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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.
Bill Gaskin, shares his memories and experiences as PMA celebrates our 75th
anniversary. Q: How long have you been at PMA?
A: I am closing
in on 40 years. Jon Jenson, who was president of American Metal Stamping
Association (AMSA) from December 1975 through August 2000, hired me in February
1977 with an official “start date” of March 1, 1977. (See below for more on this) Q: What is your current role? Have you
held any other positions at PMA previously?
A: My current
role includes being President of three separate, but related entities:
Metalforming Association, which is a 501 (c) (6) not-for-profit trade
Educational Foundation, a 501 (c) (3) not-for-profit charitable organization
supporting training and education· (3) PMA
Services, Inc., a for-profit company (owned equally by PMA and PMAEF) engaged
primarily in publishing and management of other associations, such as Women in
My first job
title was Staff Repres…
Guest Blog: Laurie Harbour President and CEO, Harbour Results, Inc.
In 2016 the U.S. manufacturing industry was relatively stable with overall production slightly up from previous years. Specifically, the automotive tool and die industry was predicted to be busy with forecasted tooling spend on the rise. However, taking a closer look, the year proved to be a bit more challenging. Data collected through the Harbour Results’ Harbour IQ pulse survey (a business intelligence tool for performance, financial, operational, trend and market data), which was completed by more than 100 tool shops globally in the second quarter of 2016, has shown that capacity reached a low of 81 percent among die shops in late 2015 and early 2016, but was expected to rebound to 78 and 86 percent respectively by year end.
So what caused the slow down? Program delays—on average, just over 20 percent of vehicle launches were delayed in 2015 and 2016. Work on hold—in early 2016, 18 percent of all work that had been …
A Metal Processor's Best Friend Guest Blogger: Mike Tieri Director of Sales & Marketing, Chemcoaters Scrap…What a problem! Are you having trouble with higher
scrap loss than you can understand or more importantly tolerate? It could be
the metal but perhaps it’s a problem in the processing itself. Have you looked
at dry-film lubricants (DFLs)? If it’s been a while, you should look again.
Largely used by the automotive and appliance industries, you surely know that
if it didn’t provide a tremendous benefit, they would never add that cost into
the process. When I asked why, I was shown all of the benefits it provided. CASE: One company
monitored costs of using oil against DFL. One item evaluated was worker gloves.
They said that bringing material in with oil showed that workers wore 5.6 pairs
of gloves per week. By going to DFL, the workers’ gloves didn’t get saturated
and usage was dropped to 2.4 pairs of gloves per week. It might not seem to
matter much but on 1800 workers the cos…