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Stress Levels Are Increasing In The Press Shop
Pete Ulintz PMA Technical Director
high-tensile-strength materials can affect the size, strength, power and
overall configuration of every major piece of press-line equipment, including, presses,
feed systems and coil-straightening systems.
blanking and punching stresses produce unloading forces in stamping presses
called “snap-through” or “reverse-tonnage” loads. Because high-strength
materials require greater stress to blank and cut as compared to mild steel,
they generate proportionally greater snap-through loads. These forces can
easily exceed the limits for which the machine was originally designed,
resulting in premature wear, damage and sometimes catastrophic failures.
Energy is expended with each stroke of the press and
this energy must be replaced. Critical attention must focus on the size of the
main drive motor (horsepower), flywheel mass and the rotational speed of the
flywheel when stamping higher-strength materials. The main motor, with its
electrical connection, is the only source of energy for the press and it must
have sufficient horsepower to supply the demands of the stamping operation.
stamping presses are not the only equipment affected by higher-strength
materials have a greater tendency to retain their coil set, which makes straightening
them to an acceptable level of flatness very challenging. Straightening in a
traditional five- or seven- roll flattener may require larger-diameter straightening
rolls and wider roll spacing in order to work the stronger material more
effectively. But increasing roll diameter and center distances will limit the
range of other materials that can be straightened. Additionally, roll defection
- due to material strength and the deeper roll penetration required - can
present significant problems. Close-center precision straighteners, having nine
to 21 straightening rolls that are backed up with support rolls, often are required
systems may require additional servo-motor power and/or torque capability to
pull the stronger material through the straightener. Additional back tension
between the feeder and straightener also is required as the higher yield
strength material in the loop tends to push back against the straightener or
the feed system.
assume that stamping higher-strength materials will be a “business as usual”
condition for an existing press line – that can be a very costly mistake. These
materials can easily push press line performance requirements well beyond the
capabilities and limitations for which they were originally designed.
President Trump yesterday signed a proclamation placing tariffs of 25 percent on steel imports and 10 percent on aluminum imports. Mexico and Canada are exempted from the tariffs for now. The tariffs take effect at 12:01 a.m. on March 23. The President’s action is the result of recommendations from two Section 232 (national security) investigations conducted by the U.S. Commerce Department.
According to the proclamation, within 10 days, the Commerce Department will announce the process for filing a request for an exclusion for steel and aluminum products not available in the U.S.
These tariffs will place at risk the jobs of millions of Americans who are employed in the metalforming, metal stamping and other U.S. industries that use steel. Restricted availability and increased costs for raw materials will likely lead to current customers sourcing finished products from overseas competitors, who will produce them with foreign steel or aluminum and import them tariff-free.
Guest Blogger: Bill Frahm
President, 4M Partners, LLC
Sheetmetal forming has many challenges and opportunities to offer students and new employees. New metals, new forming technologies, and evolving information and simulation technologies offer opportunities for engaged employees to shape the future. Adapting to change and leading the industry discussion requires the experience of seasoned employees, along with the energy and new ideas of knowledgeable young employees.
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We can generally sort Manufacturing Business processes into three groups: Make to Order, Assemble to Order, and Make to Stock. Make to Order is also known as custom build. Assemble to Order is used in repetitive manufacturing. And Make to Stock covers mass production of end products.
Let’s look at each one and see where to apply scheduling and planning tools for the best order to fulfillment timing.
Make to Order
Make to Order is the manufacturing process in which a large group of components can be made into very specific end products.
A printer may carry stock of many types and grades of paper and have the ability to create thousands of Ink colors. Skilled workers can use the tools and materials to create any item a customer may want printed. Then they can mass produce that Item into as many copies as the customer would like.
A die maker has large billets of steel in stock and with tools and produces very detailed dies to the c…