forming and
quenching simulation are most important, because most
of the deformation and heat transfer take place during
these two operations.
24 Automotive Intelligence
Incentives are down, vehicle prices are up, and the trans-
action value of the average automotive purchase has
risen accordingly, Bernard Swiecki says. Will it last for
suppliers? he asks in “Pricing sanity returns to the auto-
motive industry.”
29 Classified Advertising
29 Advertisers’ Index
3
MEET THE PRESS
Breathe at last. Breathe at last.
Thankgodamighty, we can
breathe at last!
Let’s get the party started
I
’ve done my share of reporting dour news,
so now that I have good news to relay, let
the exclaiming begin. The U.S. economy
is bouncing back; manufacturing is on a
consistent upswing; and the automotive seg-
Kate Bachman,
ment is rebounding. Uncork the fizz and
STAMPING Journal Editor
clip the cigars. It appears that stampers can
heave a sigh of relief at last.
Economic activity in the manufacturing
sector expanded in December for the 17th
consecutive month, and the economy grew
for the 20th consecutive month, the Institute
for Supply Management™ reported recently.
The gross domestic product in 2010 was
up 3.8 percent from the preceding year.
Manufactured Goods
Orders Up
New orders for manufactured goods in
December increased by 0.2 percent to
New orders for $426.8 billion, following a 1.3 percent rise
in November; new orders for all manufac-
manufactured tured durable goods for 2010 increased by
13.6 percent over 2009, the U.S. Census
durable goods Bureau reported. New orders for fabricated
for 2010 metal products were up by 8.6 percent year
over year; for machinery, new orders were
increased by up by 21.6 percent.
U.S. manufacturing technology consump-
13.6 percent tion was up in December by 85.3 percent
over 2009, according to AMT—The Asso-
over 2009. ciation for Manufacturing Technology and
AMTDA, the American Machine Tool Dis-
tributors’ Association, Vicki Bell reported on
www.thefabricator.com.
Automotive on the Rise
It’s good to be able to read automotive head-
lines without flinching. GM added a third
shift and restored 750 jobs at its iconic Flint,
Mich., assembly plant, Just.auto.com report-
ed recently. CNNMoney’s reports echoed the
same rosy outlook. “The nation’s automak-
ers posted double-digit percentage sales
4 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
gains for January, as Americans appear to be
returning to showrooms after a long hiatus.”
Financial health has, in fact, returned to
the automotive industry, Bernard Swiecki
reports in this issue’s Automotive Intelligence
(p. 24). “Ford had the most profitable year in
its history … and its stock shares are trading
at more than 10 times their 2009 price. GM’s
financial performance has justified an IPO
successful beyond even the most optimistic
expectations. Chrysler is reporting operating
profits. And international automakers have,
for the most part, also experienced financial
success,” he said.
Many suppliers are reporting posi-
tive financial performances and revenue
growth—in fact, supplier stocks are becom-
ing popular on Wall Street, Swiecki added.
One die design/software business owner
echoed the cheery news. “Most of the shops
in western Michigan are filling with new
work fast. We are currently designing several
dies for these shops. The work is automo-
tive,” relayed Mark Hansen, design manager
of 3-D Solutions Design Service in Rockford,
Mich. Hansen expects the tool and die busi-
ness activity to continue ramping up, he
added. “It’s refreshing to see so much work
released in the eight weeks.”
Stampers, still dealing with downturn fall-
out debt and banker lending reluctance, may
have good reason to anchor their optimism
in caution, but the sunny reports of recent
months are good signs that they can cele-
brate—or at least, heave elated sighs of relief.
So, let’s get the party started.
Ummm … It’s been awhile. Does anybody
remember how? S
Got thoughts? I’d love to hear from you.
kateb@thefabricator.com
 READERS RESPOND
www.stampingjournal.com
stamping journal staff
President & CEO, FMA Gerald M. Shankel
Need Fuel-efficient Cars EV products, including charging stations,
Group Publisher Edward Youdell I read your January Stamping News Brief made right here.
Editor-in-Chief Dan Davis
Stamping Journal Editor Kate Bachman commentary “Automotive new moon ris- Getting the middle class back to work
Senior Editor
TPJ Editor
Tim Heston
Eric Lundin
ing.” These are good signs for U.S. auto- and earning decent wages is the only sure
Senior Copy Editor Teresa Chartos makers. But what about the gas prices, way to a sustainable recovery. Without
Associate Editor Amanda Carlson
Contributing Editor Amy Nickel which keep on rising? our domestic economy back on track, all
Graphic Designers Margaret Clark, Janell Drolsum, We need more energy-efficient cars. In the tax breaks in the world will not work.
Mary Mincemoyer, Jennifer Paulson
Publishing Coordinator Jean Thompson order to capture the market, we need to We can once again support our
Director of Circulation Kim Clothier
Web Content Manager Vicki Bell make them cheaper than other countries’ own economy, but we must work at
Multimedia Specialist Sherry Young cars—gas, hybrid, fuel cell, or electric. this. We need to innovate and grow our
Senior Web Developer Jason Bartholme
Web Developer Johanna Albee Our automakers are shy of showing own manufacturing base again. Embrace
their fuel efficiency ratings in their ads, new technologies and protect them
Advertising Sales
which makes potential customers think somehow! I am sick and tired of seeing
Associate Publisher Jim Gorzek • 815-227-8269
jimg@thefabricator.com twice before buying a U.S. car [for fuel products invented here, but then made
Senior Account Representatives efficiency]. Instead, they buy U.S. cars offshore.
Michigan/Northeast Sean Smith • 815-227-8265
seans@thefabricator.com because the size, robustness, or comfort Randy Juras
Indiana/Ohio/ Mike Lacny • 815-227-8264 makes them feel safe. SSREA Director
Southeast/
International
mikel@thefabricator.com
Javed Latif Homer Glen, Ill.
Tennessee/Alabama/ Tony Arnone • 815-227-8263 Mechanical Engineer
Mississippi/ West tony@thefabricator.com Glendale Heights, Ill. Young Engineers
Minnesota/Iowa/ Amy Hudson • 815-227-8237
Illinois/Wisconsin/ amyh@thefabricator.com
Need Practical
Canada EVs, Renewables, Manufacturing Training
Classified Patty D’Amico • 815-227-8278 Opportunity for U.S. I read your commentary in the October
Manufacturers
Advertising patriciad@thefabricator.com
Director of Accounting Bob Young
Stamping News Brief, “Solutions for an
Accounts Receivable/ Mary Simons
I read your December Stamping News industry in peril.”
Credit Coordinator Brief column, “With EV powertrains, will A problem I see compounding the lack
How to Contact Us weight matter?” A lot of places are willing of tool and die expertise today is some-
833 Featherstone Rd., Rockford, IL 61107 to spread a little cash to upgrade lighting thing I have witnessed throughout my
Phone 815-399-8700 • Fax 815-484-7700
E-mail info@thefabricator.com to LED types. Immediately, and with state career at several different companies.
Web site www.stampingjournal.com
and federal rebates and grants, the cost Some companies place emphasis on
Statement of Policy
The STAMPING Journal’s objective is to disseminate new and
savings are huge! making sure their engineers understand
complete information relating to the metal stamping industry. The problem I am seeing is that most both the design and manufacturing end
The main editorial text consists of articles and news releases
designed to assist owners, managers, manufacturing engineers, of this new lighting still is coming from of forming metal parts. Other compa-
supervisors and foremen in the evaluation of new methods and
techniques. It is an official publication of the Fabricators & China, of all places. It truly is sad to see nies—especially in the current econo-
Manufacturers Association, International. The policy of the
publisher and this journal is to be nonpartisan, favoring no one
America so far behind in manufacturing my—assume that the new hires know
product or company. The representations of facts and opinions
expressed in the articles are those of the author and are not
these renewable-energy and sustainable- how to design formed parts.
necessarily endorsed by the publisher and this journal. By living products. Several young engineers who were
including information on new products, new literature, news of
the industry, articles, etc., this impartiality is strived for and ex- I have watched China for decades now. hired straight out of school or by way of
tends to the mention of trade names. Unless product identifica-
tion makes reference unavoidable, the generic name is used. We The Chinese are finally reaching the point internships have no practical knowledge
acknowledge that on occasion there may be oversights or errors;
the editors regret such oversights and re-emphasize their policy
where they have a good enough domes- of the forming processes. Many of them
to be impartial at all times. The Publisher reserves the right tic economy that they can support them- even have difficulty designing manufac-
to refuse advertising it deems inappropriate for publication in
STAMPING Journal®, including ads for classes of products and selves. As time goes by, and soon, they turable parts using a sheet metal pack-
services not considered of significant interest to the readership.
(ISSN 1091-2460) STAMPING Journal is a trademark of FMA will not depend solely on exporting. They age on the CAD system. Many of today’s
Communications Inc. All rights reserved. Pub­li­cations of FMA
Communications Inc., maintain a policy of keeping editorial will be able to support their own econo- younger engineers have no grasp of how
and advertising separate to ensure editorial integrity that most
benefits our readership. Editorial content, including feature
my with domestic sales. to design a part to be produced. They are
articles and press releases, is determined solely by the publisher. Electric vehicles represent a great thrown into a work environment where
Editorial content cannot be purchased, nor can it be used as a
benefit of advertising dollars spent. Edit­orial is free-of-charge, opportunity for America and local econo- there is no time to teach them these skills,
subject to space availability, and open to all interested parties
that submit items meeting our editorial style and format as mies to do a little catching up. Instead of or their superiors do not have the skills
determined by the publisher. Standard Rate & Data Service
lists our advertising rates in Section 88. Consult SRDS or our ignoring the fact that the price of fossil themselves because they are managers,
current rate card for full rates and data.
Note: Some photographs printed in this publication may
fuel is only going to go up, we should not design engineers.
be taken with safety equipment removed for photographic start now to get off this overly expensive Some of them are open to learning and
purposes. However, in actual operation, it is recommended that
correct safety procedures and equipment be utilized. energy source. It would be great to see mentoring to build their skills; others

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 5

 REadERS RESPOnd

suffer from the “not invented here” brought me in contact with very expe-
syndrome. rienced people willing to teach me on
This leads to poorly designed prod- the job.
ucts that are expensive and difficult to R. Remmers
Your Quality Tempered Source manufacture. Mechanical Engineer
I feel fortunate that my career has Lawrenceburg, Tenn.
The Shortest Lead time in the
Metal Industry From the Blog
In House Tempering/Rolling: comment on post, “Detroit auto show gets serious about caFE cars”
• 1/8 Hard • 1/4 Hard I blogged on this very subject myself earlier, and it was great to see your
• 1/2 Hard • 3/4 Hard view on it, Kate.
• Full Hard • Extra Full Hard Thomas
In House Quality Laboratory comments on post, “wikileaks confirms china’s leverage”
ISO Certified
This is a very serious issue for the United States. On one hand you have the
“banker” who you need to pay the bills; on the other hand you have the “bank-
er” who helped create them. China has long subsidized its manufacturing sector
to entice developed nations, like the U.S., into buying more and more cheap
goods.
This vicious circle has fed right into China’s goal, to be the only superpower!
China doesn’t need to invade the country with an army of soldiers. They are
doing it simply by undermining the financial stability of the U.S. economy.
Think about that next time you go to the big box store to purchase goods that
were once built in America and are now made in China.
It’s not the automotive industry that is killing the U.S. It’s everything else that
moved offshore.
For the U.S. to get out of this mess, it will have to walk a very careful line.
If global markets start to turn away from the U.S. and seek new opportuni-
ties in other countries such as India and Brazil, American manufacturers and
the economy will continue to spiral downward. The debt will increase and the
”banker” will come calling.
Good luck, U.S. This is going to be the most important war you ever fight.
Dave
***
I think the U.S. priced itself out of the market years ago. Overpriced labor,
reverse golden parachutes, and innovative doldrums are the culprits. Capitalism
is not just for Americans. Make more imaginative stuff better and cheaper, and
the tide will swing. Stop whining.
Joe
Locations: ***
Sterling Heights, MI I agree, Joe. Also, regarding Dave’s comment about China subsidizing manu-
facturing, I, too, see that as a large force for U.S. manufacturers to combat.
800-334-7509 • Fax: 586-731-0729
However, the U.S. government can help by ensuring that regulatory fees, com-
tctmi@tctstainless.com
pliance costs, and taxes are low to compete through efficiency as opposed to the
Lebanon, TN Chinese government’s backing of manufacturing and the low-cost labor there.
800-877-8366 • Fax: 615-449-6079 In other words, the government can back manufacturing by standing back
tcttn@tctstainless.com and letting us get to work!
Nathan
Dallas, TX
877-472-2422 • Fax: 214-348-1092
6
bgreen@tctstainless.com
STaMPInG JOuRnaL • an fma publication
Enter reader service code 507212 at www.ffid.net
 NEWS & Notes
> > Fox is new Feed Lease Sales Manager • Amada America is 40 • Porter joins McGregor < <

Amada America McGregor Metalworking hires metal stamping, machining, robotic

celebrates 40 years corporate quality director welding, split metal pulley manufac-
turing, and custom tooling.
This year marks Amada America Cynthia Porter has joined McGregor
Inc.’s 40th year in North America. Metalworking, Springfield, Ohio, in Kenmode receives ISO
Starting as a research and develop- the newly created position of cor- 13485:2003 certification
ment company in Seattle, the com- porate director of quality. In this
pany is now a leading fabricating position, she has direct responsibil- Kenmode Precision Metal Stamping,
machine tool builder. ity for the quality programs at each Algonquin, Ill., a producer of medi-
The anniversary comes on the heels of the company’s five manufacturing cal device precision metal stampings,
of Amada’s most recent investment to facilities. has received ISO 13485:2003 certi-
serve the manufacturing industry - - An experienced lead auditor and fication.
the opening of the Amada Solution trainer in both TS 16949 and ISO The certification is the quality
Center in Schaumburg, Ill. Set on 14001, Porter is also lean-certified management system standard spe-
10.5 acres, this high-tech campus fea- and held corporate positions with cific to the medical industry. The
tures machine exhibits where users multiplant responsibilities in quality, requirements emphasize critical areas
can experience the latest manufac- safety, and lean. impacting design, process, qual-
turing trends, new applications, and McGregor Metalworking is a con- ity, and manufacturing reliability for
emerging technologies. An example tract manufacturer specializing in medical device products.
of this type of exhibit is the facility’s
Laser Technical Center, where metal
fabricators can see advanced laser
technology, such as the company’s
FOL-Fiber laser. The Schaumburg
facility also regularly hosts industry
leaders, who are invited to present
seminars on cutting-edge topics.
Amada Co. Ltd., the parent com-
pany of Amada America Inc., also
has subsidiary companies in Japan,
Europe, Africa, and Oceania.
“We’d like to say thank you to our
customers with whom we celebrate
40 years of innovation,” said Mike
Guerin, COO of Amada America.

Feed Lease appoints

sales manager

Feed Lease Corp., a Rochester Hills,

Mich.-based manufacturer of coil
feed systems, has appointed Joe Fox Enter reader service code 112922 at www.ffid.net
as general sales manager.
Fox has more than 20 years of
experience in the coil feeding indus-
try and is responsible for growing
the company’s brand awareness and
market share both domestically and
internationally.
an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 7
PRODUCT INNOVATIONS
Double-metal detector suited for magnetic-conveyor transport applications
Prime Controls Inc. has introduced
the Fluximity, a double-metal detec-
tion system that uses an external
magnet as the operating signal to
measure metal thickness.
The system is suitable for applica-
tions in which a magnetic conveyor
transports metal parts from process
to process. The sensor detects the
Enter reader service code 842576 at www.ffid.net
8 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
flux of the magnets under the con-
veyor, and the controller reacts to
changes in the magnetic flux when a
metal part is present on the belt or if
two parts are present instead of one.
If a missing or double part is
detected on the belt, the controller
signals the production control sys-
tem, which can halt the line and alert
the operator or activate a reject gate.
For applications in which no built-in
magnet is available, an external mag-
net can be used.
The system comprises a passive
magnetic sensor probe that is con-
nected to a microprocessor-based
controller. Several types of sensor
probes are available to detect a vari-
ety of ferrous metal parts from 0.002
to 0.100 in. thick.
Four controller models pro-
vide different output configura-
tions, depending on the application
requirements. All controllers have
two outputs: one for metal present
and one for double detection. Status
and setup controls on the controller
face include a green power indicator,
a multifunction/multicolor LED indi-
cator, and a push-button switch.
Prime Controls Inc., 4551 Gateway
Circle, Dayton, OH 45440-1711,
866-435-8659, www.primecontrols.
com
Gap-frame press runs with
minimal maintenance
Stamtec offers the OCP-
110 single-point, gap-
frame press. The extra-
heavy, one-piece welded
steel frame is fully stress-
relieved and designed to
resist deflection.
The transmission-like,
low-maintenance wet
clutch and brake system
delivers rated torque at
relatively low air pressure, reduc-
ing lining wear and air consump-
tion, according to the company.
The linings run in an enclosed oil
bath, which aids heat dissipation for
extended lining life.
Hydraulic overload protection
relieves the pressure of a tonnage
overload in milliseconds, stopping
the press immediately, the com-
pany reports. Hydraulic pressure is
restored with the push of a button,
and normal operation resumes after
the press is inched to TDC.
The press’s compact design elimi-
nates the need for a die cushion
under the press. The cushion is bolt-
ed to the bolster for quick removal to
allow clear access for maintenance.
Stamtec Inc., 4160 Hillsboro High-
way, Manchester, TN 37355, 931-
393-5050, www.stamtec.com
 STAMPING SOLUTIONS

3-D review process eliminates die engineering

company’s duplicated efforts
Situation
Moving from a conceptual pre-
liminary die process to the final
3-D die process can be challenging
for any stamping company.
For Norgren Automation Solu-
tions, Clinton Township, Mich., it
caused many hours of duplicated
efforts, as the company maintained
two master files: one in a solid 3-D
CAD and another in a Microsoft®
Office® tool, such as Excel® or Pow-
erPoint®. CAD model all in one document Norgren Automation Solutions,
has improved overall process tim- 44831 Groesbeck Highway, Clin-
Resolution ing substantially. Duplicated efforts ton Township, MI 48036, 586-493-
The company’s die engineering proc- have been eliminated, and the time 6344, www.norgrenauto.com
ess team developed a method that required to go from preliminary to
allows full use of all information in final process has been cut by weeks.
a traditional die process that can be
printed on an 8.5- by 11-in. size doc-
ument and provides the benefits of
having a true solid-model CAD file.
Using CATIA® V5 as its process-
ing tool, the company exports its die
model into PowerPoint or Excel using
a viewer package called 3DXML.
Double-clicking anywhere on the
picture of the part makes it become a
dynamic solid model.
The 2-D detail description infor-
mation is completed within the solid
model and is exported from the
master CATIA V5 CAD model. All
updates are made within the mas-
ter CAD file, eliminating the need
for duplicate efforts. If an update is
required, an export of the updated
3DXML is placed into a 2-D Pow-
erPoint or Excel document, and the
process is updated.
Technical data for the die process
resides within the PowerPoint or
Excel document in a traditional for-
mat. As a result, customers can view
a 3-D model in detail with all the
visual tools of a full CAD program.
Having open issues, product
concerns, the die process, and the
Enter reader service code 750652 at www.ffid.net

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 9

DIE SCIENCE
Attempting to defy the laws
of physics, Part I
Variables make part tolerancing a
pipe dream
By Art Hedrick
T
rying to form a very small part
or locate a pierced hole to a
precise tolerance can be diffi-
cult. Achieving consistency in these
tasks is even more daunting.
In my career as a consultant, I
have been exposed to part toleranc-
es so small that a change of even a
few degrees in the part or inspection
temperature can put the part out of
specification. The forms and posi-
Called-out part tolerances often are
more stringent than the tolerances on
the incoming material.
tional tolerances called out on prod-
uct designs often defy the physical
abilities of the product’s material.
Sheet Metal Variability
Let me make two facts crystal clear:
1. No coil of any material on earth
has identical mechanical properties
from beginning to end.
2. No two coils of material are
identical, even those slit from the
same master coil.
That doesn’t mean the material is
not within a given specification—
statistically speaking, it most likely
is. However, the metal has tolerance
limits within which it must fall to be
qualified as a given grade, and it can
vary substantially within those limits.
Called-out part tolerances often are
more stringent than the tolerances on
the incoming material. In these cases,
10 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
unless you somehow are requalifying
and re-establishing a tolerance, such
as the metal’s thickness in the die,
you already have lost the battle. For
example, you might have a form tol-
erance of ±0.002 in. on both sides of
the part, but the incoming metal has
a thickness tolerance of ±0.003 in.
Sound crazy? It is. In simple terms,
the stamped part must have more tol-
erance than the incoming metal. And
you can’t expect the die to correct the
incoming material’s inconsistency.
Strain Versus Consistency
For the shape of a stamped part to be
consistent, the amount and distribu-
tion of strain also must be consistent.
In other words, the amount of stretch
and compression that occurs during
forming must be consistent. Many
factors control the amount of strain
that occurs during metal forming;
lubricant type, die geometry, forming
temperature, and forming speed are
just a few.
Certain grades of advanced high-
strength material, such as dual
phase, continue to act on the effects
of strain, stress, and heat after the
forming process has been completed.
The part can change its shape as it is
sitting idle. I have seen shaped parts
twist and deform as much as 0.138
in. over a period of two hours as a
result of cold working. Attempting
to hold a very small surface tolerance
defies the natural behavior of this
material type.
One way to prevent this problem
is to pressure-clamp the part into its
fundamental shape using a fixture
before inspection. Attempting to
qualify a tight-tolerance, deeply con-
toured formed part made from dual-
phase 600, for instance, in its free,
unclamped state is a waste of time.
Even if the part does check within
the given tolerances, chances are it
won’t be consistent in shape. Higher-
strength materials not only react to
strain and stress more adversely, but
they often have a much larger toler-
ance range than low-carbon, high-
formability materials.
In certain part shapes, you can
expect a geometry change as the
die warms up and cools down. Of
course, all parts made from high-
strength materials will not exhibit
these behaviors. It all depends on the
material type and thickness, the part
geometry, and the process used to
create the geometry.
There’s a big push in the automo-
tive industry to use thinner, lighter-
weight materials. Thin, high-strength
materials formed to deep contoured
shapes have a higher tendency for
geometry change after forming.
Die Geometry
I was taught that the process used
to manufacture a part—the dies, the
press, the lubricant, and the sheet
metal—must be engineered and built
to 10 times the stamped part’s toler-
ance.
However, all of these process
factors also must have tolerance.
Clearances that allow a die to func-
tion properly, such as the clearance
around pilot pins, often result in the
inability to achieve certain tolerances.
 DIE SCIENCE
COMPLEX
DESIGNS
Although reducing the clearance between the pilot pins and
the hole they enter into may help to achieve the desired toler-
IN DAYS
ance, doing so may cause the strip to stick to the upper die, NOT WEEKS
resulting in a miss-hit and possible die damage.
Items such as cams that perform piercing and cutting also
must have a certain amount of clearance or slope to function.
Take, for example, a cam slide engineered and built with
0.001 in. of working clearance. This is a high-precision cam
by today’s standards, but the positional tolerance of a hole
made using this cam would need to be 10 times greater, or
no less than ±0.005 in. (0.010 in. overall).
Even though dies are built to very small tolerances, they 3-D DESIGN SOFTWARE
are not perfect. FOR TRANSFER DIES AND
This might sound like gloom and doom, especially if COMPLEX PROGRESSIVE DIES
you’re a product designer or quality control inspector. How-
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you can. Many problems with achieving part tolerances can Thousands of SMART 3-D Modeled Die Components
be resolved by changing the product and process design. POWER APPS
Until next time … Best of luck!S NEW! Automated Functions for CATIA V5 Users

Art Hedrick is president and senior consultant of Dieology, 8730 10 Mile Road MEET US AT
Enter FABTECH
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R&D UPDATE
Hot-stamping boron-alloyed
steels for automotive parts
FE simulation of the process
By Ambikapathy Naganathan, Deepak Ravindran, and Taylan Altan
Editor’s Note: This article discusses the
recent advances made in the simulation
of the hot-stamping process. A three-
part article providing an overview of
this growing technology appeared in the
December 2006, January 2007, and
February 2007 issues of STAMPING
Journal®.
T
he use of ultrahigh-strength
steel (UHSS) in the automotive
industry has increased in the
last few years as manufacturers try
to improve crash safety and reduce
weight. Parts such as B-pillars, side
impact reinforcement beams, and
bumpers are increasingly manufac-
tured from UHSS by hot stamping.1
In hot stamping, the blank is heat-
ed in a furnace to its austenitization
Heat Generation due to Plastic Deformation
Mechanical Field
•Mechanical Thermal Expansion
material Phase
properties transformation
•Volume change depends on
due to phase stress and strain
transformation Microstructure Evolution
Figure 1
The effects of deformation, heat transfer, and microstructural evolution are inter-
related.2
(a) Initial Simulation Step (b) Final Simulation Step
Figure 2
An example hat shape was simulated using DEFORM-3D.3
12 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
hot stamping (see Figure 1). This
makes FE simulation of the process
challenging. Most researchers use a
combination of different FE codes
to capture what occurs during hot
stamping.
When using FE simulation, mak-
temperature (about 900 degrees C), ing suitable assumptions while ignor-
formed in an internally cooled die ing the effects of some of the less sig-
set, and quenched under pressure nificant parameters can help shorten
at a minimum cooling rate of 27 the time needed to obtain reasonably
degrees C per second. This minimum accurate results. Some parameters,
cooling rate ensures the formation however, are required as input to the
of martensitic microstructure in the FE codes.
part, which gives it strength of about The essential material properties
1,500 MPa. include emissivity and flow stress as
Finite element (FE) simulation of a function of temperature, strain, and
the hot-stamping process can help strain rate. Also required are Young’s
manufacturers predict such final part modulus, Poisson’s ratio, thermal
properties as thickness, temperature, conductivity, specific heat capacity,
and hardness distribution. and coefficient of thermal expansion,
each as a function of temperature.
Properties, Parameters The essential process parameters
for FE Simulation are final austenitization temperature;
Mechanical deformation, heat blank transfer time; blank tempera-
transfer, and microstructure evolu- ture as forming begins; die stroke ver-
tion occur simultaneously during sus time; contact heat transfer coeffi-
cient between the blank and tool as
a function of pressure and distance
Thermal Field
between the tool and die surface;
•Thermal material coefficient of friction as a function of
properties
Microstructure
depends on •Latent heat due pressure; initial tool temperature for
to phase nonisothermal simulation; average
temperature
transformation tool temperature for isothermal sim-
ulation; temperature of the cooling
medium needed to cool dies; blank
holder force; closing pressure of the
tools; and time required for quench-
ing and air cooling.
In the hot-stamping process, form-
(c) Formed hat shape (only
P one-quarter is modeled due ing and quenching simulation are
to symmetry) most important, since most of the
840 deformation and heat transfer take
DEFORM 3D (FEA)
Temperature (C)
820
800
Experiment place during these two operations.
780
760
740
Forming Simulation
720
0 1 2 3 4 5 6
The Center for Precision Forming
Time (s) (CPF) is developing an FE-based
(d) Comparision of Experimental and procedure for the simulation of hot-
Simulation Results at Point P
stamping operations, applying the
process to the design of various hot-
stamping dies. For instance, CPF
 R&D UPDATE

900
Ambikapathy Naganathan and Deepak Ravin-
800

Temperature (C)
700
dran are graduate research associates and Taylan
600 Altan is professor and director of the Center for
500
400 P1 Precision Forming (CPF), The Ohio State Univer-
300 P2
200 P3 sity, 339 Baker Systems, 1971 Neil Ave., Colum-
100
0 bus, OH 43210-1271, 614-292-9267, www.
0.0 2.5 5.0 7.5 10.012.5 15.0 17.5 20.0 22.5 25.0
cpforming.org.
Quenching Time (s)
(b) Temperature Versus Quenching Time
Notes
Figure 3 1. T. Altan, “Hot-stamping boron alloyed steels
for automotive parts, part 1: Process methods and
Quenching was simulated in a B-pillar section after 10 hot stampings.4 uses,” STAMPING Journal, December 2006, pp.
40-41.
used DEFORM™-3D to simulate the tions between the tool and part 2. M. Eriksson, “Modelling of forming and
forming of a simple hat shape from a •Elastic deflection of the dies dur- quenching of ultra high strength steel components
22MnB5 blank at an initial tempera- ing forming and quenching for vehicle structures,” Doctoral thesis, Lulea Uni-
ture of 827 degrees C.3 During the •Volumetric change caused by versity of Technology, 2002.
experiment, temperature was mea- microstructure evolution 3. P. Akerstrom, “Modelling and simulation of
sured at Point P (see Figure 2) using CPF, other research groups, and hot stamping,” Doctoral thesis, Lulea University of
a thermocouple. This thermocouple software companies are address- Technology, 2006.
measurement was later compared ing these issues to develop software 4. N. Pierschel, A. Naganathan, and T. Altan,
with the simulation. design tools to improve die and proc- “Thermal simulation and die design in hot stamp-
ess design.S ing tools,” CPF Report No. CPF-5.5/10/02, ERC/
Quenching Simulation NSM, The Ohio State University, 2010.
Determining the optimal size and
location for cooling channels is very
important in hot-stamping tool
design. During the design of cool-
ing channels for complex parts like a
B-pillar, heat transfer simulations can
be used on critical 2-D sections of
the part to determine cooling chan-
nel size and location. Based on the
results obtained from the 2-D simu-
lations, the initial cooling channel
configuration can be selected for the
whole part.
Figure 3 shows the temperature
distributions in the tool and part
during quenching simulation for a
selected section in a B-pillar after 10
hot stampings.
FE simulation of hot stamping
poses many challenges:
•The need for reliable material
data for manganese boron steel at
high strain rate values
•The inability of commercial sheet
metal forming codes to handle com-
bined thermal and mechanical simu-
lation
•Predicting exact contact condi-
an fma publication • STAMPING JOURNAL 13
Enter reader service code 263137 at www.ffid.net

Figure 1
The contact angle between the previous
workpiece and die radius in sequence
drawing should be within 45 degrees
to prevent shock lines and subsequent
cracking.
14 MARCh/APRIL 2011 WWW.STAMPINGJOURNAL.COM
The importance of the contact
angle in deep drawing
How to prevent problems with
cylindrical parts
By seijiro oshima
D
rawn parts with very precise cir-
cularity, roundness, and straight-
ness, as well as no score marks,
are in strong demand in the automo-
tive, medical, and electronics indus-
tries. Cylindrical parts that used to be
produced by machining or grinding
now are being produced more fre-
quently with sheet metal deep draw-
ing for improved productivity and
reduced costs.
In the production of a drawn cup,
the workpiece diameter is reduced
gradually, step by step. A previous
workpiece touches the die- ip of the
next drawing stage, and it is pulled
into the die mouth.
Until recently there has been no
clear standard for this contact angle.
When the contact angle is too large,
the portion of the first tool touch is
expanded to the outside, and a shock
line appears inside the drawn part.
Mild material can assimilate these
faults by the end of the deep-drawing
stroke, but if the material is too hard,
a crack will form at the shock line
(see Figure 1).
To prevent such problems, 45
degrees has been chosen as an
approximate standard contact angle
to be tested (see Figure 2). It is con-
sidered suitable for normal-quality
drawn cups.
Malfunctions Caused by Die Radius Swelling
The material of the contact portion
expands outward during this process.
Even if the contact angle is less than
45 degrees when the cup round of the
workpiece touches the die radius, the
contact angle becomes far larger than
45 degrees when the vertical wall of
the workpiece passes through the die
radius a moment later (see Figure 3).
A small swell grows at the die radi-
us as the flow stagnates. The swell-
ing tends to be unnoticeable because
it doesn’t appear when processing is
complete, but if the swell is not the
same size all around, it can cause sev-
eral problems:
•Score marks—If swelling occurs
when the material is drawn into the
perpendicular wall of the die, a por-
tion of the material can be scraped
Workpiece
Within 45°
Die
Figure 2
A contact angle of 45 degrees is a suit-
able standard for normal-quality drawn
cups.
Workpiece
Punch
A B
Swell
Vertical
Wall
Die
Contact Angle
Cup
Round Larger Than
45°
Figure 3
When the cup round touches the die
radius of the next process, the con-
tact angle becomes far larger than 45
degrees when the vertical wall passes
through the die radius a moment later.
The size of gap A is different from gap B
because the swell pushes the cup wall.
STaMPInG JOuRnaL • an fma publication
A B
Figure 4
A swell that is not the same size all around can cause scoring (A), curving (B), and
unbalanced flange lip roundness (C).
off, causing roughness in the surface
(see Figure 4a).
•curved drawn parts—The
size of gap A is different from gap B
because the swell pushes the cup wall
(see Figure 3). The unbalanced resis-
tance force during processing causes
a curve in the middle of the finished
part (see Figure 4B).
•unbalanced flange lip round-
ness—With swelling, the wall thick-
ness distribution of the vertical drawn
cup is not uniform along the circum-
ference. When parts curve this way
in the middle of processing, a flange
lip bias occurs (see Figure 4c).
When these malfunctions happen,
the workpiece typically suffers from a
wall break, and galling appears on the
die lip. As a result, the finished prod-
uct is defective because of imprecise
roundness and straightness.
The 15-degree Conic Lip
A die with a conic lip of 15 degrees
can be used in drawing to prevent
swelling when the workpiece’s verti-
Cone
Cone Intermediate
Figure 6
Adding an intermediate process with a large-radius die will push the cone out to the
flange in the final process to prevent galling.
an fma publication • STaMPInG JOuRnaL
C 15°
cal wall passes through the lip (see
Figure 5). This conic lip is very effec-
tive for preventing the swelling and
can eliminate almost all of the result-
ing problems. As a whole, the draw-
ing force decreases while the life of
the die increases.
While the 15-degree conic lip
is good for preventing swelling, it
causes a 15-degree neck under the
flange in the workpiece, which is not
acceptable for the final product.
When a very small neck is needed
for the final product and this small
radius is used in the final drawing
die, the small die radius shaves off
a portion of the cone, causing severe
galling. Adding an intermediate proc-
ess with a large-radius die will push
the cone out to the flange in the final
process to prevent galling (see Fig-
ure 6).
Figure 7 shows precise cylindrical
parts deep-drawn with a 15-degree
conic lip die and the added interme-
diate process. Made of 0.02-in.-thick
C2680 material, the part is 1.19 in.
Final Flattening
Workpiece
Vertical
Wall
Die
Figure 5
A die with a conic lip of 15 degrees can
be used to prevent swelling in sequence
drawing when the vertical wall passes
through.
long with a straightness of 0.0004 in.
Outer diameter is 0.16 in. and inner
diameter is 0.14 in., with roundness
of 0.0004 in. and a neck round of
0.006 in.
This type of precision drawing
work can be achieved by paying
attention to the contact point of the
drawing die with the workpiece and
using a contact angle between 15 and
45 degrees. While an angle smaller
than 15 degrees is preferable, the
parabola shape sometimes is applied
as a die lip, and it’s not easy to make
this shape or to confirm its accuracy.
Taking a proactive approach dur-
ing the process is key to precision
results.S
Seijiro Oshima is president of APT Giken, 3052-
1 Moto-oshima, Matsukawa, Shimoina, Nagano
399-3303 Japan, 81-265-36-3256, apt@clio.
ne.jp, www.clio.ne.jp/home/apt.
Figure 7
These precise cylindrical parts were
deep-drawn with a 15-degree conic lip
die and an added intermediate process.
WWW.STAMPINGJOURNAL.COM MARCh/APRIL 2011 15
 5 ways to empower
die designers for
better die results
How effective design leads to an
improved bottom line
By mark Hansen Ineffective communication can be
blamed on time restraints, distances

D
uring the last decade many tool
and die shops switched from
2-D to 3-D software for design,
shifting more of the tasks for die pro-
duction to the design department.
Designers now are responsible for
showing full 3-D solids throughout
the entire design; form stations with
full surface shape, including over-
bend where needed; and all clear-
ances for machining, trimming, and
stripping.
Given their added responsibil-
ity, now more than ever you need to
give your die designers the tools they
need to get the job done right. The
more accurate their designs, the fast-
er those dies will build and work in
tryout. When you empower your die
designers to produce a high-quality
design, your entire shop will benefit.
But how do you accomplish this?
between departments, division or
strife, and even pride. Some people
have the attitude that the design,
machining, and build departments
all are separate teams. They miss the
fact that all the departments together
make one team, working together
toward a common goal.
Allow and encourage your design-
ers to meet with the machinists and
diemakers (see Figure 1). Use kickoff
meetings and continuous improve-
ment meetings as venues for sharing
information. Make sure conversa-
tions in which different opinions are
expressed stay positive and on sub-
ject; don’t let them become personal.
Remind everyone of their shared
objective. Removing communication
barriers between the design depart-
ment and other departments will
result in fewer design errors, lower
die cost, and a better overall product.
Figure 1
Communication between die designers
and other departments needs to be more
effective. Here, Centerline Engineering
diemaker Tim Evans (left) and die
designer Dean Dault confer. Photo
couresty of Centerline Engineering Inc.,
Comstock Park, Mich.
ers; specific brands and styles of pur-
chased components; and information
about the production press, such
as flow direction, shut height, feed
height, and mounting requirements.
Don’t hesitate to obtain this infor-
mation from the customer. Supply-
ing the designers with these types
of details will reduce design review
changes and improve end delivery
time.

No. Improve While a picture is worth a thou-

The first step to empower- No. The second way to empow-

Communication Supply Information sand words, a good sample design

1. ing
is worth even more. It should be a

2.
your die designers is to
increase the effectiveness of
communication between
them and other depart-
ments. Design requirements, feed-
back on recurring design problems
and errors, and ideas for improve-
ment must flow freely through the
entire shop.
er die designers is to sup-
ply as much information as
possible upfront. Designers
need accurate standards
and requirements so they
know how to proceed. They also
need to know the material thickness,
material type, and tolerances of the
stamped part; inch or metric fasten-
recent design for a similar part from
the same end customer, running in a
well-functioning die in a similar pro-
duction press. Again, don’t be afraid
to ask your customer for a good sam-
ple design. The information that the
sample design conveys will reduce
the cost and time required to com-
plete the design.

16 MARCh/APRIL 2011 WWW.STAMPINGJOURNAL.COM STaMPInG JOuRnaL • an fma publication

No. Establish
Standards
Die Design
3. Another
designer
step toward
empowerment
is to create and maintain
easy-to-understand yet in-
depth die design standards.
Many stamping companies, even
those that have ISO or equivalent
certification, do not have any design
standards. They have never taken the
time to write them up.
Design standards are the road map
for designers. They should include:
•Accepted CAD formats and lay-
outs.
•A list of deliverables.
•Preferred die components.
•Internal design requirements.
•A description of your design
review process.
•Requirements for machining, die
build, and tryout.
To ensure the design standards
communicate the requirements clear-
ly, use common trade terminology
and easily understood words. Adding
a simple diagram or picture often can
replace half a page of words.
Once established, keep the design
standards updated and maintained.
If you provide obsolete standards
to your designers, you are literally
throwing away time and money.
No. Eliminate
Design Tasks
Repetitive
4. The fourth way to help your
die designers is to eliminate
the repetitive tasks that
take large amounts of their
time. Given the advance-
ments in 3-D CAD software, why
should designers remodel or redraw
the same components over and over
for every design?
Reduce repetitive steps by saving
the components in a place where
they can be reused. Better yet, use a
catalog or seed model system to com-
plete designs (see Figure 2). These
an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011
Figure 2
This large cast progressive die design was completed with a catalog and template
system.
allow designers to bring into the
design a headed punch, gas spring,
or wear plate that can easily adjust or
morph into the one they specifically
need.
Some software packages even
allow designers to bring in entire
template assemblies, including stock
strip, die set, stripper pad systems,
nitrogen manifolds, made and pur-
chased cams, cast assemblies, stamp-
ing press, and transfer systems.
Once these components are inserted,
designers can make minor adjust-
ments to the parameterized assembly
until they achieve the desired fit and
functionality.
Inserting and adjusting entire
assemblies to fit a particular stamping
die can reduce overall design cost by
as much as 80 percent. The template
assemblies can be made customer-
specific by allowing the use of only
certain components. Templates also
can self-check the design to ensure
die design requirements are met.
Another way to reduce repetitive
design steps is to automate the cre-
ation of drawings, detail prints, and
the stock list. Programs are available
that fully automate these processes;
some are linked so that if changes
are made to the 3-D solids, the draw-
ings and stock list will automatically
update. Using the latest CAD soft-
ware and programs available will
reduce design time, improve accu-
racy, and reduce design cost.
No. Invest in New
Equipment
5. that
The final improvement
can benefit your die
designers and your com-
pany is to replace obso-
lete hardware with new
equipment. If a designer spends 20
minutes a day waiting on hardware
to crunch data, the waiting cost
works out to roughly $5,000 a year
at shop rate. Given the price of some
of the latest hardware packages, your
return on investment will be quick.
One word of caution when pur-
chasing new hardware: Make sure it
is compatible with your shop’s CAD
software. All CAD software programs
have specific hardware require-
ments, with some even calling out
certain graphics cards, processors,
and operating systems. The benefits
of buying fast, compatible hardware
include reduced risk of lost or cor-
rupt CAD data, reduced design time,
and reduced design cost.
Empowering your die designers
with the right tools will lead to short-
er lead-times, lower prices, and faster
delivery times, all of which will have
a positive impact on your company’s
bottom line. S
Mark Hansen is the design manager for 3-D
Solutions Design Service LLC, 4753 Four-
teen Mile Road, Suite B, Rockford, MI 49341,
616-696-9344, mark@3ddiedesign.com,
www.3ddiedesign.com.
17

Before
Coil processing
equipment—
new or
retrofit?
Modernization without a big
price tag is possible
By jim ward
C
ompetition among manu-
facturers for market share
in the new global economy
is fierce. Many manufacturers have
seen their markets dwindle, with
some of their customers disappear-
ing from the landscape entirely.
Given the intense competition,
attaining the highest productiv-
ity possible from the shop floor is
increasingly important.
With these challenges, install-
ing new equipment is not always
an option. So optimizing produc-
tivity often comes down to finding
18 MARCh/APRIL 2011 WWW.STAMPINGJOURNAL.COM
After
ways to maximize the use of existing
resources.
Some conditions are clear clues
that it is time to upgrade the coil
line—either by refurbishing or
replacing components or refurbish-
ing or replacing the entire coil line.
Excessive downtime, increased
maintenance that affects overall pro-
ductivity, and safety deterioration
are indicators that the equipment
needs upgrading.
Or it may be that existing equip-
ment is functional, but that produc-
tivity needs a boost. In this case,
various types of upgrades to coil
handling and feeding equipment
Excessive downtime, increased maintenance
that slows productivity, and safety deteriora-
tion indicate the need to upgrade coil feed
equipment. Some coil handling and feeding
equipment upgrades can be done that double
productivity at half the cost of new equipment.
can help stampers achieve measur-
able gains in their production effi-
ciencies.
Controller Upgrade
First, replacing the controller is a
relatively easy way to simplify setups
and increase functionality (see Fig-
ure 1). Many new servo controllers
are designed to be installed quickly
into coil lines—sometimes even over
a weekend.
Many new servo
controllers are
designed to be
installed quickly
into coil lines—
sometimes even
over a weekend.
servo. Many servo feeds in opera-
tion today were installed when servo
technology was new. While they
were a great replacement to air and
mechanical feeds, many were built
STaMPInG JOuRnaL • an fma publication
on unsupported hardware and soft- ductivity, such as storage recipes, rate sensing of the loop position
ware platforms. The failure of a criti- operator prompts, servo feed diag- and precise feedback of the straight-
cal drive, motor, or motion control- nostics, multilingual programming, ener or reel drive. These are crucial
ler can cause extended downtime. and direct downloading of press for effective operation of the coil
variable speed. Many original parameters. feeding system. Original loop
straighteners and reels in coil feeding loop control. Loop control control systems are often simple
systems were designed with simple upgrades can help improve accu- on/off switches or potentiometers.
drive mechanisms. Today’s variable-
speed controls are programmable.
This allows stampers to customize
parameters to optimize uncoiler and
straightener machine performance
to provide the proper torque neces-
sary for these operations.
interfaces. Many roll feeds in
operation today have outdated
operator interfaces. These are often
simple devices that offer only the
basic setup functions of feed pro-
gression and speed percentage. This
limits their effectiveness in today’s
stamping operations. With a mod-
ern upgrade, stampers gain many
new features that reduce setup time,
improve consistency, and raise pro-

Before

After
Figure 1

Upgrading the controller is a relatively

easy way to simplify setups and increase
functionality and can be done quickly— Enter reader service code 240054 at www.ffid.net
sometimes over a weekend.

an fma publication • STaMPInG JOuRnaL WWW.STAMPINGJOURNAL.COM MARCh/APRIL 2011 19

 Lawn Mower Company Retrofits
Husqvarna in Orangeburg, S.C.,
manufactures 4,000 Craftsman®
lawnmowers a day. The company
wanted to extend the life of its coil
line equipment, as well as to take
advantage of available upgrades.
Coe Press Equipment analyzed
the 16-year-old line and proposed a
series of upgrades. Part of the analy-
sis was a comparison of the cost of
new equipment to upgrades. Coe
would provide new equipment for
$275,000, or upgrade the system for
$150,000.
Husqvarna opted to upgrade.
Equipment upgrades included:
•Changed the reel from traveling
type to stationary type
20 MARCh/APRIL 2011 WWW.STAMPINGJOURNAL.COM
•Replaced the stationary coil lift
with a traveling coil car
•Added a new heavy-duty peeler/
threader/hold-down station
•Added new threading table for
the conventional loop area
The following rebuild items were
added to the scope of work:
•All new straightener bearings
•Two new lower straightener rolls
•New straightener gears and idler
shafts as required
•New machine covers and guards
as required
New configurations and line mod-
ifications included:
•Changed the direction of the reel
and straightener from L-R to R-L
Enter reader service code 750848 at www.ffid.net
•Changed the straightener
from an incline head to a standard
arrangement
•Changed from an overhead loop
to a standard loop area
•Relocated all operator controls
for the new R-L feed direction
•Repaired damage to the straight-
ener keyways
Additionally, the servo feed was
upgraded to a new Coe ServoMaster®
controller and motorized passline
height adjustment to improve setup
and reliability of the servo feed.
All combined, the upgrade is
expected to extend Husqvarna’s coil
line for another 15 years.
STaMPInG JOuRnaL • an fma publication
Modernized loop controls—ultra-
sonic, photoeye, and laser—provide
noncontact detection­technology to
meet higher-quality requirements.
Loop height and response output
signals are programmable to achieve
optimal coil line performance for
each job setup.
Straightener Capacity. The
increased use of higher-strength
materials has created coil straight-
ening problems for many stampers.
Much of the existing equipment was
designed to straighten only mild
steels with low yield strengths. It
is now common for yield strengths
to exceed 60,000 PSI. Straighten-
ers can be upgraded to meet this
demand with new, high-perfor-
mance drives and motors, improved

Mechanical
Upgrades
Other potential areas for press line
optimization are the coil, feeder, and
straightening equipment itself.

Before

After
Figure 2

Straighteners can be upgraded to meet

the higher demands of high-strength
steels with high-performance drives and
motors, improved reduction packages,
and a center backup assembly to prevent
deflection.

Line Speed. Output rates may

be constrained by the straightener
or reel line speed capability. Many
progressive press lines were origi-
nally specified to run at a max-
imum line speed of 40 to 60 feet
per minute (FPM). Upgrades to the
machine drive and reducer package
Enter reader service code 458793 at www.ffid.net
can double coil rate speeds—up to
100 FPM.

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 21

 reduction packages, and by adding a
center backup assembly to prevent
deflection of the straightening rolls
(see Figure 2).
Coil Containment. Many stamp-
ers are being challenged to process
Enter reader service code 170574 at www.ffid.net
22 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
not only higher-strength materials,
but also a wider range of mate-
rial thicknesses using their existing
equipment. Upgrades to the thread-
ing drive system and the addition
of hold-down arms, lower hold-up
arms, and motorized end-wheels
can help stampers process more
thicknesses.
Load Direction Changes. Press-
es and auxiliary equipment often
are shuffled around to make room
for new presses or to improve the
stamping process flow. The feed
and loading direction of the coil
can limit the flexibility and options
for optimizing plant layout. Chang-
ing the loading direction of the coil
reel or the controls position on the
straightener and servo feed can give
stampers the flexibility to improve
plant layout.
Field retrofits to
existing lines can
be performed in
less time than
those that require
the system to be
shipped to a
service center.
Threading Safety. Although
quick changeover is essential to
pressroom productivity, it is not
efficient or safe to allow operators
to manually thread heavy-gauge
or high-strength coil strip into a
straightener or feeder. Existing coil
feed lines can be upgraded with
thread tables, peeler tables, debend-
ers, and hands-free peeler/threader
hold-downs to improve coil change
efficiency and safety.
Motorized Line Functions.
Motorizing key functions of the coil
feed line can enhance setup speed
and consistency. Machine axis such
as passline height setting, edge
guide adjustments, and straightener
roll depth settings can be effectively
motorized.
of the existing system, production
requirements, and a cost compari-
son by a qualified coil line profes-
sional can help stampers determine
the best approach.S
Jim Ward is sales manager of Coe Press Equip-
ment, 40549 Brentwood, Sterling Heights, MI
48310, 586-979-4400, jtw@cpec.com, www.
cpec.com. Coe Press Equipment manufactures
and installs both new equipment and retrofits.

Rebuild Versus
New: Cost Analysis
To companies that are not in a posi-
tion to make a capital investment in
new equipment, the decision to ret-
rofit may be a favorable alternative.
Refurbishing an old press to bring
it up to new standards required for
today’s demand for quality, clear-
ances, and control can result in
significant savings over the cost of
a new press.
However, extensive rebuilds
often can take up to six months to
complete. Field retrofits to exist-
ing lines can be performed in less
time than those that require the
system to be shipped to a service
center. Field retrofits may include
line speed increases, the addition of
coil containment devices, loop con-
trol upgrades, and threading system
improvements.
Thus, the decision to remanufac-
ture or upgrade press equipment
should be made only when the
expected workload and part vol-
ume justify the cost to rebuild.
Each situation is unique regarding
the decision to upgrade or purchase
new equipment. It is important to
evaluate all aspects of the stamp-
ing process, from the standpoint of
mechanical, electrical, power train,
line configuration, and line speed,
to help arrive at the best solution.
After analyzing the separate yet
interrel-ated issues of time, cost of
new versus retrofit, and potential
productivity gains, each company
will come to its own conclusion.
Obviously, sometimes new
equipment—or a combination of
new and upgrades—makes more
Enter reader service code 261649 at www.ffid.net
sense than a retrofit. An analysis

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 23

AUTOMOTIVE INTELLIGENCE
Pricing sanity
returns to the
automotive
industry
Will it last for suppliers?
By Bernard Swiecki
L
ast year’s improved automotive
sales numbers were tempered
by the fact that they didn’t
improve as much as many analysts
had forecast—and hoped—before
the year began. The 11 percent
increase, though mild, was accom-
panied by one important caveat:
Automotive industry profits recov-
The newly found pricing sobriety
is one of the key factors driving
today’s automotive market to be
smaller than it was in years gone by.
ered much more quickly than auto-
motive sales did. Financial health, it
seems, has returned to the automo-
tive industry, even if the glory days of
roaring vehicle sales have not.
The reasons for this significant
improvement start at the top of the
automotive value chain. Automak-
ers have held the ground on the sales
incentives that had eaten away at the
industry’s profitability for a decade.
What’s more, they have not gotten
involved in the one-upmanship of
competitive reductions in vehicles’
base price. Incentives are down,
24 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
vehicle prices are up, and the trans-
action value of the average automo-
tive purchase has risen accordingly.
Consumers are still getting a great
deal—they’re just paying a fair price
for the product they’re buying.
This newly found pricing sobri-
ety is one of the key factors driv-
ing today’s automotive market to be
smaller than it was in years gone by.
The other, more obvious factors are
still there, including a national labor
market that isn’t improving as fast as
hoped for, tighter access to lending,
and jitters about the staying power of
the economic recovery.
Automakers have clearly benefit-
ed. Ford had the second-most prof-
itable year in its history, despite the
historically shockingly small market,
and its stock shares are trading at
more than 10 times their 2009 price.
GM’s financial performance has justi-
fied an IPO successful beyond even
the most optimistic expectations.
Chrysler is reporting operating prof-
its. And international automakers
have, for the most part, also experi-
enced financial success.
What It Means for
Suppliers
The benefits have, at least partially,
made their way to suppliers. Many
are reporting positive financial per-
formances, revenue growth, and a
return to functioning outside the
panic mode of the last two years.
Supplier stocks are becoming popu-
lar on Wall Street, as many analysts
have been recommending them as
poised to take advantage both of the
gradual recovery of automotive sales
and of the automotive industry’s
newfound fiscal sensibility.
Not all of the credit for these recent
successes goes to pricing, of course.
A key reason that the industry is able
to be profitable in so small a market
is that both automakers and sup-
pliers have cut waste and capacity
so deeply. This smaller automotive
market is being serviced by a smaller
industry.
Concerns are surfacing, however,
that all might not be well for suppli-
ers. Many are still running extremely
lean and would find themselves
highly vulnerable to a number of
potential disruptions: an economic
downturn, an automotive sales dip,
automaker financial pressure, or
insufficient access to capital.
This last factor is perhaps most
responsible for keeping automotive
supplier executives awake at night,
despite the positive news otherwise
surrounding the industry. Automak-
ers’ purchasing staffs are likewise
concerned about the capability of
their supply base to make the neces-
sary investments to ramp up parts
production as the recovery continues
and orders from automakers increase
in volume but not necessarily in
 AUTOMOTIVE INTELLIGENCE

profit margin.
It is therefore a possible blessing
in disguise that the automotive sales
recovery has been slower than hoped
for. The gradual return to volume
production has allowed the supply
base to ramp up production more
gradually, giving it more time to find
elusive financing from a still-stingy
financial sector.
monumental achievement of having
survived a crisis that destroyed so
many others.
Whether the automotive industry
as a whole has taken to heart the les-
sons of cooperative relationships that
made surviving the crisis possible is
an open question that soon will be
answered.S
Bernard Swiecki is director, market analysis, at
the Center for Automotive Research, 1000 Victors
Way, Suite 200, Ann Arbor, MI 48108, 734-929-
0484, bswiecki@cargroup.org, www.cargroup.org.

Cooperative
Reliability. Service. Value.
Makes a Difference
All told, things can be described as
Clearly COE Press Equipment
proceeding as well as could be hoped
for. The question for suppliers is,
Will it last? Automaker shareholders
and their purchasing executives have
been noticing the positive financial
reports and stock forecasts hinting
that certain firms in the supplier sec-
tor may be a bit more profitable than
they need to be.
Many suppliers would not have
survived the crisis if not for extreme-
ly understanding and cooperative
actions of the automakers. Now that
the worst of the crisis is over, this
pricing and contractual flexibility is
at risk of reverting to the less cooper-
ative levels experienced in years past. When you want a no-nonsense, coil feeding
The U.S. automotive industry con-
equipment partner you can count on, it’s
tinues to undergo structural change.
The biggest driver of change looming clearly COE Press Equipment. With a heritage
on the horizon is fuel economy stan- of reliability since 1976, North American stampers,
dards that will become increasingly fabricators and manufacturers have depended
stringent over the next few years. upon COE for productivity-enhancing solutions that improve
Automakers already are redesigning their bottom line. A single source supplier, COE delivers
their products to be more fuel-effi-
best-in-class machinery, on-site engineering and manufacturing,
cient, lighter, and environmentally
friendly. These changes add tremen- 24/7 support, and unparalleled service. Simplify your life and
dous costs to vehicles that already improve your operations. COE is clearly the one-stop shop for
have been getting more expensive all your coil feeding needs.
because of material costs and the
inclusion of more safety and infor- • On-site Service & Support
mation technology.
• Fully Integrated Systems COE Press Equipment
Supplier executives must therefore
judge the months ahead with a wary • Roll Feeds Tel (586) 979-4400
eye. The ever-evolving business envi- • Coil Reels Email info@cpec.com
ronment of the automotive industry • Straighteners www.cpec.com
will give them little time to savor the Enter reader service code 111347 at www.ffid.net

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 25

 2011 Mechanical Press Buyers’ Guide©
Clutch/ Gearing Suspension Guiding Structure

Slide Down, Adjustment

Brake Arrangement Points

Up (w/standard stroke,

Straight-side w/o Tie Rod

Shut Height Over Bed

Straight-side w/Tie Rod

min. - max.inches)
Flywheel-nongear

Gap or C Frame
Maximum SPM
Double Gear
Link-Motion
Single Gear

Knuckle Joint
Stroke

Pneumatic

Inclinable
Hydraulic
Capacity Length

Muliple

4-Point
6-Point
8-Point
Single
Servo
Range (min. - max.,

Other
Model (tons) inches)
AIDA-America, Dayton, OH Enter code 240054 at www.ffid.net
NC1 Series 35-250 3 3 3 3 3-12 9.8-17.7 130 3 3
NC2 Series 110-250 3 3 3 3 4.3-11 13.7-21.6 100 3 3
PMX Series 300-1,000 3 3 3 6-16 24-40 90 3
SMX Series 300-2,000 3 3 3 3 To spec. 24-40 30 3 3
TMX Series 300-4,000 3 3 3 3 To spec. 24-40 30 3 3
Amada America Inc., Buena Park, CA Enter code 122726 at www.ffid.net
TP-EX Series 49.5-275 3 3 3 2-12 9-21.6 100 3 3
TPL Series 49.5-330 3 3 3 3 2-12 9-18 125 3 3 3
TPW Series 121-330 3 3 3 3-12 10-20 125 3 3
TPWL Series 110-550 3 3 3 3 3-12 10-20 125 3 3 3
SDE Series 49.5-330 3 3 3 0-12 11.4-21.6 225 3 3 3
SDEW Series 220-330 3 3 3 3-10 10-17, 12-19 60, 80 3 3
Bruderer Machinery Inc., Ridgefield, NJ Enter code 101416 at www.ffid.net
BSTA 10 - BSTA 2500 10-250 3 3 3 .24-2.95 To spec. 2,000 3 3
Dirinler Machinery Inc. Co., Izmir, Turkey Enter code 1109592 at www.ffid.net
CDCS 251 P81 25 3 3 3 .39-2.56 9.45 150 3 3
CDCS 401 P81 40 3 3 3 .20-2.95 11.02 150 3 3
CDCS 630 P81 63 3 3 3 .16-4.02 13.98 54 3 3
CDCS 800 P81 80 3 3 3 .71-4.49 15.16 54 3 3
CDCS 1000 P81 100 3 3 3 .55-4.48 15.15 60 3 3
CDCS 1300 P81 130 3 3 3 .20-4.33 15.74 60 3 3
Durable Mecco, Franklin Park, IL
MC11D .6 3 3 .4527-.1377 12.25 60 3
MC18D 3.25 3 3 .6299-2.2047 13.25 60 3
MC30D 6.5 3 3 .7874-2.5196 20.3 60 3
MC19 .5 3 3 3 .4527-1.3779 11.75 60 3
MC21 2.75 3 3 3 .6299-2.2047 11.125 60 3
MC35 10 3 3 3 .7874-2.5196 12.25 60 3
Eagle Press, Oldcastle, ON Canada Enter code 750683 at www.ffid.net
SC1 Single Point Crank 100-500 3 3 3 3 3 2-20 To spec. 80 3 3 3
SC2 2 Point Crank 100-1,000 3 3 3 3 3 2-20 To spec. 80 3 3 3
SCL2 2 Point Crank Link 400-1,000 3 3 3 3 12-20 To spec. 60 3 3
SE2 2 Point Ecc. Gear 600-4,000 3 3 3 3 3 10-48 To spec. 50 3 3
SEL2 2 Point Ecc. Gear Link 600-2,000 3 3 3 3 16-48 To spec. 40 3 3
SE4 4 Point Ecc. Gear 600-4,000 3 3 3 3 3 10-48 To spec. 50 3 3
SEL4 4 Point Ecc. Gear Link 600-4,000 3 3 3 3 16-48 To. spec. 40 3 3
Fagor Arrasate USA Inc., Bensenville, IL Enter code 777592 at www.ffid.net
Blanking 440-1,500 3 3 3 3 3 3 8-18 48-60 80 3 3
Double Action 1,100-3,200 3 3 3 3 3 40-60 60-78 25 3 3
General Purpose 400-4,000 3 3 3 3 3 3 30-60 18-70 50 3 3
Monoblock 100-800 3 3 3 3 3 3 4-24 24-40 150 3 3
Progressive Die 300-1,500 3 3 3 3 3 3 16-24 36-50 60 3 3
Tandem Line 400-4,000 3 3 3 3 3 3 28-60 50-78 25 3 3 3

The Mechanical Press Buyers’ Guide has been edited to fit this editorial space.
To view the complete guide, visit http://www.thefabricator.com/buyersguides
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 buy-
ers’ 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.

26 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication

 2011 Mechanical Press Buyers’ Guide©
Clutch/ Gearing Suspension Guiding Structure

Slide Down, Adjustment

Brake Arrangement Points

Up (w/standard stroke,

Straight-side w/o Tie Rod

Shut Height Over Bed

Straight-side w/Tie Rod

min. - max. inches)
Flywheel-nongear

Gap or C Frame
Maximum SPM
Double Gear
Link-Motion
Single Gear

Knuckle Joint
Stroke

Pneumatic

Inclinable
Hydraulic
Capacity Length

Multiple

4-Point
6-Point
8-Point
Single
Servo
Range (min. - max.,

Other
Model (tons) inches)
Heim Group, The, Chicago, IL Enter code 118635 at www.ffid.net
4/6 B & SS 40-60 3 3 3 3 1-5 7-29 105 3 3 3
G1-150-200-250-300 150-300 3 3 3 2-14 12-32 40 3 3
S1 Maxi 150-600 3 3 3 2-20 12-48 60 3 3
S2/S4 Standard 150-400 3 3 3 3 2-14 12-48 60 3 3
S2/S4 Maxi 200-1,000 3 3 3 2-20 12-60 40 3 3
Komatsu America Industries LLC, Rolling Meadows, IL Enter code 111604 at www.ffid.net
OBS Series General Purpose 29-220 3 3 3 2-11.8 7.7-18.9 240 3 3
H2F Series Straight Side Servo 220-2,500 3 3 3 3 3 0-15.7 20.5-37.4 80 3 3 3
W Series General Purpose 121-330 3 3 3 4.3-11.8 14.7-21.6 100 3 3 3
G Series General Purpose 220-4,500 3 3 3 3 3 3.9-32.6 20.1-37.4 150 3 3
M Series Progressive Die 220-3,000 3 3 3 3 3 3.9-11.8 18.7-27.5 150 3 3
S Series Auto Class Transfer 1,000-5,000 3 3 3 3 3 18.9-43.5 25.6-65.5 30 3 3
Minster Machine Co., The, Minster, OH 109914 Enter code 109914 at www.ffid.net
Amada Gap TP-EX/TPL Series 50-220 3 3 3 3 2.75-11.81 10.04-18.11 180 3 3
Amada Gap TPW/TPWL Series 120-550 3 3 3 3 4.33-11.81 13.78-18.11 110 3 3
Amada SDE Series 50-330 3 3 3 0-12 11.4-21.6 150 3 3
2011 Mechanical66-90 3 Press3 Buyers’ Guide
©
HB Series 3 .59-2.5 13-19.0 1,000 3
P2 Series 60-200 3 3 3 3 1-8 11-20 600 3 3
P2H Series 71-180 3 3 3 3 .79-7.88 8.9-23.6 600 3 3
Morsco-Flexopress, Cincinnati, OH
Flexopress 15-70 3 3 3 3 3 2-12 6.0-16.0 800 3 3 3 3
Flexopress 60-400 3 3 3 3 3 3 2-18 12.0-24.0 800 3 3 3 3
Oak Press Solutions Inc., Sturgis, MI Enter code 461989 at www.ffid.net
PP-1A 30-45 3 3 3 0-2 8.50-10.50 1,000 3 3
SS-30 30 3 3 3 0-2 8.00-10.00 1,500 3 3
SS-60 60 3 3 3 0-2 9.00-12.00 1,000 3 3
LP-30 30 3 3 3 0-1.5 8.00-10.00 400 3 3
LP-60 60 3 3 3 0-2 9.00-12.00 400 3 3
LP-100 100 3 3 3 0-3 9.00-12.00 400 3 3
Schuler Inc., Canton, MI Enter code 261649 at www.ffid.net
SPE S Series Prog. Die 1,100-1,750 3 3 3 20-24 48-52 50 3 3
STL4 S Series Transfer 1,350-3,500 3 3 3 24-36 50-60 30 3 3
PME2 and PME4 Progressive Die 880-3,600 3 3 3 16 39.4-55.1 60 3 3
PML2 and PML4 Prog. Die 880-3,600 3 3 3 20 39.4-55.1 50 3 3
HUQ Prog. and Transfer 440-1,800 3 3 3 3 3 To spec. To spec. 120 3 3 3
TME2 and TML2 Transfer 880-3,600 3 3 3 3 20-36 47.2-55.1 40 3 3
SEYI-Presses Inc., Tullahoma, TN Enter code 43422 at www.ffid.net
SN1 Gap 28-275 3 3 3 3 1.38-9.84 7.87-17.72 180 3 3
SN2 Gap 121-330 3 3 3 3 2.75-11.02 13.78-21.65 120 3 3
SNS1 Straight Side 88-330 3 3 3 3 2.36-11.02 11.81-19.69 150 3 3
SLS1 Link Motion Straight Side 88-330 3 3 3 3 3 3.94-9.84 11.81-17.72 110 3 3
SNS2 Straight Side 176-440 3 3 3 3 3.15-11.81 15.75-23.62 115 3 3
SLS2 Link Motion Straight Side 176-440 3 3 3 3 3 5.12-11.81 15.75-23.62 90 3 3
Shengyuan Mechanical Equipment Eng. Co. Ltd., Dongguan City, GD China
35-250 3 3
Stamtec Inc., Manchester, TN Enter code 136680 at www.ffid.net
OCP Single Point Gap Frame 25-260 3 3 3 3 1.57-11.81 9.65-21.26 180 3 3
G2 Series Two Point Gap Frame 110-250 3 3 3 3 4.33-11.02 15.75-21.65 100 3 3

an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 27

 2011 Mechanical Press Buyers’ Guide©
Clutch/ Gearing Suspension Guiding Structure

Slide Down, Adjustment

Brake Arrangement Points

Up (w/standard stroke,

Straight-side w/o Tie Rod

Shut Height Over Bed

Straight-side w/Tie Rod

min. - max. inches)
Flywheel-nongear

Gap or C Frame
Maximum SPM
Double Gear
Link-Motion
Single Gear

Knuckle Joint
Stroke

Pneumatic

Inclinable
Hydraulic
Capacity Length

Multiple

4-Point
6-Point
8-Point
Single
Servo
Range (min. - max.,

Other
Model (tons) inches)
GL1 Link Motion Single Point 80-200 3 3
3 3 3 3.94-7.87 11.8-17.7 110 3 3
Gap Frame
GL2 Link Motion Two Point 110-260 3 3 3 3 3 4.33-11.02 15.8-21.7 90 3 3
Gap Frame
SC1 Single Point 160-287 3 3 3 3 3.15-7.87 13.78-18.11 115 3 3
Straightside
SC2 Two Point Straightside 121-275 3 3 3 3 3.15-7.87 13.78-18.11 115 3 3
S1 Single Point Straightside 165-660 3 3 3 3 3 3 5.91-12.2 15.75-30.12 120 3 3
Sutherland Presses, Malibu, CA Enter code 130073 at www.ffid.net
MARK 1 Gap 25-275 3 3 3 3 3 2-12 8-24 150 3 3
Mark 1 HS High Speed 25-220 3 3 3 1-6 Up to 21 180 3 3
MARK 2 Gap 121-275 3 3 3 3 4-10 13-24 90 3 3
SC1 Single Point 88-660 3 3 3 4-14 13-22 110 3 3 3
SL1 Link 176-1,000 3 3 3 3 3 4-14 13-32 100 3 3 3
CRS Double Point 176-440 3 3 3 4-10 24 80 3 3
Winset Technologies LLC, Islandia, NY Enter code 459494 at www.ffid.net
LS01 1-10 3 3 .25-1.5 3.5 300 3 3
LS02 1-20 3 3 .25-1.5 5 300 3 3
LS03 1-30 3 3 .25-1.5 6 300 3 3

Enter reader service code 1017651

at www.ffid.net
28
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an fma publication • STAMPING JOURNAL WWW.STAMPINGJOURNAL.COM MARCH/APRIL 2011 29

ASK THE EXPERT

What springs are best for are not alike. Some springs are
manufactured and color-coded to
forming HSLA down and look just like the top U.S. brands,
but they are cheap knockoffs. Know

drawing up? where your springs came from. Top-

By Thomas Vacca
Q: We are stamping a small mechanical properties.
bracket, about 1 in. wide by 2 in. The carbon content is between
long and 0.050 in. thick. Made of 0.05 and 0.25 percent to retain
high-strength, low-alloy steel, it formability. Other alloying elements,
has a drawn feature on one end including titanium, vanadium, and
and multiple forms on the other. niobium, are added to maintain
To meet the customer’s require- and increase the material’s strength
ments, we have to form down and relative to the grain size. While they
draw up. Any advice? alter the microstructure of the steel
For HSLA, choose compression
springs that are cut to
length, manufactured
with flat ends, and ground
Tom Vacca Dennis Cattell so they seat squarely.
A: This is a common question. and produce a very fine, even mix of
First, when choosing springs, use carbides in the matrix, they do not
this rule: If the requirements push help in the stamping process. With
the limits of the coil springs, always its high strength and toughness,
consider nitrogen springs first. HSLA steel is much harder to form
You will be out of luck if you than carbon steel.
design and build a tool that cannot For HSLA, choose compression
accommodate the holding pressure springs that are cut to length, manu-
you need to yield a capable part. The factured with flat ends, and ground
key word here is capable. Remem- so they seat squarely. Buying foot-
ber, it is easy to change the result- long springs and cutting them down
ing dimension of a stamping by just is inconsistent and not repeatable for
changing the tooling; it is not pos- maintenance over time.
sible to do this on a dimension that When purchasing from a standard
has unacceptable variation. compression spring catalog, you can
With that said, HSLA material is choose between carbon and chrome-
relatively difficult to work with on vanadium styles. Carbon springs are
its own, and adding tooling require- cheaper and good for light duty, but
ments only makes it more chal- they will not work as hard over time.
lenging. HSLA steel has improved I do not recommend these. Chrome
mechanical properties and greater springs are best for reducing down-
resistance to corrosion than carbon time. Stainless and special-alloy
steel. It is not made to meet a specif- springs also are available for envi-
ic chemical composition, although ronmental, magnetic, and special
there are guidelines and limits, applications.
but is produced to meet stringent Of course, all compression springs
30 MARCH/APRIL 2011 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • an fma publication
quality springs are carefully pro-
cessed through the following mul-
tiple steps; for the cheap imitations,
some of these steps are not con-
trolled, or they are left out entirely:
•Vacuum degassing of the mol-
ten metal to prevent inclusions and
resulting stress accumulators
•Continuous casting of the metal
for uniformity
•Rolling and processing the wire
to size, using gaseous decarburiza-
tion to minimize oxides and slag for-
mation on the outer layer that ulti-
mately could get rolled into the wire
•Atmosphere-controlled heat-
treating and annealing practices to
ensure proper temper
•Shot peening of the formed and
heat-treated springs to remove,
equalize, and normalize residual
stresses
•Full compression to home and
testing to reduce failure and improve
fatigue life within the recommended
working compression zone
I have seen Belleville springs used
in stacks for extreme applications,
but I don’t recommend it. They
work best in static applications and
will fail if repeatedly cycled.
Top-quality springs are essential
to tooling performance. Know your
supplier’s process and buy direct.
Saving a few dollars upfront will cost
much more in production problems.
Good luck and happy stamping!S
Has a shop floor stamping or tool and
die question stumped you? If so, send
your questions to kateb@thefabricator.
com to be answered by Thomas Vacca,
director of tooling and design engi-
neering at Micro Stamping Corp., or
by industry veteran and press expert
Dennis Cattell.
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