8408276 Key Design Principles for Successful Deep Drawing Wwwitilmcom

8/13/2019 8408276 Key Design Principles for Successful Deep Drawing Wwwitilmcom

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SOCIETY4PAKSWISSIANS

Key design principles for successful deep

drawing

By Art Hedrick, Contributing Writer My !", #""$

Succe%%&u' dee( dr)ing de(end% on *ny &ctor%+ Ignoring een one o& t-e* during diede%ign nd bui'd cn (roe di%%trou%+

Succe%%&u' dee( dr)ing de(end% on *ny &ctor%+ Ignoring een one o& t-e* during diede%ign nd bui'd cn (roe di%%trou%+ Ho)eer, regrd'e%% o& t-e *ny &ctor% ino'ed,t-e *o%t i*(ortnt e'e*ent to %ucce%%&u' dee( dr)ing o(ertion i% inititing *et'&'o)+ T-e &o''o)ing re key e'e*ent% &&ecting *et' &'o), nd ec- o& t-e* %-ou'd becon%idered )-en de%igning, bui'ding, or troub'e%-ooting dee( dr)ing %t*(ing die%.

$+ Mteri' ty(e#+ Mteri' t-ickne%%!+ N nd / 'ue%4+ B'nk %i0e nd %-(e1+ Prt geo*etry2+ Pre%% %(eed 3r* %(eed5+ 6r) rdii7+ 6r) rtio8+ 6ie %ur&ce &ini%-$"+ 6ie te*(erture

$$+ 9ubricnt$#+ 6r) bed -eig-t nd %-(e$!+ Binder (re%%ure$4+ Binder de&'ection$1+ Stndo&& -eig-t

Becu%e t-icker *teri'% re %ti&&er, t-ey -o'd toget-er better during dee( dr)ing+T-icker *teri'% '%o -e *ore o'u*e, %o t-ey cn %tretc- 'onger di%tnce%+

T-e N 'ue, '%o c''ed t-e )ork -rdening e:(onent, de%cribe% t-e bi'ity o& %tee' to%tretc-+ T-e / 'ue;t-e ('%tic %trin rtio;re&er% to t-e bi'ity o& *teri' to &'o) or

dr)+ B'nk %i0e% nd %-(e% t-t re too 'rge cn re%trict *et' &'o), nd t-e geo*etryo& (rt% &&ect% t-e bi'ity o& *et' to &'o)+ Pre%% %(eed% *u%t ''o) ti*e &or *teri'% to&'o)+

6ie %ur&ce &ini%-e% nd 'ubricnt% re i*(ortnt becu%e t-ey cn reduce t-e coe&&iciento& &riction, ''o)ing *teri'% to %'ide t-roug- too'% *ore e%i'y+ 6ie te*(erture% cn&&ect t-e i%co%ity o& 'ubricnt%+




A% contro''er o& *et' &'o), dr) bed -eig-t nd %-(e cn cu%e *teri'% to bendnd unbend to crete re%trictie &orce% going into too'+ Incre%ing binder (re%%ure e:ert%*ore &orce on *teri', creting *ore re%trint on *teri' going into t-e too'+

T-e re*ining key e'e*ent% &&ecting *et' &'o) re e:*ined in *ore deti' in t-e

re*inder o& t-i% rtic'e+ To i''u%trte t-e (rinci('e% o& *et' &'o), t-i% rtic'e e:*ine%t)o b%ic dr) %-(e%, round nd %<ure+ A'' de&or*tion *ode% t-t occur in ny gien (rt %-(e re (re%ent in one o& t-e%e co**on %-(e%+

Figure 1 In t-e i''u%trtion o& incorrect dr) rtio (L), t-e too=%*'' (o%t )ou'd cu%e *et' to t-into t-e (oint o& &i'ure, )-i'e t-e correct dr) rtio (R) )i'' re%u't in %ucce%%&u''y dee(dr)n (rt+

T-e dr) rtio i% *ong t-e *o%t i*(ortnt e'e*ent% to be con%idered )-en tte*(tingto dee( dr) round cu(+ T-e dr) rtio i% t-e re'tion%-i( bet)een t-e %i0e o& t-e dr)

(o%t nd t-e %i0e o& t-e b'nk+ T-e dr) rtio *u%t &'' )it-in cce(tb'e 'i*it% to ''o)*et' to &'o)+

6uring &or*ing, b'nk i% &orced into circu*&erenti' co*(re%%ion, )-ic- crete% re%i%tnce to &'o)+ I& t-e re%i%tnce i% too gret, t-e cu( &rcture%+ I& t-e (o%t i% too %*''or too &r &ro* t-e b'nk edge, t-e *et' %tretc-e% nd t-in% to t-e (oint o& &i'ure+ I& t-e (o%t i% t-e ((ro(rite di%tnce &ro* t-e b'nk edge, nd t-e die entry rdiu% i%cce(tb'e, t-e *et' cn &'o) &ree'y, (rogre%%ie'y t-ickening % it enter% t-e die city3%ee Figure 1+

W-en ery t'' %*''=di*eter (rt i% being (roce%%ed, dr) reduction% 'ike'y )i'' be

nece%%ry 3%ee Figure 2+ A dr) reduction i% (roce%% in )-ic- (rt i% &ir%t &or*ed)it-in cce(tb'e dr) rtio 'i*it% nd t-en i% (rogre%%ie'y reduced or re%-(ed to de%ired %-(e nd (ro&i'e+




Figure 2 /eduction (ercentge% &or riou% t-ickne%%e% o& dr)=<u'ity %tee'+

T-e *o%t i*(ortnt &ctor to re*e*ber )-en (er&or*ing dr) reduction% i% t-t '' o&t-e *teri' nece%%ry to *ke t-e &in' (rt %-(e *u%t be (re%ent in t-e &ir%t dr)+Figure 3 i% reduction c-rt &or t-e &ir%t, %econd, nd t-ird dr)% )it- dr)=<u'ity %tee'+/eduction (ercentge% re b%ed on *et' t-ickne%% nd ty(e+

To deter*ine t-e (o%t di*eter nd -eig-t o& t-e &ir%t dr), t-e tot' %ur&ce re o& t-e&ini%-ed (rt *u%t be c'cu'ted+ 3I& t-e (rt i% to be tri**ed, ''o) ddition' *teri'during t-i% c'cu'tion+ T-e c'cu'ted %ur&ce re i% t-en conerted into &'t b'nk

di*eter+

Figure 3 6uring dr) reduction%, t-e b'nk di*eter %-ou'd not c-nge &ter t-e &ir%t dr)+

T-e (ri*ry %te( in c'cu'ting t-e &ir%t dr) (o%t di*eter i% deter*ining t-e b'nkdi*eter+ Mu'ti('ying t-e b'nk di*eter by t-e (ercentge gien in t-e c-rt, nd t-en%ubtrcting t-e re%u't &ro* t-e origin' b'nk di*eter, yie'd% t-e di*eter o& t-e &ir%tdr) (o%t+ It i% i*(ortnt to re*e*ber t-t '' di*en%ion% re tken t-roug- t-e




center'ine o& t-e *teri'+ T-e -eig-t o& t-e &ir%t dr) i% n re c'cu'tion direct'yre'ted to t-e *ount o& *teri' nece%%ry to *ke t-e &ini%-ed (rt+

Die Entry Radii

Ot-er i*(ortnt &ctor% &or %ucce%%&u' dee( dr)ing re t-e %i0e, ccurcy, nd %ur&ce&ini%- o& t-e die entry rdiu%+ 6eci%ion% regrding t-e die entry rdiu% %-ou'd be b%ed on*teri' ty(e nd t-ickne%%+

I& die entry rdiu% i% too %*'', *teri' )i'' not &'o) e%i'y, re%u'ting in %tretc-ing nd,*o%t 'ike'y, &rcturing o& t-e cu(+ I& die entry rdiu% i% too 'rge, (rticu'r'y )-en dee(dr)ing t-in=guge %tock, *teri' begin% to )rink'e &ter it 'ee% t-e (inc- (oint bet)een t-e dr) ring %ur&ce nd t-e binder+ I& )rink'ing i% %eere, it *y re%trict &'o))-en t-e *teri' i% (u''ed t-roug- t-e die entry rdiu%+

Figure 4 Mini*u* die entry rdii re %-o)n in t-i% c-rt &or round dr)% ino'ing riou%t-ickne%%e% o& dr)=<u'ity %tee'+

Figure 4 (roide% gener' guide'ine% &or die entry rdii &or round dr)% o& dr)=<u'ity%tee' rnging in di*eter% &ro* bout $+1 to $1 inc-e%+

T-e die entry *u%t be (roduced ccurte'y in &%-ion t-t *ke% it true nd co*('ete+ It%-ou'd be -ook=&ree nd (o'i%-ed in t-e direction o& &'o)+ Hig-=)er too' %tee' %-ou'd beu%ed &or die entry rdii+

Binder ressure




Su&&icient binder (re%%ure *u%t be (re%ent to contro' *et' &'o)+ I& binder (re%%ure i%inde<ute, t-e *teri' )rink'e% during co*(re%%ion+ T-e )rink'e% t-en cu%e t-e binderto &urt-er %e(rte &ro* t-e dr) ring %ur&ce, nd contro' o& t-e *teri' )i'' be 'o%t+Wrink'e% )i'' '%o be &orced to un)rink'e )-en t-e *teri' i% %<uee0ed bet)een t-e (o%tnd t-e city )''%+ T-i% cn (u'' *et' on t-e to( o& t-e cu( nd re%u't in &rcture+

T-e (rob'e* o& too *uc- binder (re%%ure cn be oerco*e by u%ing %tndo&&%+ Stndo&&%*intin gien %(ce bet)een t-e dr) ring %ur&ce nd t-e binder, nd t-ey %-ou'd be%et t $$" (ercent o& t-e *et' t-ickne%% to ''o) &or co*(re%%ie t-ickening+ I& t-e%tndo&& g( i% too %*'', t-e *teri' )i'' be (inc-ed tig-t'y bet)een t-e dr) ring ndt-e binder %ur&ce, reducing it% bi'ity to &'o) &ree'y+ I& t-e %tndo&& g( i% too 'rge, t-e*teri' )i'' )rink'e during circu*&erenti' co*(re%%ion+

T-e reco**ended binder (re%%ure &or round dr)% o& 'o)=crbon dr)=<u'ity %tee' i%2"" (ound% (er 'ine' inc- round t-e (o%t 3dr) (o%t di*eter : !+$4$+ >or -ig-=%trengt-, 'o)=''oy, nd %tin'e%% %tee'%, $,7"" (ound% o& (re%%ure (er 'ine' inc- %-ou'd

be u%ed+Ot-er guide'ine% to re*e*ber )-en t-e (roce%%ing dr) reduction% re.

$+ 6e%ign o(en=ended dr) citie% &or dr) de(t- d?u%t*ent+#+ Once t-e (ro(er dr) rtio i% c-ieed, *et' )i'' &'o) nd t-e (rt cn be dr)n

(rti''y or co*('ete'y o&& t-e binder+!+ A&ter t-e &ir%t dr), t-e b'nk di*eter %-ou'd not c-nge+ 3See Figure 3+

!"uare Draws

Figure #

S<ure dr)% re %i*i'r to round dr)% becu%e t-ey contin &our 8"=degree (ro&i'erdii+ Becu%e o& t-e rdi' corner (ro&i'e, *teri' &'o)ing to)rd t-e corner% i% &orcedinto co*(re%%ion+ T-e %trig-t %ection% o& t-e %<ure re %i*('y being bent nd unbent+




Con%iderb'y 'e%% &'o) re%triction tke% ('ce in t-e %trig-t )''% o& %<ure dr) t-nin t-e corner% 3%ee Figure #+

Incre%ing t-e (ro&i'e rdiu% o& t-e dr) gret'y incre%e% t-e bi'ity to dr) dee(er in %ing'e o(ertion 3%ee Figure $ becu%e 'rger=(ro&i'e rdiu% reduce% co*(re%%ion+ Too

*uc- co*(re%%ion in corner re%trict% *et' &'o), re%u'ting in &rcture+

Incre%ing t-e (ro&i'e rdiu% nd reducing t-e b'nk %i0e reduce &or*ing %eerity+Mitering t-e corner% o& t-e b'nk '%o cn -e'( to reduce co*(re%%ion+

To -e'( b'nce *et' &'o) condition% during %<ure dr)% ino'ing -ey *et'%, it*y be nece%%ry to dr) %(ot t-e corner re% o& t-e binder or dr) ring &ce )it-re%(ect to t-e incre%ing *teri' t-ickne%%+ T-i% (roce%% ''o)% *et' to t-icken incorner% )it-out being (inc-ed e:ce%%ie'y bet)een t-e dr) ring nd t-e binder+

Figure $

I& (ro(er dr) %(ot i% c-ieed, b'nk -o'ding &orce i% een'y di%tributed t-roug- t-e (eri*eter o& t-edr)n %-e''+ W-en t-in *et' i% u%ed, dr) %(otting t-e corner% *y cu%e unde%irb'e )rink'ing in t-ere'ieed re%+ T-i% re%u't% (ri*ri'y &ro* 'ck o& contro' o& t-e *et' &'o) nd t-e inbi'ity o& t-in %tockto re%i%t )rink'ing+

I& t-e %<ure dr)n %-e'' i% too t'' to be dr)n in %ing'e o(ertion, it *u%t undergo dr) reduction+ A%)it- round dr)%, '' *teri' nece%%ry to *ke t-e &in' (rt *u%t be (re%ent in t-e &ir%t dr)+ 6r)reduction% &or %<ure %-e''% re c-ieed by incre%ing t-e (ro&i'e rdiu% to cce(tb'e co*(re%%ion 'i*it%nd incre%ing t-e )idt- nd 'engt- to obtin t-e nece%%ry %ur&ce re o& t-e &ini%-ed (rt+

Ot-er guide'ine% to &o''o) )-en dr)ing %<ure %-e''% inc'ude.

$+ @%e t-e *ini*u* b'nk %i0e re<uired to *ke t-e (rt+#+ @%e %tndo&&% to contro' *et' &'o), not binder (re%%ure+!+ To redr) %<ure %-e'', incre%e t-e )idt-, 'engt-, nd (ro&i'e rdiu% o& t-e &ir%t dr) to contin

t-e nece%%ry %ur&ce re o& t-e &in' (rt geo*etry+

Succe%%&u' dee( dr)ing i% co*bintion o& *ny i*(ortnt &ctor%+ T-i% rtic'e -ig-'ig-t% on'y t-e *o%t&re<uent'y io'ted de%ign nd bui'd (rinci('e%+ A't-oug- de%igning nd bui'ding dee( dr) die% i% &%t

beco*ing %cience, t-e &und*ent' *et' &'o) (rinci('e% %-ou'd neer be ignored, &or t-ey re t-e&oundtion% o& %ucce%%&u' dee( dr)ing o(ertion+




TP = T-e Tube Pi(e ourn'

%uto&atic or &anual'

%uto&ation doesnt sole process pro*le&s+ eople do+

By Bob WntOctober 8, #""5

W-et-er it i% % %i*('e % %ing'e CNC tube bender 'oded by robot or % co*('e: % &u''y uto*ted 'ine t-t turn% r) coi' into &ini%-ed nd (ckged bent tubu'r (roduct,uto*ted )orkce''% -e *de t-eir )y into ner'y eery *nu&cturing t-eter+ Once'i*ited to t-e uto*otie indu%try )it- it% u'tr-ig- (roduction o'u*e%, uto*ted ce''%no) re &ound in ny indu%try in )-ic- t-e (roduction rte i% D*ke or brekD %(ect o&co%t=e&&ectie *nu&cturing+ A% r) *teri' co%t% nd 'bor co%t% continue to ri%e ndcutt-rot co*(etition &orce% (rice% do)n, uto*ted ce''% re being u%ed to (roduce *oreco*('e: )ork(iece% t-n eer be&ore+

Tri'% bound+ T-e de*nd &or -ig-er (roduction co*e% )it- n in-erent re<uire*entt-t t-e (roce%% run% ner'y continuou%'y+ Auto*tion in tube bending ce'' *u%t be)e''=('nned nd )e''=e:ecuted %i*('y to bring t-e (ro?ect to %ucce%%&u' 'unc-+ Oncet-e )orkce'' i% u( nd running, t-e *intennce %t&& *u%t kee( it running &or t)o ort-ree %-i&t% dy, %i: to %een dy% )eek;nd t-t% not-er c-''enge entire'y+

lan, lan, lan

Succe%%&u' tube bending i% (o%%ib'e on'y &ter n'y0ing t-e (('iction nd *tc-ing t-e(('iction to t-e (ro(er tec-ni<ue%, *c-inery, nd too'ing+ I& t-e (('iction i% border'ine;t-t i%, ?u%t bre'y %ucce%%&u';)-en cco*('i%-ed *nu''y, no *ount o&uto*tion )i'' *ke it *ore %ucce%%&u'+ In ot-er )ord%, uto*tion doe%nt reduce (rob'e*%F it *ere'y incre%e% t-e out(ut+ I& *nu' (roce%% -% $" (ercent %cr( rte,




under t-e be%t condition% %i*i'r uto*ted (roce%% -% $" (ercent %cr( rte+6ebugging nd %i*('i&ying t-e *nu&cturing (roce%% be&ore uto*ting it i% critic'+

Tken % %tnd='one o(ertion, tube bending i% it%e'& ?ugg'e o& c-nging rib'e%+ To%i*('i&y t-i% &cet o& )orkce'' ('nning, initi' con%idertion% *u%t inc'ude.

• /) *teri' ducti'ity+ 6oe% t-e tube bend to t-e de%ired rdiu% )it-out&rcturingG I& t-e *teri' doe% not -e enoug- e'ongtion, con%ider incre%ingt-e bend rdiu% or u%ing n 'ternte *teri', ''oy, or te*(er+

A'%o co**on'y oer'ooked i% r) *teri' con%i%tency+ It i% b%o'ute'y e%%enti't-t '' t-e tube% (ro(ertie%;t-e c-e*ic', *ec-nic', nd (-y%ic'c-rcteri%tic%;be con%i%tent &ro* 'ot to 'ot+ Mke certin &ro* t-e %trt t-t t-e*teri' %e'ected i% to'ernced to o(ti*i0e (roduction, rt-er t-n rib'e t-t*ke% %tedy, con%i%tent (roduction i*(o%%ib'e+

•

Bent (rt con&igurtion+ 6oe% t-e (('iction re<uire *ore t-n one benderG 9e&t=-nded, rig-t=-nded, or bot-G Ho) *ny bend% re in t-e (rtG 6oe% t-e)ork(iece -e %u&&icient 'engt- o& %trig-t tube bet)een bend%, or doe% itre<uire gri((ing bent %ection to (roduce t-e ne:t bendG I& %o, t-e (('ictionre<uire% %tcked too'ing+ Ho) *ny %tcked %et% doe% it needG

• Bend %eerity nd die too'ing %e'ection+ 6oe% t-e (('iction need co*('ete die%et%, inc'uding intern' b'' *ndre'% nd )i(er die%G Adding one or bot- o& t-e%etoo'% *ke% bending *uc- *ore co*('icted+ T-e%e too'% re in con%tnt &riction)it- t-e )ork(iece, %o t-ey *u%t be 'ubricted+ T-ey *u%t be %et nd d?u%ted (ro(er'y, nd *intined t-t )y+ T-ey '%o *u%t be c-nged <uick'y &or*:i*u* (roduction e&&iciency+

Mny too'ing de%ign tec-ni<ue% cn -e'( *eet (roduction de*nd%, but t-etoo'ing *u%t be % %i*('e % (o%%ib'e, e%(eci''y in -ig-=(roduction=o'u*eeniron*ent+ 6ont t-ro) *ore tec-no'ogy 3nd co*('iction% t t-e (('ictiont-n nece%%ry+

• Bending *c-ine %e'ection+ Si*('y %tted, %(eci&y t 'e%t enoug- bender c(cityto get t-e ?ob done+ I& t-e )orkce'' i% e:(ected to run c'o%e to #45, *kecco**odtion% &or '' *nu&cturer% (reentie *intennce reco**endtion%+6ont %i*('y &o''o) t-e*+ E:ceed t-e*+ Ignoring routine *intennce gurntee%troub'e )-en 3t-t i% )-en, not i& t-e ce'' goe% do)n+ Wit- regrd to

*intennce, t-e degree o& neg'ect nd t-e *en ti*e bet)een &i'ure reiner%e'y (ro(ortion'+

In (('iction% t-t re<uire %eer' die %tck%, *ke certin t-t t-e *c-ine i%rigid enoug- to kee( '' t-e die %et% in (ro(er 'ign*ent+ T-i% o&ten re<uire%oer-ed tie br %u((ort% &or t-e bend die %tck+ W-i'e o&&ering *ore %trengt- nd%u((ort, t-e%e tie br% '%o cn inter&ere )it- %o*e bent tube con&igurtion%+ Be




certin t-t you nd t-e *c-ine *nu&cturer under%tnd t-e re<uire*ent% o& t-e (ro(o%ed bent (rt+

Wit- regrd to %eer' %tcked )i(er die%, re*e*ber t-t t-e%e &rgi'e too'% *u%t be -e'd in t-eir (ro(er (o%ition% %ecure'y+ Ot-er)i%e t-ey )i'' not '%t or )ork

e&&ectie'y+ It i% o&ten nece%%ry to -e cu%to* )i(er brcket 3-o'der *de tokee( )i(er die% %ecured nd 'igned (ro(er'y nd t-u% c-iee cce(tb'e die 'i&end greter (roductiity+

• Acce(tnce criteri+ Set benc-*rk %tndrd &or tube cce(tnce be&orette*(ting to c'cu'te t-e (roduction rte o& t-e uto*ted ce''+ Criteri *u%tinc'ude '' %(ect% &ro* (roce%%ing r) %tri( to (ckging &ini%-ed (rt%+ Becu%eec- o(ertion -inge% on t-e %ucce%%&u' co*('etion o& t-e (reiou% one, eeryo(ertion *u%t -e re%onb'e nd re(etb'e gono=go ttribute or to'erncet-t cn 3nd )i'' be *onitored+ /egrd'e%% o& -o) t-i% i% done;i%u''y, )it-&i:ture%, or )it- %o(-i%ticted coordinte *e%uring e<ui(*ent;t-e &ct i% t-t

'' %(ect% o& t-e (roce%% *u%t -e %o*e (eriodic in%(ection+ Ot-er=)i%etroub'e%-ooting )i'' be i*(o%%ib'e+

T-i% '%o (reent% *nu&cturing %cr(+ E*(o)ering t-e o(ertor% to eri&y (rtcon&or*nce &re<uent'y t-roug-out t-e *nu&cturing (roce%% enb'e% t-e* totroub'e%-oot t-e (roce%% )-en t-ey di%coer noncon&or*ing (rt%+ 6oing %oe&&icient'y i% *tter o& c-ecking (rt% rndo*'y nd &re<uent'y )-i'e t-ey re being *nu&ctured, not &ter t-ey re &ini%-ed+

• Aboe '', kee( it %i*('e+




A co*('ete %et o& rotry dr) bender too'ing inc'ude% bend die, c'*( die, (re%%ure die,)i(er die, nd *ndre'+ @nder%tnding t-e ro'e o& ec- nd -o) ec- interct% )it- t-eot-er% i% cruci' &ir%t %te( in troub'e%-ooting bending (rob'e*%+

!ync-roni.e t-e /or0cells perations

Becu%e tube bending gener''y i% t-e nuc'eu% o& )orkce'', t-e ot-er (roce%%e% *u%t be%ync-roni0ed to t-i% (roce%%+ 6eter*ine t-e o(ti*' cyc'e ti*e &or bending, nd d?u%tt-e 'oder %(eed ccording'y+ I& t-e ce'' ino'e% %-er t-t cut% t-e tube or, in ne:tre*e c%e, tube *i'' t-t (roduce% t-e tube, t-e%e o(ertion% *u%t be ti*ed %o t-e bender i% neit-er oer= nor under&ed+

Be )re t-t t-e oer'' %(eed o& t-e uto*ted ce'' or 'ine *u%t be b%ed on t-e &%te%tto'erb'e cyc'e o& t-e %'o)e%t o(ertion o& t-e ce''+ A'%o be )re t-t ti*ing i% not-ing)it-out debugging+ Set u( nd troub'e%-oot eery o(ertion indiidu''y be&orette*(ting to integrte t-e* in n uto*ted (roce%%+

Launc- t-e ell

So(-i%ticted ni*tion %o&t)re cn &ci'itte ('cing nd integrting eery (iece o&e<ui(*ent in t-e )orkce''+ Mo%t )ork &'o) (rob'e*% nd e<ui(*ent co''i%ion% recug-t in t-e (rogr**ing %tge+ Ho)eer, in t-e re' )or'd it cn tke %o*e ti*e nd (rogr* t)eking to c-iee t-e *ec-ni0ed b''et )e %trie &or in )orkce''+ W-en t-eo(ti*' cyc'e ti*e% re di'ed in nd benc-*rk% %et &or %(eed nd ot-er cce(tnce (r*eter%, t-e ne:t critic' (-%e o& t-e %trt=u( begin%+

Trin t-e O(erting nd Mintennce Cre)%+ Procedure% &or o(ertion% nd *intenncetrining ry con%iderb'y &ro* co*(ny to co*(ny+ So*e co*(nie% -e t-ree%e(rte grou(%;one &or too'ing %etu(, %econd &or *c-ine *intennce, nd t-irdt-t o(erte% t-e ce'' nd *onitor% (roduction+ Con%idering t-e ce'' i% 'ike'y intended too(erte &or t)o to t-ree %-i&t% (er dy, %een dy% )eek, it i% obiou% t-t con%i%tentout(ut *ong '' %-i&t% re<uire% con%i%tent trining *ong '' (er%onne'+

Wit-out *intennce trining, e<ui(*ent o(ertor% cn do not-ing *ore to %o'e bending (rob'e*% t-n &ind t-e &e) kno)'edgeb'e troub'e%-ooting (er%onne' nd in&or* t-e* o&t-e (rob'e*+ 9ike)i%e, t-e too'ing %etu( %t&&% re%(on%e% to (rob'e*% cn be 'i*ited+D9et% re('ce t-e too'ingD i% &%t, e%y, yet ine&&ectie re%(on%e i& t-e troub'e %trt%

e'%e)-ere+Ide''y, '' (er%onne' receie t-e %*e trining nd %et o& )ritten (rocedure% %o t-teeryone 'ern% %ing'e ((roc- to troub'e%-ooting+

Kee( Accurte, T-oroug- /ecord%+ E<u''y i*(ortnt;nd -rder to i*('e*ent;i% nccurte *et-od o& *onitoring u(ti*e nd do)nti*e, cyc'e %(eed%, %cr( rte%,*intennce (rocedure%, too'ing %etting%, nd c-ngeoer%+ T-i% dt i% nece%%ry &or




*king in&or*ed deci%ion% regrding e<ui(*ent nd too'ing condition+ Ad?u%ting (rocedure% b%ed on t-i% in&or*tion cn -e'( *ini*i0e do)nti*e nd ntici(tect%tro(-ic &i'ure+

Any %te(% &or dee'o(ing con%tnt'y u(dted 3nd con%i%tent'y &or*tted record% re

'ub'e+ T-e record% t-e*%e'e% re in'ub'e i& t-ey re &re<uent'y n'y0ed nd u%ed&or ('nning (reentie *intennce ctiitie%+

I& not-ing e'%e, good recordkee(ing (reent% running out o& con%u*b'e too'ing ite*%3)i(er die% nd *ndre'%, &or e:*('e+ Ho) *ny ti*e% do you need to run out o& J1")i(er ti(%, cu%ing t-e *u'ti*i''ion=do''r )orkce'' to %-ut do)n nd 'eing your be%tcu%to*er %trnded, be&ore you re'i0e t-t you %-ou'd -e %u(('y o& '' too'ing nd %tedy &'o) o& con%u*b'e ite*% on recurring b'nket order%G Pro(er docu*enttionn'y%i% nd (roctie (roce%% i*('e*enttion re t-e on'y )y% to (reent con%u*b'e%-ortge%+

rou*les-oot to t-e !ource

W-i'e it i% ?u%t -u*n nture to ru%- to get -ig-=%(eed )orkce'' or (roduction 'ine u(nd running % <uick'y % (o%%ib'e &ter (rob'e* ri%e%, it i% nece%%ry to trce t-e cu%eo& it '' t-e )y to it% %ource+ >o''o) t-e (roce%% bck to t-e &ir%t %te( t-t did not *eett-e cce(tnce criteri+ T-e (rinci(' re%on &or doing t-i%, o& cour%e, i% to %o'e t-e (rob'e* nd not *ere'y ddre%% t-e %y*(to*+ A''o)ing t-e (rob'e* to continueunc-ecked *en% it )i'' co*(ound 'ter on+ /e%o'ing t-e (rob'e* no) '%o (reent%re(eted nd e:ce%%ie do)nti*e 'ter+

I& t-e )orkce'' i% co*('ete'y uto*ted 'ine, it *ig-t ino'e tube *i''F %trig-tening,

(unc-ing, nd &or*ing *c-ine%F )e'd %e* detectorF bending *c-ineF-ydro&or*ing (re%%F '%er cutting %y%te*F )e'ding %ttionF nd, o& cour%e, *teri'-nd'ing %y%te*+ T-e co*('e:ity nd %(eed o& %uc- %y%te* *en% t-t %*'' (rob'e*er'y in t-e (roce%% -% t-e (otenti' to get co*('ete'y out o& -nd in t-e b'ink o& n eye+Con%tnt <u'ity *onitoring nd (ro(er nd (rg*tic (rob'e*=%o'ing re not ?u%tdi%ed+ T-ey re re<uired+

Bo*s rou*les-ooting ips

Troub'e%-ooting bending o(ertion i% 'ike troub'e%-ooting ny ot-er *nu&cturing

(roce%%;kee( record%, )tc- &or c-nge%, nd kee( %y*(to*% nd cu%e% %e(rte+onsu&a*les+ Py ttention to con%u*b'e u%ge+ >or e:*('e, n incre%e in )i(er ti(reorder &re<uency i% not (rob'e*+ More t-n 'ike'y, it i% %y*(to* o& (rob'e*+

A )i(er die% %u((ort co*e% &ro* t-e tube grooe o& t-e bend die contour+ Con%ideringt-t t-e )i(er i% ?u%t "+""! inc- t-ick t t-e ti( i& *c-ined correct'y, it i% e%y tounder%tnd t-t t-i% ti( )i'' con&or* to t-e bend die regrd'e%% o& it% condition, ne) or




)orn+ I& t-e bend die% grooe contour i% )orn, t-e )i(er ti( 'i&e )i'' be &rction o& )-tit %-ou'd be+ Ho) *ny ti(% did you di%crd '%t <urter &ter (re*ture &i'ureG Ho)*ny re('ce*ent bend die bodie% )ou'd -e (reented t-i%G

S-ort )i(er die 'i&e '%o cn indicte t-t t-e too'ing *ounting %ur&ce% re *i%'igned+

T-i% *i%'ign*ent, in turn, cn be cu%ed by e:ce%%ie nd uneen %trin on t-e bender,)-ic- i% re%u't o& e:ce%%ie bender &orce+ T-i% doe%nt ?u%t (re*ture'y )er or ruin t-etoo'ingF it -% t-e %*e e&&ect% on t-e bender it%e'&+

ality+ Bend o'ity, t-e degree to )-ic- t-e bent tube i% out o& round, '%o i% %y*(to* nd '%o cn -e one o& %eer' cu%e%+

T-e *o%t co**on 3nd gener''y )rong %te( to reduce o'ity 'o%% i% to re('ce t-e b''%on t-e *ndre' nd 'ee it t t-t+ T-e *ndre', 'ike t-e )i(er ti(, i% in con%tnt contct)it- t-e )ork(iece+ T-e bending (roce%% dee'o(% tre*endou% *ount o& (re%%ure nd)er% out t-e *ndre' b''%+

W-i'e re('cing t-e *ndre' b''% )i'' i*(roe bend o'ity, t-i% i%nt nece%%ri'y t-e be%tcour%e o& ction+

I& correct'y *de, *ndre' %-nk 3t-e cy'indric' %ection t-e rticu'ted b''=nd='ink%%e*b'y ttc-e% to i% gener''y "+""1 in+ greter in di*eter t-n t-e b'' %eg*ent%+T-e %i0e di&&erence nd t-e (ro(er ('ce*ent o& t-e 'eding corner o& t-e %-nk 3%'ig-t'y-ed o& t-e bend tngent dictte t-t t-e %-nk doe% t-e initi' &or*ing nd ber% t-egrete%t 'od in t-e &or*ing (roce%%+ ener''y %(eking, i& t-e %-nk i% )orn nd t-ene) b'' %eg*ent% re t-e %*e di*eter % 3or 'rger t-n t-e %-nk, '' t-e 'od &''% ont-e b''=nd='ink %%e*b'y, re%u'ting in (re*ture 'ink &i'ure nd *ndre' brekge+

Ho) *ny broken 'ink% cou'd -e been (reented, nd -o) *uc- do)nti*e )ou'd-e been u(ti*e, i& t-i% condition )ere correct'y digno%ed in t-e &ir%t ('ceG

T-e%e i%%ue% )it- )i(er% nd *ndre'% re %i*('y t)o co**on (rob'e*% in -ig-=%(eeduto*ted )orkce''%+ Wi(er% nd *ndre'% re con%u*b'e ite*%, %o t-eir (re*ture)er o&ten i% treted 'ig-t'y+ A't-oug- t-ey re %*'', t-ey %-ou'dnt be regrded %in%igni&icnt+ A 'itt'e kno)'edge nd %o*e (reentie ction% )ou'd e:tend t-e %erice'ie% o& t-e%e ite*% nd incre%e t-e )orkce''% u(ti*e con%iderb'y+

urning t-e corner on &a0ing doors56ort- arolina co&pany strea&lines t-e

process

By 9ind B'd)in, Contributing Writer nury $", #""$




A %*'' &brictor Nort- Cro'in, &*i'y=o)ned co*(ny *nu&cture% %tndrd ndcu%to* e'ectric' enc'o%ure% &or t-eco**erci' con%truction indu%try nd gro)ing nu*ber o& OEM%+

W-i'e %o*e &brictor% &ee' t-e (inc- o&tody% tig-tening econo*y, %*''&brictor in Nort- Cro'in -% re*inedo(ti*i%tic+

DProduction i% our re%triction+ We -e *nyo((ortunitie% in t-e *rket+ I& )e cn (roduce *ore, t-e de*nd i% t-ere,D %id i*Au%tin, (re%ident o& T-e Au%tin Co*(ny,Ydkini''e, N+C+

T-e &*i'y=o)ned co*(ny *nu&cture% %tndrd nd cu%to* e'ectric' enc'o%ure% &ort-e co**erci' con%truction indu%try nd gro)ing nu*ber o& OEM%+ T-e co*(ny -%doub'ed it% %'e% nd %i0e in t-e '%t $" yer%+

A't-oug- e'ectric' enc'o%ure% re in -ig- de*nd, t-e 'o) une*('oy*ent rte inYdkini''e nd t-e %urrounding re -% &o''o)ed t-e ntion' do)n)rd trend, &orcingAu%tin to ret-ink t-e co*(ny% (roduction (roce%%+

DWit- %-ort %u(('y o& <u'i&ied )orker%, )ee ine%tigted ot-er )y% to incre%et-roug-(ut+ We c*e to (oint )-ere uto*tion )% nece%%ry to kee( u( )it-

de*nd,D Au%tin %id+ DWee been cre&u' to ine%t in e<ui(*ent t-t )i'' <uick'y reduceco%t% nd incre%e (roduction+D

Mo%t enc'o%ure% *de by t-e co*(ny inc'ude door% con%tructed %i*i'r'y to %-oebo:'id+ W-en n'y0ing )-ere t-e ne:t ine%t*ent )ou'd be *de, Au%tin noted t-e 'bor=inten%ie &briction o& t-e%e door%+

DT-e *et' &or t-e 'id i% %-ered, t-e corner% re notc-ed, nd t-e &our %ide% re bent+ T-ene:t t)o %te(%, *nu''y )e'ding nd %nding t-e %e*%, )ere ti*e=con%u*ing+ We'dingnd grinding re n rtF t-ere re incon%i%tencie% in t-e%e %te(%,D Au%tin %id+

W-i'e corner% )ere 'bor=inten%ie nd re%u't% cce(tb'e but incon%i%tent, Au%tin %id -e-d not identi&ied t-e* % (roduction (rob'e* unti' -e %) routine %'e% (re%enttion&or ne) (roduct+

DOnce )e %) it, )e *de tri( to Ne) er%ey to %ee corner=&or*ing *c-ine,D -e%id+ DWe '%o %ent %*('e% o& our o)n (roduct %o )e cou'd %ee -o) it )ou'd )ork &oru%+D

Figure 1. A %&ety door on t-e &or*ing*ec-ni%* (rotect% o(ertor% u%ing t-e

*c-ine+ A &oot (ed' contro'% t-e*c-ine, )-ic- )i'' not )ork un'e%% t-e

door i% %-ut co*('ete'y+




Au%tin %id -e -d t)o criteri &or bringing corner &or*er into -i% o(ertion. It %-ou'd reducet-e 'bor ino'ed in *king nd &ini%-ingcorner%, nd it %-ou'd (roduce *ore uni&or*door &'nge+

DI )%nt )re o& nyone e'%e )-o *de *c-ine t-t )ou'd do t-i%, %o once it *et *ycriteri, )e broug-t it in,D -e %id+ He (urc-%edCIMI6% AC> Mu'ti&'e: uto*tic corner&or*er+

DIt *ke% uni&or* corner% in t-ree %te(% in%tedo& &ie,D -e %id+ DIt )% t-e ne:t 'ogic' %te( in uto*ting our (roduction+D

>or*ing 6oor Corner%

In t-e ne) (roce%%, o(ertor% &or* (rt u%ing %tndrd (re%% brke (rocedure%, e:ce(t&or t-e botto* L die+ T-ey *c-ine re'ie& on t-e botto* L die &or t-e 'e&t %ide nd t-erig-t %ide o& t-e (rt+ T-i% re'ie& (roduce% &'re t t-e corner, in%ted o& 8"=degreeng'e+ T-ey t-en tke t-e (rt to t-e corner &or*er nd ('ce it on to( o& b%e b'ock t-t-% t-e %*e rdiu% % t-e (re%% brke nd t-e e:(ected corner+

In it% turn, t-e corner &or*er (u''% e:tr *teri' be'o) t-e edge o& t-e (ne' %ide+ T-i%*teri', )-ic- t-e *c-ine %-er% o&& i**edite'y &ter &or*ing, i% t-e di&&erence bet)een t-e *:i*u* bend=u( -eig-t nd t-e *ini*u* bend=u( -eig-t+ T-e *c-inet-en re(et% t-i% (roce%% &or t-e re*ining t-ree corner%+

DT-e corner &or*er -% %ub%tnti''y reduced 'bor co%t% %%ocited )it- &brictingdoor%,D Au%tin %id+ DT-e %*e o(ertor doe% t-e bending nd t-e corner &or*ing in boutone *inute (er (rt+ No) )e cn %-i&t e*('oyee% to e%e )e'ding nd grinding bott'eneck% in ot-er re% o& t-e co*(ny+D

In ddition, corner &or*ing e'i*inte% t-e need &or %tcking to )e'd nd re%tcking togrind+ T-e (rt doe% not need to be trn%(orted to t-e )e'ding de(rt*ent nd t-en ginto t-e grinding de(rt*ent+ O(ertor% *oe t-e (rt once to t-e corner &or*er+

DT-e %-eet% &or door% nd to(% o& *et' ?unction bo:e% cn be ery 'rge+ Mteri'

-nd'ing i% big i%%ue,D Au%tin %id+ DIncre%ing t-roug-(ut nd contro''ing 'bor co%t%-e re%u'ted &ro* *oing (rt% % 'itt'e % (o%%ib'e+ @%ing corner &or*er -% '%oreduced *teri' co%t% %ince t-ere re no br%ie% or )e'ding %u(('ie% needed+D

W-i'e t-e corner &or*er incre%e% (roduction, it i% '%o %&er t-n t-e trdition' )e'dingnd grinding (roce%%e%+ A %&ety door on t-e &or*ing *ec-ni%* (rotect% o(ertor% u%ingt-e *c-ine+ A &oot (ed' contro'% t-e *c-ine 3%ee Figure 1, )-ic- )i'' not )ork

Figure 2. Au%tin% &or*er cn (roducecorner% )it- rdii o& u( to 4 in+ T-et-ickne%% o& t-e *teri'% cn rnge

&ro* 7 to ## g+ Bend=u( -eig-tde(end% on *teri' t-ickne%% nd

bend rdiu%+




un'e%% t-e door i% %-ut co*('ete'y+ In ddition, corner &or*ing e'i*inte% )e'ding &u*e%,grinding du%t, nd t-e noi%e &ro* grinding+

>or*ing O(tion%

Au%tin% &or*er cn (roduce corner% )it- rdii o& u( to 4 in+ T-e t-ickne%% o& t-e*teri'% cn rnge &ro* 7 to ## g+ Bend=u( -eig-t% de(end on *teri' t-ickne%% nd bend rdii 3%ee Figure 2+ Hi% *c-ine cn -nd'e corner% )it- *u'ti('e bend -eig-t%,reer%e or return &'nge%, nd bu'' no%e%+

Becu%e enc'o%ure% re *o%t'y o& t-e &*i'ir %-oebo: 'id con&igurtion, Au%tin% corner&or*er gie% -i* t-e o(tion to con%ider ot-er *rket% in t-e &uture, %uc- % try%,&urniture, %-e'ing, oen door%, &ood %erice e<ui(*ent, tr&&ic %ign%, '' ty(e% o&coer%GGnyt-ing t-t -% %-eet *et' corner% t-t re )e'ded nd ground+

T-e corner &or*er -% no 'i*ittion% on t-e %i0e o& t-e (ne'% it cn cce(t, becu%e on'y

t-e corner i% ('ced into t-e *c-ine+@%ing corner &or*er -% gien Au%tin &'e:ibi'ity in o(erting -i% (roduction 'ine+ Wit-one %et o& too'ing, -i% o(ertor% cn &or* &our di&&erent t-ickne%%e% o& *teri' in ''''oy% nd in '' bend=u( -eig-t%+ C-nging too'ing to cco**odte di&&erent rdii tke%t-e* &ie *inute%, ccording to Au%tin+

DT-i% tec-no'ogy -% %tre*'ined our door &bricting (roce%%,D Au%tin %id+ Dro)ingour bu%ine%% undoubted'y *en% &uture ine%t*ent% in ot-er uto*ted e<ui(*ent+D

u&ping up productiity on older press*ra0es

7ncreasing productiity wit-

adanced tooling, cla&ping,

crowning syste&s

By 6id Bi%-o(, Contributing Writer une 7, #""4

In recent yer% &%ter, *ore e&&icient cutting nd b'nking *et-od% -e e*erged+ Ho)eer, t-e%ecutting e&&iciencie% nd corre%(onding incre%e% in (roductiity -e not ')y% been *et )it- %i*i'rincre%e% in (re%% brke (roductiity+ Con%e<uent'y,t-i% -% creted need to &ind ne) )y% to i*(roe (re%% brke (roce%% (roductiity+

T'' goo%eneck (unc-e% cn bend

dee( (rt% nd (rt% )it-co*('icted bend %e<uence%+




Once (re%% brke -% been in%t''ed, *et-od% to i*(roe it% &unction'ity to incre%e bending c(city *y be 'i*itedF t-ere&ore, you *ig-t con%ider (urc-%ing *ore (re%% brke%, but t-t )i'' re<uire *ore &'oor %(ce nd *ore o(ertor%+ An 'terntie &ori*(roing (re%% brke (roductiity nd e'i*inting t-e bott'eneck *y be )it- *orednced too'ing, ntide&'ection 3cro)ning %y%te*%, nd c'*(ing %y%te*%+

Too'ing Sy%te*%

In t-e (%t )-en botto* bending nd coining )ere t-e on'y o(tion%, it )% co**on &or (re%% brke o)ner% to ccu*u'te 'rge inentorie% o& (re%% brke too'ing+ Ho)eer, t-edent o& CNC (re%% brke%, (reci%ion=ground %eg*ented too'ing, nd (reci%ion ir bending -% *de it (o%%ib'e to &or* *ore *teri'% nd (rt con&igurtion% )it- &e)ertoo'%+

T-e t)o *o%t er%ti'e (unc- ty(e% &or ir bending (('iction% re cute=ng'e (unc-e%nd goo%eneck (unc-e% 3%ee introductory i&age+

oo%eneck (unc-e% ''o) you to &or* dee( c-nne'%, bo:e%, nd ot-er (rt% )it- 'ongreturn &'nge%+ oo%eneck (unc-e% )it- ti( ng'e o& 77 degree% or 'e%% cn -e'( youde' e&&ectie'y )it- %(ringbck+

Acute=ng'e (unc-e% ''o) you to bend '*o%t ny ng'e+ T-ey cn be u%ed to crete t-ecute bend re<uired &or -e**ing (('iction%+

W-en (roduced &ro* -ig-=%trengt- ''oy %tee' nd (ro(er'y -et=treted, bot- (unc-%ty'e% re &ir'y %trong nd bend rnge o& *teri' ty(e% nd t-ickne%%e%+ ener''y, t-et''er (unc- i%, t-e *ore er%ti'e it i%+ T-e &'e:ibi'ity t-e%e t)o (unc- %ty'e% (roide

nor*''y re%u't% in &e)er (unc- c-nge%+ Con%e<uent'y, 'e%% ti*e i% needed &or %etu(, nd (roductiity )i'' incre%e+

A't-oug- t-e ng'e o& t-e L o(ening on t-e die *u%t *tc- t-e ng'e o& t-e (unc- ti( in botto* bending nd coining o(ertion%, t-i% i% not nece%%ry )it- ir bending, becu%et-e &in' bend ng'e i% deter*ined by t-e (enetrtion o& t-e (unc- into t-e die+ >ore:*('e, you cn u%e cute=ng'e (unc-e% )it- #7=degree ti( nd goo%eneck (unc-e%)it- n 72=degree ti( )it- die% )it- !"=degree L o(ening%+

T-i% cn reduce t-e tot' nu*ber o& die% re<uired to bend "+"!2= to "+$!1=inc- 3$+"= to!+1=** *i'd %tee', 'u*inu*, nd %tin'e%% %tee'+ Be %ure to u%e e:tr cution to oid

oer(enetrting t-e die nd (o%%ib'y d*ging it )-en u%ing die t-t -% L o(ening)it- n inc'uded ng'e t-t i% 'e%% t-n t-t o& t-e (unc- ti(+

W-en %e'ecting die, con%ider it% oer'' )orking -eig-t+ T'' die% re &'e:ib'e nd ''o)you to bend (rt% )it- 'ong do)n &'nge% 3%ee Figure 1+ S-ort die% nor*''y re 'e%%e:(en%ie nd con%u*e 'e%% o(en -eig-t+




Becu%e %ing'e=L die% re nrro)er t-n t-e #=L die% co**on )it- *o%t Euro(en=%ty'etoo'ing %y%te*%, t-ey re 'e%% 'ike'y to inter&ere )it- (rt% )it- co*('icted bend%e<uence+

In ddition, %ing'e=L die% nor*''y re de%igned )it- co**on tng, %o t-t &u'' rnge

o& die% cn be u%ed in %ing'e die -o'der or ntide&'ection deice 3cro)ning %y%te*+ T-i%reduce% %etu( ti*e becu%e it e'i*inte% t-e need to uti'i0e *u'ti('e die -o'der% tocco**odte *u'ti('e die de%ign%+

Dura*ility+ Too'ing durbi'ity i% n i*(ortntcon%idertion+ Mny too'ing *nu&cturer% no) o&&er%ur&ce -rdening on %tndrd (re%% brke too'ing+ T-e%e-rdening (roce%%e% inc'ude CNC dee( -rdening, '%er-rdening, induction -rdening, nd coting+ A'' (roce%%e% (roide good )er re%i%tnce co*(red totoo'% )it- un-rdened )er %ur&ce%+ >or e:*('e,

re%erc- -% %-o)n t-t too'% t-t -e been CNC dee(=-rdened )i'' '%t %een to nine ti*e% 'onger t-n too'ing)it- un-rdened %ur&ce%+

orta*ility+ >in''y, good (re%% brke too'ing %y%te*%-ou'd be (ortb'e+ It %-ou'd be %u((orted by %erie% o&-o'der% &or t-e u((er nd 'o)er be* 3r* nd bed t-t''o) you to *oe it &ro* one (re%% brke to not-er+

C'*(ing Sy%te*%

T-e dent o& -ig-=(reci%ion, <uick=c-nge (re%% brketoo'ing %y%te*% -% re%u'ted in -uge (roductiity gin%+Ho)eer, it i% <uite co**on &or (reci%ion=ground (unc-e% to be u%ed direct'y gin%t t-e u((er be* o& t-e (re%% brke nd to be -e'd in ('ce by t-e *nu' r*c'*(% origin''y (roided )it- t-e *c-ine+ On *ny (re%% brke%, t-e 'od=bering%ur&ce% o& t-e u((er nd 'o)er be* re *i''ed to &ini%- rt-er t-n (reci%ion=ground+Incon%i%tencie% in t-e%e %ur&ce% direct'y 'ter t-e <u'ity o& t-e &ini%-ed (rt%+ T-i% ty(eo& in%t''tion '%o doe% not %(eed u( t-e 'oding nd un'oding o& too'ing+

Adnce*ent% in c'*(ing %y%te* tec-no'ogy in recent yer% -e been drien by

reduced 'ot %i0e% nd n incre%e in t-e nu*ber o& %etu(% t-t (re%% brke o(ertor% *u%t (er&or*+ >ortunte'y, you -e *ny c'*(ing %y%te*% to %e'ect &ro*, inc'uding *nu'c'*(ing %y%te*% t-t %i*('y o(en nd c'o%e t-e c'*(% <uick'y nd -ydru'ic''y drien%y%te*% t-t c'*(, %et, center, nd 'ign '' o& t-e too'ing )it- t-e (u%- o& %ing'e button 3%ee Figure 2+

Preci%ion c'*(ing %y%te*% '%o (roide -ig-=(reci%ion, 'od=bering %ur&ce &or (unc-e%, t-ereby reducing t-e (rob'e*% )it- incon%i%tent bend ng'e% cu%ed by (oor'y

Figure 1

T'' die% cn bend (rt% )it-'ong do)n &'nge%+




*c-ined %ur&ce% or *oderte'y d*ged %ur&ce% ont-e u((er be*+ T-ey '%o ct % n in%u'tor gin%td*ge to t-e u((er be* o& t-e (re%% brke+

>in''y, *ny dnced c'*(ing %y%te*% enb'e you to

c'*( (unc-e% eit-er )it- t-e re'ie& re &cing to)rdt-e rer o& t-e *c-ine or &cing to)rd you+ T-i% (roide% ddition' er%ti'ity becu%e (rt e:trctiono&ten i% e%ier nd 'e%% cu*ber%o*e )-en t-e (unc- i%'oded )it- t-e re'ie& re &cing to)rd you+

Antide&'ection 3Cro)ning Sy%te*%

I& your (re%% brke i% 7 &eet 'ong or 'onger, un'e%% you bend not-ing but t-in *teri'% or re &ortunte enoug-to -e (re%% brke )it- bui't=in de&'ection

co*(en%tion, you (robb'y -e been %-i**ing die% tooerco*e *c-ine de&'ection+ T-e ti*e con%u*ed ndt-e %ub%e<uent co%t% o& t-i% tediou% nd (roductiity=robbing (roce%% re o&ten oer'ooked+

Antide&'ection 3cro)ning %y%te*% re i'b'e t-t e'i*inte t-i% (rob'e*+ B%ic%y%te*% re *nu''y d?u%ted, nd %et %cre)% c'*( 'o)er die% in ('ce+ Ot-er% ree<ui((ed )it- *ore dnced c'*(ing br% t-t cn be tig-tened gin%t t-e die*nu''y or )it- -ydru'ic% &or u'tr&%t die c-nge%+ C'*(ing br% *ke it (o%%ib'e &oryou to (o%ition %*'' die %eg*ent% ny)-ere 'ong t-e &u'' 'engt- o& t-e unit to c-ieee<u' c'*(ing (re%%ure+ T-i% (reent% t-e* &ro* being *oed or knocked oer )-i'e

-nd'ing t-e *teri'+T-e de&'ection=co*(en%ting co*(onent% in t-e%e %y%te*% cn be %i*('e %et o&o((o%ing )edge% or %et o& -ig-'y dnced o((o%ing )e%+ 6e(ending on t-e de%ign,t-e *otion o& t-e )edge% or o((o%ing )e% gin%t ec- ot-er cu%e t-e unit to de&'ectin n u()rd *otion to co*(en%te &or t-e *ount o& de&'ection t-t i% being genertedin t-e (re%% brke )-en it co*e% under 'od+ You cn d?u%t t-e%e unit% )it- b%ic 'eer, -nd crnk t t-e end o& t-e unit, or )it- n e'ectronic *otor drien by t-e CNC on t-e (re%% brke+

So*e o& t-e *ore dnced ntide&'ection %y%te*% i'b'e '%o &eture 'oc'i0ed

d?u%t*ent%+ T-i% enb'e% you to incre%e or decre%e t-e *ount o& de&'ectionco*(en%tion t &re<uent inter'% 'ong t-e &u'' 'engt- o& t-e unit+ T-i% *ke% it (o%%ib'eto &ine=tune t-e de&'ection=co*(en%ting cure o& t-e unit to oerco*e t-e nunce% bui'tinto t-e *c-ine, % )e'' % co*(en%te &or )er t-t i% %(eci&ic to (rticu'r re o& t-eu((er nd 'o)er be* or %(eci&ic (unc- or die+

Figure 2

T-i% -ydru'ic c'*(ing%y%te* &or Nort- A*ericn=

%ty'e (re%% brke% i% e<ui((ed

)it- cro)ning %y%te* t-tu%e% o((o%ing )e tecno'ogyto co*(en%te &or *c-ine

de&'ection+




In t-e end, t-e c-oice o& )-ic- cro)ning unit i% be%t &or you %-ou'd re%t %o'e'y on )-ic-&eture% nd bene&it% be%t %uit your need%+ W-ic-eer %y%te* you c-oo%e cn e'i*inte%-i**ing )it- (roce%% t-t re<uire% on'y *tter o& %econd% to co*('ete+

Ironic''y, (re%% brke neer co*e% into contct )it- t-e *teri' t-t it bend%F on'y t-e

too'ing nd bckguge do t-t+ W-en con%idering )y% to i*(roe (re%% brke (roductiity, it i% i*(ertie t-t you e:*ine '' o& t-e e'e*ent% t-t &&ect oer'' (roductiity+ T-i% inc'ude% t-e *c-ine, contro', o(erting %o&t)re, nd eeryt-ing t-tgoe% bet)een t-e u((er nd 'o)er be*%;t-e too'ing %y%te*, c'*(ing %y%te*, ndde&'ection=co*(en%ting deice+ >ortunte'y, )-en it co*e% to dnced too'ing %y%te*%,c'*(ing %y%te*%, nd ntide&'ection %y%te*%, t-e c-oice% -e neer been better+

8sing *enc-&ar0ing for *end deductions

By Stee 6+ Ben%on, Contributing Writer

My !", #""#Benc-*rking i% ery good ide &or your o(ertion;?u%t *ke %ure your benc-*rk%re your o)n nd not %o*eone e'%e% ide o& (er&ect+

Benc-*rking i% u%ing *e%ure*ent or e'ution to ?udge %i*i'r (roce%%e%, (rt%,c-rt%, nd *et-od%+

T-e ter* benc-*rk i% be'ieed to co*e &ro* *edie' ti*e%;*ore %(eci&ic''y, &or*t-e %tone*%on% )-o bui't t-e gret ct-edr'% o& Euro(e+ Be&ore t-t ti*e 'oc'cr&t%*en bui't eery (iece o& &urniture nd cut eery (iece o& %tone to %i0e by ?udging

'engt-, )idt-, nd -eig-t by eye+ T-i% *ent t-ere )ere no %tndrd% by )-ic- to ?udgeco*(onent% &or 'engt-, )idt-, nd -eig-t re'tie to ny ot-er (rt+ In ot-er )ord%,eeryt-ing )% eyeb''ed+

At %o*e (oint %o*eone c*e u( )it- t-eide o& ('cing *rk or gouge into )orkbenc- to indicte t-e 'engt- or)idt- o& (rt+ By co*(ring ec- 'ego& &urniture or b'ock o& %tone gin%t t-e benc-*rk, t-e bui'der cou'd be %%uredt-t ec- %ub%e<uent (iece )% (retty

*uc- t-e %*e %i0e % t-e (reiou% one+Modern Ler%ion;Bend 6eductionC-rt%

A benc-*rk, t-en, i% *e%ure*ent t-t cn be u%ed % re&erence &or ot-er*e%ure*ent% or dt %et%+ In t-e *odern %-eet *et' %-o(, bend deduction c-rt% re




good e:*('e o& benc-*rking+ A bend deduction c-rt creted in %-o( )-ere bending*et-od%, bend ty(e%, nd too'ing re greed u(on by '' beco*e% 'id benc-*rk+

Ide''y, *odern benc-*rk% )ou'd %eret-e %*e unier%' (ur(o%e % t-e notc-

in t-e benc- did &or our ncient brot-er%+A te%t run o& t-e *teri' being &or*ed)ou'd 'idte t-e bend deduction 'ue%t ny ti*e+

Ho)eer, )-en in((ro(rite benc-*rk% re u%ed, (rob'e*% ri%e+ >orin%tnce, benc-*rk% cn be renderedin'id )-en t-eyre u%ed in di&&erent%-o( )-ere too'ing or &or*ing *et-od% di&&er &ro* t-e benc-*rk% %ource+

Figures 1 nd 2 %-o) t)o di&&erent bend deduction 3B6 c-rt% &or t-e %*e *teri't-ickne%% nd bend rdii+ Notice -o) di&&erent t-e bend deduction 'ue% re, eent-oug- bot- re correct &or t-e %-o( in )-ic- t-ey )ere creted+ One %-o)% benddeduction o& "+$"2 &or $!#=in+ in%ide rdiu% &or $2=guge co'd=ro''ed %tee'F t-e ot-erc-rt %-o)% it i% "+$!2+ T-e%e re (er&ect e:*('e% o& -o) not-er %-o(% benc-*rk*y or *y not be correct &or you+ I& you try to (('y %o*eone e'%e% benc-*rk to your (roce%%, c-nce% re it )ont *tc- t-e *rk% on your )orkbenc-, 'eing you )it- one'eg t-t i% too 'ong+

Mt-e*tic%. E%tb'i%-ing Co**on Benc-*rk

A% 'ong % you u%e t-e %*e &or*ing *et-od% nd too'ing t-t )ere u%ed to crete t-eorigin' dt %et, 'idting t-e origin' nu*ber% %-ou'd be e%y+ I& eeryone u%ed t-e&o''o)ing &or*u'% nd (roce%%e% to crete o& t-eir bend deduction c-rt%, t-ey cou'de%tb'i%- co**on benc-*rk+

To %et %tndrd benc-*rk &or your bend deduction c-rt%, you *u%t tke n ccurte*e%ure*ent o& t-e in%ide rdiu%, eit-er by *eeting (rt %(eci&iction% or by ('nning &or)-t i% going to be done+ T-i% rdiu% *e%ure*ent cn be tken on t-e ti( o& t-e (unc-rdiu% in botto* bending or coining+ It '%o cn be tken % (ercentge o& t-e L=dieo(ening in ir &or*ing u%ing t-e%e (ercentge%;#" (ercent &or !"4 %tin'e%% %tee', $1 (ercent &or co'd=ro''ed %tee', $1 (ercent &or H!# 1"1# 'u*inu*, nd $# (ercent &or -ot=

ro''ed (ick'ed in oi'+ Si*('y *u'ti('y t-e L=die o(ening by "+#", "+$1, or "+$# to &ind t-e'ue &or t-e in%ide rdiu%+

Once 'ue &or t-e in%ide rdiu% i% %et, %i*('y ('ug it into t-e &o''o)ing &or*u'% toe%tb'i%- (ro(er benc-*rk in your bend deduction c-rt% &or gien *teri' t-ickne%%nd in%ide rdiu%+

Bend %llowance (B%)




BA 3+"$541! : /( Q 3+""57 : MtR :

utside !et*ac0 (!!B)

OSSB tngent 3#R : 3Mt Q /(

Bend Deduction (BD)

B6 3# : OSSB = BA

W-ere.

Co*('e*entry ng'e o& bend

Mt Mteri' t-ickne%%

/( /diu% o& t-e (unc- 3coining nd botto* bending or in%ide rdiu% 3ir &or*ing

A% 'ong % t-e in%ide rdiu% o& t-e bend cn be *e%ured )it- rdiu% guge, '%o benc-*rk, t-e benc-*rk %u(('ied by *t-e*tic% cn be your% to (('y in your %-o(nd in ny ot-er %-o( t-t *e%ure% nd c'cu'te% t-e%e 'ue%+

T-e Key

T-e key to 'id benc-*rking i% under%tnding -o) t-e benc-*rk re'te% to t-e t%k%,too'%, nd *et-od% e*('oyed in your (rticu'r eniron*ent+ Benc-*rking t-e t%k%t-t you gener''y (er&or* rt-er t-n u%ing benc-*rk %o*eone e'%e -% creted )i''

%teer you in t-e rig-t direction, un'e%% t-ey '%o re u%ing *t-e*tic''y deried benc-*rk%+ T-en youre OK+

9etting control of your cut:to:lengt- line

;ow to select t-e &ost suita*le drie and controller

By Mrtin Mrincic, Contributing Writer u'y $$, #""#

T-ere re *ny &ctor% to con%ider )-en %e'ecting drie nd contro' %y%te* &or cut=to='engt- 'ine+ A&ter c-oo%ing t-e 'ine, you need to c-oo%e t-e drie, c'cu'te t-e 'odinerti, c'cu'te t-e &eeder %(eed, nd c-oo%e *otion contro''er+

Mny &ctor% %-ou'd be con%idered )-en %e'ecting drie nd contro' %y%te* &or cut=to='engt- 3CT9 'ine+




>ir%t, decide t-e ty(e o& CT9 'ine be%t=%uited &or your (('iction, %(eci&iction%, nd budget+ 9et% %%u*e youe c-o%en 'oo( ro'' &eed+ W-ere do you go &ro* t-ereG

6rie C-oice%

Figure 1 %-o)% %o*e ty(ic'&re<uency re%(on%e rnge% &or ''ty(e% o& drie% i'b'e tody+Per&or*nce rie% )ide'y*ong *nu&cturer%+

In gener', AC drie% re (re&erred )-en (o)erre<uire*ent% re 'o)er t-n 51HP, )-en %igni&icnt nu*ber% o&drien %ection% re 'ike'y to be brking continuou%'y, &or -ig-=(er&or*nce (('iction%,

nd &or 'rge (roce%% 'ine% u%ing *ny drien %ection%+6C drie% re *o%t %uitb'e )-en (o)er re<uire*ent% re -ig-er t-n 51 HPF )-en (o)er re<uire*ent% re (o%itie &or '' %ection%F )-en t-ere i% 'rge 6C in%t''ed b%eFnd )-en t-e (('iction re<uire% )ide, con%tnt=-or%e(o)er %(eed rnge+

>or t-e ro'' &eed CT9 'ine, n AC ector drie (robb'y )ou'd be t-e *o%t %uitb'ec-oice+

Motion Pro&i'e

No) t-t youe %ett'ed on n AC drie &or your ro'' &eed, you need to %i0e t-e *otor &ort-e (('iction by deter*ining -o) *uc- tor<ue i% re<uired t )-t %(eed nd )-t kindo& (er&or*nce you cn e:(ect+ Becu%e t-e 'ine *o%t 'ike'y )i'' run *teri'% o& riou%'engt-%, you'' need to c'cu'te &or t-e entire (roduct rnge+

T-i% (('iction c''% &or you to *oe %tri( o& *teri' kno)n di%tnce+ You cnrecord nd gr(- t-e e'ocity oer (eriod o& ti*e, re%u'ting in *otion (ro&i'e c-rt&ro* )-ic- you cn deter*ine di%tnce, *:i*u* %(eed, nd cce'ertion rte%+

One o& t-e *o%t co**on'y u%ed *otion (ro&i'e% i% t-e $!=$!=$! (ro&i'e+ T-e ti*e''octed &or %tri( *oe*ent i% diided into t-ree e<u' ti*e %eg*ent%. one=t-ird &or

cce'ertion, one=t-ird &or trer%e, nd one=t-ird &or dece'ertion 3%ee Figure 2+ T-edi%tnce nd ti*e re<uire*ent% re kno)n, %o you cn %o'e &or *:i*u* %(eed N3*:.

N3*: $+1 U Tot' di%tnce Tot' ti*e 3inc-e% (er %econd

T-i% 'ue &or N3*: cn be conerted to /PM.

Inc-e%%econd U 2" %econd%*inute U $ rottionP inc-e%

Figure 15

6rie &re<uency re%(on%e rie% )ide'y *ong*nu&cturer%, but rnge% cn be identi&ied &or ''

ty(e% o& drie% i'b'e tody+




)-ere. P inc-e% (er reo'ution

9od Inerti

@%ing t-e re<uired (('iction dt

in&or*tion gt-ered &or t-e *c-ine,you cn c'cu'te t-e tot' connected'od inerti+ T)o o& t-e *o%t co**ongeo*etric %-(e% encountered in t-e%e(('iction% re %o'id nd -o''o)cy'inder%+ To c'cu'te t-e inerti o&ec-, u%e t-e &o''o)ing &or*u'%.

So'id cy'inder &or kno)n )eig-t nd rdiu%.

3$# U 3Wg U r #

So'id cy'inder &or kno)n den%ity, rdiu%, nd 'engt-.

3$# U 3Pi U $ U (gR U r 4

Ho''o) cy'inder &or kno)n )eig-t nd rdiu%.

3$# U 3Wg U 3or # Q ir #

Ho''o) cy'inder &or kno)n den%ity, rdiu%, nd 'engt-.

3$# U 3Pi U $ U (gR

U 3or4 = ir4

)-ere. inerti 3'b+ in+ %ec+#

W )eig-t 3'b%+

g grittion' con%tnt 3!72 in+ (er %ec+#

' 'engt- 3in+

( den%ity 3'b%+in+!

r rdiu% 3in+

or # out%ide rdiu% 3in+

ir # in%ide rdiu% 3in+

Figure 25

In t-e $!=$!=$! *otion (ro&i'e, t-e ti*e''octed &or %tri( *oe*ent i% diided into

t-ree e<u' ti*e %eg*ent%. one=t-ird &orcce'ertion, one=t-ird &or trer%e, nd one=

t-ird &or dece'ertion+




To &ind t-e tot' connected 'od inerti, dd toget-er t-e inerti o& ec- drien e'e*ent+

>eeder S(eed

No) t-t you kno) t-e 'od inerti nd *otion (ro&i'e, you cn %e'ect t-e correct *otor

nd gerbo: co*bintion &or 'od cce'ertion+

>ir%t, 'ook t t-e *:i*u* re<uired &eeder 'od %(eed you c'cu'ted u%ing t-e *otion (ro&i'e+ I& you kno) t-e b%e %(eed o& t-e *otor, you cn c'cu'te reducer ger rtio+You no) cn c'cu'te 3/e, t-e 'od inerti re&'ected t-roug- t-e gerbo: bck to t-e*otor %-&t.

3/e 3$ /# 3'b+ in+ %ec+#

)-ere. 3/e re&'ected inerti

3$ 'od inerti

/ gerbo: rtio

I& t-ere i% ny 'od tor<ue, t-e gerbo: )i'' reduce t-e *ount t t-e *otor %-&t+ You cnc'cu'te t-e 'od tor<ue re&'ected bck to t-e *otor %-&t % &o''o)%.

T3/e T3$/

)-ere. T3/e re&'ected tor<ue

T3$ 'od tor<ue

/ gerbo: rtio

Once t-e re&'ected inerti nd re&'ected tor<ue re kno)n, you cn %o'e &or t-e re<uired*otor cce'ertion tor<ue T3 u%ing t-e &o''o)ing &or*u'.

T3 V33* Q 3/e U N3*:R38+11 U t Q T3/e

)-ere. T3 *otor cce'ertion tor<ue 3in+ 'b+

3/e re&'ected inerti 3'b+ in+ %ec+#

3* *otor inerti 3'b+ in+ %ec+#

N3*: *otor *:i*u* %(eed 3/PM

t cce'ertion ti*e 3%ec+




T3/e re&'ected tor<ue 3'b+ in+

T-e *otor you %e'ect %-ou'd be b'e to (roduce t-e *ount o& cce'ertion tor<uere<uired+

Becu%e t-e 'od in t-i% e:*('e i% cyc'ic', you *u%t c-eck t-e erge *ount o&tor<ue t-e (('iction re<uire% to be certin t-t your *otor cn de'ier t-t tor<ue)it-out oer-eting+

C'cu'te t-e erge re<uired tor<ue u%ing t-e &o''o)ing e<ution.

Tr*% 3T$#t$ Q T#

#t# Q T!#t! Q XXX 3t$ Q t# Q t! Q XXXR=#

)-ere. T$ cce'ertion tor<ue 3'b+ in+ T# trer%e tor<ue 3'b+ in+

T! dece'ertion tor<ue 3'b+ in+ t$ cce'ertion ti*e 3%ec+ t# trer%e ti*e 3%ec+ t! dece'ertion ti*e 3%ec+

T-e continuou% tor<ue rting o& t-e *otor *u%t be greter t-n t-e c'cu'ted ergere<uired tor<ue+

Once youe %i0ed t-e *otor &or (rticu'r cut 'engt-, you need to c-eck t-e e:(ected (er&or*nce t '' o& t-e ot-er (o%%ib'e cut 'engt-% by rerunning '' o& t-e c'cu'tion% &orec- cut 'engt-+ @%u''y, *otor nd gerbo: %i0ed to (er&or* de<ute'y t %-ort

'engt-% *y -e 'i*ited (er&or*nce t ot-er 'engt-%+ You *ig-t -e to gie u( (er&or*nce in one re to gin it bck in not-er+ Con%trint%

One o& t-e con%trint% you )i'' -e to de' )it- i% t-e ty(e o& %-er nd t-e *:i*u*nu*ber o& %troke% (er *inute it cn -nd'e+ T-i% u%u''y %et% t-e *:i*u* nu*ber o& (iece% (er *inute 3PPM t-t t-e 'ine cn -nd'e+

Anot-er %-ort='engt- con%trint i% t-e bi'ity o& t-e *otor to cce'erte &%t enoug- to*ke t-e *oe+ T-e *otor *u%t -e enoug- tor<ue to bring t-e connected inerti u( tot-e *:i*u* %(eed in t-e ti*e ''o)ed+ So*eti*e% t-e cce'ertion con%trint i% not)it- t-e *otor but )it- t-e *c-ine it%e'&+ >or e:*('e, t-e *otor *y -e enoug-

tor<ue to cce'erte t-e 'od, but t-e &eed ro''% *y %'i( on t-e *teri' t t-t (rticu'rcce'ertion rte, cu%ing inccurte cut 'engt-%+ Or t-e cce'ertion rte *y be too -ig-&or t-e *ec-nic' (ortion o& t-e *c-ine to -nd'e+

erbo:e%, be't%, nd ot-er drien e<ui(*ent cou'd beco*e )orn out <uick'y, c-tter, ore:-ibit ot-er un%tb'e c-rcteri%tic%+ A'%o, con%ider t-e contro' o& t-e &ree 'oo(+ I& t-ecce'ertion rte ((roc-e% or een e:ceed% t-e &orce o& grity, you )i'' not -econtro' oer t-e 'oo(, 'eding to n un%tb'e condition+




On 'onger 'engt-%, con%trint t-t *y be encountered i% t-t t-e *:i*u* &eeder%(eed i% too %'o)+ You cou'd c-nge t-e %e'ected ger rtio to ''o) &or &%ter *:i*u**otor %(eed, but you )ou'd be giing u( tor<ue nd 'o%ing %o*e o& t-e dntge o&%*''er re&'ected inerti+

Anot-er 'ong=%-eet con%trint i% t-e 'ee'er ger in %(eed+ T-e *:i*u* 'ine %(eed t t-e'ee'er diided by t-e cut 'engt- gie% you t-e *:i*u* PPM &or 'onger 'engt-%+ A'%o,t-e *ount o& *teri' %tored in t-e 'oo( *u%t be con%idered &or 'onger 'engt-%+

T-e%e con%trint% *u%t be ob%ered &or '' cut 'engt-%+ You cn do %o*e t-ing% tooerco*e t-e*+ So*eti*e% it i% trde=o&& )it- ot-er con%trint%, nd %o*eti*e% 'rger, &%ter *otor )i'' do t-e trick+ But o&tenti*e% you )i'' &ind %itution o&di*ini%-ing return% % you try to (('y bigger *otor%+ T-t i%, t-e 'rger tor<ue% re<uire'rger &r*e% t-t -e 'rger inerti%, nd % you (('y t-e &or*u'%, you )i'' &ind t-tt-e e:(ected re%u't% begin to dro( o&& een t-oug- you -e 'rger *otor+

Motion Contro''er%A *otion contro''er -nd'e% '' o& t-e co*(uttion% to generte t-e *otion (ro&i'e u%ed by t-e &eeder drie+ It u%u''y i% *icro(roce%%or=b%ed nd cn be %tnd='one bo: or (rt o& t-e (rogr**b'e 'ogic contro' %y%te*+ It cn re%ide in PC or indu%tri'co*(uter, or it cn be (rt o& t-e AC, 6C, or %ero drie%+

T-e *otion contro''er c'cu'te% di%tnce%, e'ocitie%, cce'ertion%, tor<ue, nd %(eed+ It*y -e to cco**odte %eer' encoder% nd be c(b'e o& bot- n'og nd digit'in(ut nd out(ut+ It -% to be b'e to co**unicte to t-e re' )or'd to cce(t %et (oint%nd ot-er co**nd%+ And '%t, t-e *otion contro''er *u%t be &%t enoug- to %end it%

c'cu'tion% to t-e drie in ti*e &or t-e drie to rect+Sy%te* C-eck%

A &e) &in' c-eck% re*in.

I% t-e inerti o& t-e *otor e<u' to or bigger t-n t-e tot' re&'ected 'od inerti diided by !G T-i% i% nece%%ry to en%ure %y%te* %tbi'ity+

I% t-e continuou% *otor tor<ue %ti'' greter t-n t-e re<uired erge tor<ueG I& youe*de ny c-nge%, e%(eci''y t-e ger rtio, you *y -e to rec'cu'te+

I% t-e (ek tor<ue o& t-e *otor -ig- enoug- to cce'erte t-e 'od &%t enoug-G Agin,c-nge% cn &&ect (ek tor<ue re<uire*ent%+

Cn t-e *otor run t t-e to( %(eed youe de%ignedG In your e&&ort% to reduce 'odtor<ue nd inerti, you *ig-t -e %e'ected ger rtio t-t re<uire% t-e *otor% to( %(eedto be -ig-er t-n t-e *nu&cturer reco**end%+




I% t-e cce'ertion rte cce(tb'eG I% it -ig- enoug- &or good (roduction but be'o) t-re%-o'd &or good contro' o& t-e %tri( nd cce(tb'e )er on t-e *c-ineG

He t-e (er&or*nce %(eci&iction% been *etG I& not, you need to *odi&y your de%ignc-oice% or *odi&y your (er&or*nce %(eci&iction%+

Martin Marincic is president of New Era Controls, P.O. Box 25630, Garfield ei!"ts,

O ##$25, p"one 2$6%&0$%$300, fax 2$6%&0$%$305, e%'ail

neweracontrols(worldnet.att.net , )e* site neweracontrols.co'. New Era Controls is a s+ste's inte!rator t"at specialies in pro-idin! dri-es and controls for ct%to%len!t" lines

and ot"er coil processin! applications.

/"is article is adapted fro' Martin Marincics conference presented at Coil Ct%to%

len!t" )or1s"op, !. 2 and Oct. $, 200$, 4200$ *+ t"e a*ricators Manfactrers ssociation, 7ntl.

<aterial ;andling on !"uaring !-ears

%iding productiity *y &a0ing t-e operators =o* easier

By /od Stouder, Contributing Writer une $!, #""$

Pro(er *teri' -nd'ing e<ui(*ent in &ront o& nd in bck o& ut*o%t i*(ortnce to youro(ertion+ It% i*(ct on o(ertor co*&ort nd %&ety %-ou'd not be *ini*i0ed+

O&ten it i% t-oug-t t-t to get *ore (roduction &ro* %-ering o(ertion, not-er %-i&t, oreen ne) %-er *u%t be dded+ Ho)eer, becu%e o& 'ck o& &und%, (er%onne', or &'oor%(ce, ne) %-er i% not ')y% t-e n%)er+

T-e b%ic% o& (roductie %-ering o(ertion re o&ten oer'ooked+ W-t good i% it to-e %-er t-t )i'' do !" to 2" %troke% (er *inute 3SPM i& t-e *teri' co*ing intond going out o& t-e %-er i% not being (ro(er'y -nd'edG

Ty(ic''y, on'y 1 (ercent o& %-ering o(ertion i% %(ent )it- t-e %-er r* going u( nddo)n, cutting *teri'+ T-i% *en% t-t t-e ot-er 81 (ercent i% %(ent -nd'ing t-e &'o) o&*teri' being %-ered+ T-irty (ercent o& t-i% -nd'ing i% done on t-e &ront %ide, nd 21

(ercent tke% ('ce on t-e bck o& t-e %-er+

Mteri' -nd'ing ino'e% 'bor+ In t-e %-ering o(ertion, 'bor i% t-e %*e )-et-er t-e%-er o(ertor i% &eeding %-eet, cutting, or (icking u( t-e *e%% t t-e bck o& t-e %-er+

I*(roing t-e &'o) o& *teri' into nd out o& t-e %-er cn incre%e %-ering out(ut+Wit- t-e u%e o& %o*e b%ic *teri' -nd'ing e<ui(*ent, %-ering o(ertion cn be*de *ore (roductie+

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>eeding t-e S-er

T-e &ir%t ('ce to con%ider *teri' -nd'ing e<ui(*ent &or %<uring %-er i% t t-e &ronto& t-e %-er, e%(eci''y i& t-e %-er i% *ounted &'t on t-e &'oor+

Mo%t %-er% -e !#=inc- (%%'ine, )-ic- *en% t-t t-e %-er tb'e i% !# inc-e% &ro*t-e &'oor+ It -% been %id t-t %-er tb'e% -e been t t-e %*e -eig-t %ince t-e $8#"%+I& (er%on% o& erge -eig-t re (u%-ing %tee' t !#=inc- tb'e, t-t *en% t-ey re bending oer, )-ic- i% -rd on t-eir bck%+

Con%tnt'y bending oer cn cu%e bck %trin+ T-e *ore %trin t-t tke% ('ce, t-e *oret-e o(ertor )i'' %to( %-ering nd %trig-ten to re'iee t-e (in+ W-en t-ere i% 'e%% %trinnd (in, t-ere %-ou'd be *ore (roductie %-ering tking ('ce+ T-o%e )it- %-eringo(ertion% %-ou'd t-ink bout (utting t-eir %-er% on ri%er% to t 'e%t !2= to !7=in+)orking (%%'ine+

Mteri' &'o) into t-e %-er cn '%o be i*(roed )it- in&eed %%i%t tb'e%+ By kee(ingt-e ne:t (iece to be %-ered t tb'e -eig-t or 'itt'e -ig-er, t-e o(ertor cn 'et t-e*teri' &'o) do)n)rd to)rd t-e %-er+ It i% *uc- e%ier to contro' %-eet %'idingdo)n t-n it i% to 'i&t nd (u'' t-e %*e %-eet u( nd onto t-e %-er tb'e+

T-e o(ertor cn c-oo%e t-e *o%t co*&ortb'e in&eed -eig-t nd *intin t-t contro''ed-eig-t t '' ti*e%+ Agin, )-en t-e o(ertor i% )orking t co*&ortb'e )ork -eig-t,%-ering ti*e cn beco*e *ore (roductie+

B'' trn%&er nd c%ter &ie'd% or een (o)ered in&eed ro''er% cn '%o reduce %trin on%-er o(ertor%+ W-en 'e%% &orce i% u%ed &eeding t-e *teri' into t-e %-er, *ore &ini%-ed

*teri' %-ou'd co*e out t-e bck+/e*oing Mteri' &ro* t-e S-er

T-e ti*e t-t (%%e% bet)een t-ecutting o& *teri' nd re*oing it&ro* t-e %-er cn ccount &or %*uc- % 21 (ercent o& t-e %-eringo(ertion+ T-i% *en% t-t &or t-e $1or #" *inute% )ort- o& %-ering,t)ice t-i% *uc- ti*e i% %(ent %orting

nd %tcking &ini%-ed (rt% be-ind t-e%-er+

A *teri' %u((ort %y%te* 3%ee Figure 1 t t-e bck o& t-e %-er cn %e )er nddu''ing on t-e 'o)er b'de becu%e it -o'd% t-e %-eet u( nd kee(% it &ro* drgging cro%%t-e kni&e+ A %u((ort %y%te* '%o -o'd% t-e %-eet in ('ce %o t-t t-e o(ertor cn kee( -i%-nd% )y &ro* t-e b'de during %-ering+ In ddition, %u((ort %y%te* e'i*inte% t-e

Figure 15

A *teri' %u((ort %y%te* &or %-er+




need &or (er%onne' to be under or be-ind t-e %-er, )-ic- *en% %&er )ork re+ T-e%e%y%te*% '%o (roide truer bckguging o& t-e (rt%+

W-en (roducing (rt%t-t re t-e %*e %i0e,

%tcker )orking be-indt-e coneyor e'i*inte%t-e need &or (er%on to%tck by -nd+ A %tckercn ('ce t-e %-eet% in tig-t %tck &or bndingnd %-i((ing+ A %tckercn '%o %tck t-e %-eet%tig-t'y &ront=to=bck nd'oo%e &ro* 'e&t to rig-t+T-i% *ke% t-e %-eet%

e%ier to -nd'e t t-ene:t )ork%ttion+

So*e coneyor% -e *teri' %u((ort% nd tri* cut %e(rtor% bui't into t-e*+ W-i'e t-e%-er i% cutting (rt%, t-e%e deice% %e(rte t-e tri* &ro* t-e &ini%-ed (iece% going outt-e bck o& t-e %-er -ou%ing+ T-e &ini%-ed (rt% t-en &'' into %&e )ork re 3%eeFigure 2+

Working o&& o& %-er tb'e t-t -% !#=inc- (%%'ine, %tcker cn *ke %tck -eig-to& $2 to #" inc-e%+ Putting t-e %-er on ri%er% )ou'd ''o) *ore %tck -eig-t+ A% t-e%-er tb'e goe% u( &ro* t-e &'oor, %o doe% t-e u%eb'e %tck -eig-t+ In (roduction run,

t-i% *en% 'e%% ti*e i% %(ent %to((ing to re*oe %-ered %tck%+S&ety

S&ety i% *?or concern+ By dding *teri' -nd'ing e<ui(*ent, t-e ri%k o& in?ury int-e )ork('ce cn be reduced )it- t-e dded bene&it o& incre%ed (roduction out(ut+

E*('oyee Su((ort

Not eery %-ering o(ertion )i'' bene&it &ro* *teri' -nd'ing e<ui(*ent+ Ho)eer,*nger% )-o t-ink it i% )ort- con%idering %-ou'd di%cu%% e<ui(*ent o(tion% )it- t-e

%-er o(ertor%+ Wit-out t-eir in(ut, *teri' -nd'ing c-nge% *y not (y o&& inincre%ed %-er out(ut+

> ways to 0eep your s-ear in top s-ape

By /obert Kotyn%ki, Contributing Writer A(ri' $", #""$

Figure 25

A %-er )it- coneyor% cn be &itted )it- bui't=in *teri'%u((ort% nd tri* cut %e(rtor%+




I*(roing u(ti*e nd reducing *intentnce )-en u%ing %-er% &or -ig- (roductioncou'd *en &o''o)ing &e) key %te(%+

S-er% re co**on (iece% o& &bricting e<ui(*ent t-t cn be &ound in *ny *et'&or*ing ('nt%+ >ro* tube *i''% to %*'' &brictor%, t-e %-er i% one o& t-e *o%t critic'

nd dier%e too'% u%ed in *et' &bricting+

Lrying in %i0e &ro* %*'' -nd=-e'd *et' %-er% nd &oot=o(erted tri* %-er% to -ig-= (roduction in='ine &'ying cuto&&%, t-e *odern *et' %-er -% re('ced t-e %) % t-e*c-ine o& c-oice &or -ig-=(roduction *et' cutting+

T-i% rtic'e ddre%%e% i*(roing u(ti*e nd reducing *intennce )-en u%ing %-er% &or-ig- (roduction+

T-e &o''o)ing ti(% re &ro* %-er u%er% nd rebui'der% )-o &ound %ucce%% )-en t-eyi*('e*ented t-e*+

Ti( No+ $ ; @nder%tnd Your Mc-ine

It i% i*(ortnt to under%tnd t-e &unction, de%ign, nd o(ertion o& your *c-ine+ T-e*in cu%e o& %-er &i'ure i% oer'oding it beyond t-e OEM% (r*eter%+ S-er% rede%igned to cut *et' o& n e%tb'i%-ed t-ickne%% nd )idt-+ W-en t-e%e 'i*it% ree:ceeded, d*ge occur%+

In ddition to &o''o)ing t-e OEM% 'od reco**endtion%, nor*' d?u%t*ent% %-ou'd be*de regu'r'y, nd *intennce %c-edu'e% nd %erice re<uire*ent% %-ou'd be &o''o)edcre&u''y+

Mi%u%ing 'ubricnt% nd ot-er &'uid% '%o cu%e% d*ge+ 9ubricnt% nd &'uid% *u%t beu%ed % %(eci&ied by t-e OEM+

Ti( No+ # ; Per&or* nd 6ocu*ent /egu'r In%(ection%

A regi*ented in%(ection %c-edu'e %-ou'd be (o%ted nd d-ered to+ Are% t-t %-ou'd bein%(ected inc'ude t-e %-er% bi'ity to e:ecute '' &unction% o& o(ertionF on *ec-nic'*c-ine%, '' bering% %-ou'd be c-ecked &or 'o%t *otion nd )erF nd '' e*ergencynd %&ety &unction% %-ou'd be e:*ined+

Ti( No+ ! ; /eie) 6ocu*enttionA&ter regu'r in%(ection% re (er&or*ed nd docu*ented, t-e dt %-ou'd be reie)ed%y%te*tic''y+ T-i% reie) cn ree' )er (ttern%, t-e (otenti' &or ccident%, ndnoncon&or*nce %o t-t re(ir% cn be *de+




6ocu*enttion nd n'y%i% re t-e b%i% o& (reentie *intennce+ Wit- t-i%in&or*tion, c'er'y 'id out *intennce ('n cn be (re(red, e'i*inting *o%te*ergency re(ir%+

Ti( No+ 4 ; Set t-e B'de Pro(er'y

Setting t-e %-er b'de (ro(er'y i% key to e:tending b'de nd *c-ine 'i&e+ Setting t-e (ro(er c'ernce% &or b'de cutting &&ect% t-e drie, r*, too'ing, nd cut <u'ity+Addition''y, be&ore %etting t-e b'de, t-e b'de %et %-ou'd be c-ecked &or &'tne%% nd toen%ure t-t t-e too'ing i% %eted (ro(er'y to e'i*inte b'de c-i((ing cu%ed by %-i&tingduring cutting+

I& t-e c'ernce% re too tig-t, i*(ro(er cutting ction occur% becu%e t-e *et' ?*% bet)een t-e b'de nd t-e *c-ine+ I& t-e b'de% -e no c'ernce, t-ey )i'' brek+W-en c'ernce% re too 'oo%e, t-e b'de ct% % -**er t-t (('ie% *u'ti('e &orce% tot-e *c-ine% co*(onent%, cu%ing (re*ture )er nd &i'ure+

Ti( No+ 1 ; Mintin Correct ib C'ernce

Setting nd *intining (ro(er gib c'ernce% incre%e too'ing 'i&e nd *c-ine u(ti*e+T-e gib% *intin (ro(er guiding ction o& t-e r* nd ttc-ed too'ing+ I& t-e c'ernce%re not *intined, t-e %*e (rob'e*% occur % t-o%e t-t tke ('ce )-en t-e b'dec'ernce% re ignored+

Ti( No+ 2 ; I%o'te nd 9ee' t-e Mc-ine

9ee'ing %-er nd i%o'ting it &ro* ibrtion re critic' to (ro(er o(ertion+ T-e

(ro(er %e'ection nd in%t''tion o& i%o'tion (d% cn incre%e too'ing 'i&e nd %-ering%(eed, decre%e ibrtion, i*(roe &oundtion 'i&e, reduce noi%e, nd e'i*inte %-er&r*e di%tortion+

@%ing tody% i%o'tor%, *c-ine 'ee'ing cn be done in 'e%% t-n -'& -our+ Mking%ure t-t t-e %-er i% 'ee' e'i*inte% t-e t)i%ting ction t-t cn de%troy %-er+

Ti( No+ 5 ; >o''o) B%ic Mintennce P'n

T-e &o''o)ing (rt% o& %-er re<uire regu'r'y %c-edu'ed *intennce.

$+ T-e ir %y%te* %-ou'd be *intined (ro(er'y to en%ure t-t t-e ir i% c'en+ A''regu'tor% *u%t be %et %o t-t t-ey re o(erting correct'y+ Mintining t-e regu'tor%-e'(% t-e (neu*tic''y ctuted *ec-ni%*% to &unction (ro(er'y+

#+ T-e 'ubriction %y%te* *u%t be c'ened, &i''ed, nd (ro(er'y &i'tered+ Broken, kinked,or t)i%ted 'ine% *u%t be re('ced+ Ec- (oint *u%t be di%connected nd e:*ined todeter*ine i& t-e 'ubriction i% rec-ing it% de%tintion+ Su*(% nd re%eroir% %-ou'd beroutine'y e*(tied, c'ened, nd re&i''ed+




!+ T-e *c-ine c'utc- nd brke% *u%t be e:*ined &or (ro(er 'ining t-ickne%%,c'ernce%, nd %ign% o& &i'ure+ Worn 'ining% *u%t be re('ced i**edite'y+ Oertre' beyond t-e *c-ine bui'der% %(eci&iction% *u%t be d?u%ted ndor corrected u(onin%(ection+

4+ Counterb'nce cy'inder% %-ou'd be te%ted nd re)orked t t-e &ir%t %ign o& ir 'ek% or&i'ure+ A counterb'nce cy'inder t-t -% t-e (ro(er ction en%ure% t-e 'ongeity o& '')orking co*(onent% o& t-e %-er nd it% too'ing+

Ti( No+ 7 ; Mke /e(ir% % Soon % Po%%ib'e

W-en d*ge, )er, or out=o&=d?u%t*ent condition% re &ound, t-e %-er %-ou'd bei**edite'y re(ired or d?u%ted+ Mo%t ct%tro(-ic &i'ure i% cu%ed by (utting o&&%i*('e re(ir%+ Addre%%ing re(ir% <uick'y i% '*o%t ')y% 'e%% e:(en%ie t-n t-e co%to& correcting t-e d*ge t-t cn tke ('ce )-en re(ir% re ignored or (ut o&&+Addition''y, o(ertor %&ety de(end% on ti*e'y re(ir%+

Kee(ing t-e %-er (roductie cn be cco*('i%-ed by (er&or*ing t-e%e %i*('e t%k%+W-en %-er i% *intined (ro(er'y, re('ce*ent co%t% nd ct%tro(-ic &i'ure reoided+

Ti( No+ 4 ; Set t-e B'de Pro(er'y

Setting t-e %-er b'de (ro(er'y i% key to e:tending b'de nd *c-ine 'i&e+ Setting t-e (ro(er c'ernce% &or b'de cutting &&ect% t-e drie, r*, too'ing, nd cut <u'ity+Addition''y, be&ore %etting t-e b'de, t-e b'de %et %-ou'd be c-ecked &or &'tne%% nd toen%ure t-t t-e too'ing i% %eted (ro(er'y to e'i*inte b'de c-i((ing cu%ed by %-i&ting

during cutting+I& t-e c'ernce% re too tig-t, i*(ro(er cutting ction occur% becu%e t-e *et' ?*% bet)een t-e b'de nd t-e *c-ine+ I& t-e b'de% -e no c'ernce, t-ey )i'' brek+W-en c'ernce% re too 'oo%e, t-e b'de ct% % -**er t-t (('ie% *u'ti('e &orce% tot-e *c-ine% co*(onent%, cu%ing (re*ture )er nd &i'ure+

Ti( No+ 1 ; Mintin Correct ib C'ernce

Setting nd *intining (ro(er gib c'ernce% incre%e too'ing 'i&e nd *c-ine u(ti*e+T-e gib% *intin (ro(er guiding ction o& t-e r* nd ttc-ed too'ing+ I& t-e c'ernce%

re not *intined, t-e %*e (rob'e*% occur % t-o%e t-t tke ('ce )-en t-e b'dec'ernce% re ignored+

Ti( No+ 2 ; I%o'te nd 9ee' t-e Mc-ine

9ee'ing %-er nd i%o'ting it &ro* ibrtion re critic' to (ro(er o(ertion+ T-e (ro(er %e'ection nd in%t''tion o& i%o'tion (d% cn incre%e too'ing 'i&e nd %-ering




%(eed, decre%e ibrtion, i*(roe &oundtion 'i&e, reduce noi%e, nd e'i*inte %-er&r*e di%tortion+

@%ing tody% i%o'tor%, *c-ine 'ee'ing cn be done in 'e%% t-n -'& -our+ Mking%ure t-t t-e %-er i% 'ee' e'i*inte% t-e t)i%ting ction t-t cn de%troy %-er+

Ti( No+ 5 ; >o''o) B%ic Mintennce P'n

T-e &o''o)ing (rt% o& %-er re<uire regu'r'y %c-edu'ed *intennce.

$+ T-e ir %y%te* %-ou'd be *intined (ro(er'y to en%ure t-t t-e ir i% c'en+ A''regu'tor% *u%t be %et %o t-t t-ey re o(erting correct'y+ Mintining t-e regu'tor%-e'(% t-e (neu*tic''y ctuted *ec-ni%*% to &unction (ro(er'y+

#+ T-e 'ubriction %y%te* *u%t be c'ened, &i''ed, nd (ro(er'y &i'tered+ Broken, kinked,or t)i%ted 'ine% *u%t be re('ced+ Ec- (oint *u%t be di%connected nd e:*ined to

deter*ine i& t-e 'ubriction i% rec-ing it% de%tintion+ Su*(% nd re%eroir% %-ou'd beroutine'y e*(tied, c'ened, nd re&i''ed+

!+ T-e *c-ine c'utc- nd brke% *u%t be e:*ined &or (ro(er 'ining t-ickne%%,c'ernce%, nd %ign% o& &i'ure+ Worn 'ining% *u%t be re('ced i**edite'y+ Oertre' beyond t-e *c-ine bui'der% %(eci&iction% *u%t be d?u%ted ndor corrected u(onin%(ection+

4+ Counterb'nce cy'inder% %-ou'd be te%ted nd re)orked t t-e &ir%t %ign o& ir 'ek% or&i'ure+ A counterb'nce cy'inder t-t -% t-e (ro(er ction en%ure% t-e 'ongeity o& '')orking co*(onent% o& t-e %-er nd it% too'ing+

Ti( No+ 7 ; Mke /e(ir% % Soon % Po%%ib'e

W-en d*ge, )er, or out=o&=d?u%t*ent condition% re &ound, t-e %-er %-ou'd bei**edite'y re(ired or d?u%ted+ Mo%t ct%tro(-ic &i'ure i% cu%ed by (utting o&&%i*('e re(ir%+ Addre%%ing re(ir% <uick'y i% '*o%t ')y% 'e%% e:(en%ie t-n t-e co%to& correcting t-e d*ge t-t cn tke ('ce )-en re(ir% re ignored or (ut o&&+Addition''y, o(ertor %&ety de(end% on ti*e'y re(ir%+

Kee(ing t-e %-er (roductie cn be cco*('i%-ed by (er&or*ing t-e%e %i*('e t%k%+W-en %-er i% *intined (ro(er'y, re('ce*ent co%t% nd ct%tro(-ic &i'ure re

oided+

Long loads, narrow aisles, easy access

!ide:loading lift truc0 -andles cu&*erso&e products in

confined spaces




By Eric 9undin, Senior Editor, T-e >AB/ICATO/Se(te*ber $#, #""2

Since %trting )it- ?u%t one )re-ou%e in $878, Ke''y Su(('ie% -% gro)n 'ong )it-Ire'nd% boo*ing con%truction indu%try+ 9i*iting &ctor% %uc- % t-e )re-ou%e%

door)y )idt-, nrro) i%'e%, nd 8"=degree turn%*ent t-e co*(ny -d to re'y on *nu' 'bor to-nd'e t-e 'ong, cu*ber%o*e ite*% in it% inentory+ A%tndrd &ork'i&t )% out o& t-e <ue%tion+ T-e co*(nyeentu''y (urc-%ed *u'tidirection' %ide='oding 'i&ttruck &ro* Co*bi'i&t &or *oing inentory in t-i%c-''enging eniron*ent+

Ire'nd i% c''ed t-e E*er'd I%'e, nd &or good re%on+/egrd'e%% o& t-e %e%on, *uc- o& t-e i%'nd i% coered)it- 'u%- green egettion+ T-e *i'd )inter )et-er i%

(roduct o& t-e u'& Stre*, t-e At'ntic Ocen currentt-t (u%-e% *oderte )et-er nort- &ro* t-e u'& o&Me:ico+ T-e ot-er &ctor, o& cour%e, i% (reci(ittion+ Itrin% 'ot in Ire'nd+ And t-t% n under%tte*ent+According to t-e country% )et-er %erice, MetZirenn, *uc- o& t-e i%'nd receie% n erge o&$,""" *i''i*eter% 34" inc-e% o& rin nnu''y, nd t-e *ountinou% region% receie t)icet-t *ount+

Seeing 'ucrtie nd gro)ing nic-e, errd Ke''y &ounded ++ Ke''y Su(('ie%, %erice center t-t (roide% rin)ter=crrying co*(onent% to Ire'nd% con%truction

indu%try+ Ke''y% ti*ing )% good;t-e con%truction indu%try -% gro)n %igni&icnt'yoer t-e (%t &e) yer%+ According to dt (roided by t-e Centr' Stti%tic% O&&iceIre'nd, co*('eted d)e''ing% incre%ed &ro* !",151 in $881 to 7",815 in #""1+Men)-i'e t-e de*nd &or gutter% nd do)n%(out% -% been % con%tnt % t-e rin% t-tkee( t-e i%'nd green, nd ++ Ke''y Su(('ie% -% gro)n rig-t 'ong )it- t-econ%truction indu%try+ Since it %trted )it- %ing'e )re-ou%e in Mong-n in $878,)-ic- %u(('ied )e%tern Ire'nd, t-e co*(ny -% dded )re-ou%e% in 6ub'in nd9i*erick nd no) %u(('ie% good% to con%truction contrctor% in '' o& t-e i%'nd% !#countie%+

Nrro) 6oor)y, Nrro) Ai%'e%

A&ter o(ening &or bu%ine%%, ++ Ke''y Su(('ie% <uick'y &i''ed it% $,#""=%<ure=*eter3$#,8""=%<+=&t+ )re-ou%e )it- inentory, )-ic- inc'ude% 'ong, cu*ber%o*e gutter% nddo)n%(out%+ T-e )re-ou%e% *in door i% ?u%t ! * 38+7 &t+ )ide, )-ere% t-e (roduct%ty(ic''y *e%ure u( to 2 * 3$8+2 &t+ 'ong+ @%ing %tndrd &ork'i&t to tke t-e (roduct%into t-e bui'ding )% out o& t-e <ue%tion+




Initi''y Ke''y% %u(('ier% 'e&t t-e de'ierie% on t-e %ide)'k ne:t to t-e )re-ou%e+etting t-e inentory into t-e )re-ou%e )% Ke''y% (rob'e*+

DWe -nd'ed eery (iece %e(rte'y &ro* t-e rod,D Ke''y %id, rec''ing t-e dy% )-en-i% )re-ou%e %t&& (roided *u%c'e (o)er to *oe t-e inentory *nu''y+

T-e door)y )%nt t-e on'y c-''enge+ T-e )re-ou%e% nrro) i%'e% nd t)o 8"=degree turn% (reented Ke''y% %t&& &ro* u%ing &ork'i&t in%ide t-e bui'ding+ Ke''yneeded %o*et-ing 'ike &ork'i&t, but %o*et-ing *uc- *ore er%ti'e+

9od It Side)y%, Moe It Any)-ere

Ke''y eentu''y &ound 'i&t truck t-t *tc-ed -i% need%; *u'tidirection' %ide='oding 'i&t truck *nu&ctured by Co*bi'i&t Inc+ T-e truck, *ode' C!1"", -% 'i&tc(city o& !,1"" ki'ogr*% 35,5"" 'b%+ nd 'i&t -eig-t o& 4,"4" ** 3$!+#1 &t+ It i%e<ui((ed )it- t)o %*'' &ront )-ee'% nd one 'rge rer )-ee'+ A'' o& t-e )-ee'% cn

rotte u( to $7" degree%, ''o)ing t-e truck to *oe &or)rd nd bck)rd nd %ide to%ide+ It '%o i% er%ti'e in t-e )y it turn% corner%+ Negotiting tig-t, 8"=degree turn i%not (rob'e*;becu%e it -% %ing'e rer )-ee', t-e truck cn *ke 0ero=rdiu% turn%+

T-e truck ''o)% Ke''y e*('oyee% to *oe t-e (roduct% direct'y into t-e )re-ou%e,e'i*inting *nu' -nd'ing o& indiidu' inentory ite*%+ It '%o ''o)% t-e* to *oecu*ber%o*e (roduct% t-roug- t-e )re-ou%e )it- e%e+ In ddition, it '%o -nd'e% not=%o=cu*ber%o*e 'od%, %uc- % t-e (''eti0ed 'u*inu* coi' t-t Ke''y %u(('ie% &or on=%itero'' &or*ing+

Moe t-e Product, Not t-e Wre-ou%e

T-e u%e o& t-i% %(eci'i0ed 'i&t truck e%ed t-e burden on Ke''y e*('oyee% by e'i*intingt-e need &or *nu' inentory trn%&er+ T-e 'bor %ing% ''o)ed Ke''y to reduce -i%)re-ou%e %t&& &ro* $" to %i:+

More i*(ortnt, t-e 'i&t truck ''o)ed Ke''y to u%e -i% )re-ou%e %(ce *ore e&&icient'y+A% t-e con%truction *rket nd de*nd &or con%truction=re'ted ite*% in Ire'nd -%gro)n, Ke''y -% been b'e to *ore e&&ectie'y u%e t-e 'i*ited %(ce in -i% Mong-n)re-ou%e, ''o)ing -i* to re*in in t-e %*e 'oction de%(ite t-e gro)t- in -i% bu%ine%%+

DBy no) )e )ou'd -e -d to *oe, i& not &or t-e Co*bi'i&t,D Ke''y %id

-e i&portance of storage planning

By oe Hrne%t, Contributing Writer October #!, #""!




Mteri' nd e<ui(*ent %torge cn be *?or concern &or &brictor%+ T-ere&ore,it i% i*(ortnt to e%tb'i%- t-e (ur(o%e o& %torge %y%te* nd under%tnd c'er'y)-t it need% to cco*('i%-+

In it% *o%t b%ic &or*, &brictor%%torge re *u%t be %ecure, dry ('ceo& %u&&icient %i0e to -ou%e re<uired ite*%+9oction nd *bient condition% re t-ecritic' &ctor%+

Con%idering t-e Criteri

In tody% &%t=(ced *teri' -nd'ing )or'd, &brictor% *u%t con%ider t-e )orkb'ecriteri be&ore t-e (ro?ect cn be i*('e*ented+ T-ey *u%t con%ider t-e b%ic cubic=&eet

re<uire*ent%, % )e'' % t-e eniron*ent re<uired &or t-e *teri'% to be inentoried+ Ando& cour%e, 'oction i% -ig-'y i*(ortnt+ >i'ure to con%ider it )ou'd co*(ro*i%eo(erting e&&iciency+

A *odern inentory *nger, un'ike inentory *nger% o& t-e (%t, -% co*('etecontro' o& '' t-e &ctor% %%ocited )it- *teri' %torge+ Wit- dnce% in tec-no'ogy,t-e inentory *nger cn bui'd -ig-er t-n )% (o%%ib'e in t-e (%t+ >brictor% '%o-e t-e bi'ity to *ke t-eir bui'ding% co'd, )r*, 'ig-t, drk, dry, or *oi%t )it-*0ing (reci%ion+

W-i'e t-e%e dnce% cn i*(roe o(erting e&&iciency nd dd 'ue to t-e (roduct,

&brictor% %ti'' *y &ee' dunted %itting t t-e conce(t %tge o& %torge %y%te*+ To bringtoget-er '' t-e rib'e% nd o(tion% i'b'e re<uire% in(ut &ro* *ny re% o&e:(erti%e+ Here i% <uick rundo)n o& )-t need% to be con%idered+

>ir%t In, >ir%t Out

Ne) rcking %y%te*% go &r beyond %i*('y %tcking (roduct%+ One o& t-e ob?ectie% o&t-e%e ne) rcking %y%te* de%ign% i% to e'i*inte or reduce t-e i%'e% % *uc- % (o%%ib'e+

>'o)=t-roug- %y%te*% re de%igned under t-e conce(t o& turning oer inentory by*king %ure t-e o'der *teri'% re u%ed &ir%t+ T-e%e %y%te*% 3crton &'o) nd (''et

&'o) ''o) *:i*u* &'oor den%ity nd (er*it t-e *teri'% to be )-ere &brictor% )ntt-e* )-en t-ey )nt t-e*, ')y% redy &or trn%&er to t-e %-i((ing dock or (roduction,-o)eer it *y be re<uired+

>ir%t In, >ir%t Out 3>I>O i% &or* o& &'o)=t-roug- %y%te* u%ing dyn*ic %torgetec-ni<ue t-t ''o)% t-e (roduct to &'o) t-roug- t-e rck i grity ro''er%,ccu*u'ting in n orgni0ed *nner redy &or t-e ne:t %te(+ T-e%e ro''er% re ng'ed%trtegic''y t (itc- t-t (er*it% t-e (roduct to *oe &or)rd+ T-e %(eed i% contro''ed




by brke% cting on t-e ro''er% t-t (reent t-e 'od% &ro* cce'erting beyond t-e de%ign%(eed+

Auto*ted Hnd'ing Truck%

Stndrd rck %y%te*% re co*('e*ented by riety o& *teri' -nd'ing truck% t-t cn be &u''y uto*ted nd ttc-ed to t-e rcking+ T-e%e re (rogr**b'e 'ogic=contro''ednd cn be (rogr**ed to o(erte round t-e c'ock+ O& cour%e, t-e (rice tg nd*intennce co%t *y %cre *nger, but i& t-e %y%te* -% been (ro(er'y (('ied,*nu&ctured, nd in%t''ed )it- t-e re<uired (reci%ion nd t-e (ro(er %c-edu'ed*intennce, it cn be -ig-'y (roductie %%et, de(ending on t-e &bricting %y%te*+

Nrro)=i%'e >ork Truck%

On t-e ot-er -nd, &ork truck% e:i%t t-t o(erte in nrro) i%'e% on'y 14 inc-e% )ide, (roducing n incre%e o& u%b'e &'oor nd ir %(ce t-t -% *?or i*(ct in *:i*i0ing

oer'' )re-ou%ing e&&iciency+ T-e%e truck% -e %ide='oding &eture t-t e'i*inte%t-e need &or t-e e-ic'e% to turn to get t-e (roduct out o& it% %torge re+

T-e conention' $#=&oot i%'e i% &%t beco*ing conention o& t-e (%t+

Auto*ted Storge nd /etrie'

Auto*ted %torge nd retrie' %y%te*% 3AS/S% o&ten re u%ed to %tore %*''er nd&re<uent'y inentoried nd retrieed (rt%+ T-i% ty(e o& %y%te* i% %e'&=contined nd u%e% %erie% o& tre'ing %-e'e% or bin%, u%u''y tre'ing in ertic' con&igurtion+

W-en (rt% re re<uired, t-e indiidu' identi&ie% t-e (rt to t-e (rogr**b'e 'ogiccontro''er, )-ic- in turn 'ook% &or t-e (iece t %(eci&ic 'oction nd (re%ent% t-ere<ue%ted ite* t t-e 'oction o& in(ut+ In ddition to -ig- %(eed nd en-nced %torgeden%ity, %ecurity i% incre%ed becu%e t-e *c-ine &orce% t-e o(ertor to %ign on to t-e%y%te*, 'ogging t-e o(ertor% identity+ T-e %y%te* '%o trck% nd identi&ie% inentoryite*% on it% %-e'e%+

A %i*i'r %torge %y%te* t-t rotte% (roduct% in -ori0ont' con&igurtion i% co**on'ykno)n % crou%e' %y%te*+ It u%e% *ore &'oor %(ce but cn be 'e%% e:(en%ie+

Coneyor%

Stndrd %torge %y%te*% cn be en-nced )it- t-e ddition o& coneyor, )-ic- cn begrity o(erted or *otori0ed+ Per%on' co*(uter% cn be u%ed to direct (roduct% to t-e%(eci&ic de%tintion3% % re<uired+ 9ike *odern -ig-)y )it- inter%ection%, *teri'%re dierted to (redeter*ined re%+




T-e coneyor een cn be con&igured to beco*e (rt o& truck tri'er+ T-e ddition o&%(eci' rck% &or *u'ti'ee' %torge ''o)% &u'' u%e o& t-e crgo re in%ide t-e tri'er+9oding nd un'oding beco*e *uc- 'e%% 'bor inten%ie+

T-e 'ogi%tic% &or t-i% ty(e o& %etu( re<uire (reci%ion in ter*% o& )eig-t nd %i0e+ Lrib'e%

*u%t be reduced to *ke t-e %y%te* *o%t e&&ectie+ To *:i*i0e %(ce nd reduce t-eoer'' -nd'ing re<uire*ent%, &brictor% need to 'od (rt% or *teri'% into (ro(er'y%i0ed bin% nd continer%+

P'nning t-e inentory %y%te* nd (ro(er (roduct &'o) i% nece%%ry to en%ure t-e be%t%torge %o'ution+ Ine%t*ent in t-e (ro(er dee'o(*ent o& &ci'itie% nd e<ui(*ent u%ing'' *odern dnce% )i'' (y bck -nd%o*e'y in ter*% o& 'bor, ti*e, nd *oney+

rgani.ing your tooling

o co&puteri.e or not to co&puteri.e?t-at is t-e"uestion

By Crig PdgetAugu%t 7, #""5

Are you bu%y (utting out &ire%G I% *nge*ent by cri%i% (reenting you &ro* being (roctie nd e%tb'i%-ing (reentie *intennce %y%te* &or your too'ingG 6oe% yourtoo'ing gt-er *ore du%t t-n u(ti*eG 6o you t-ink you kno) your too'ing need%, or doyou co''ect dt t-t %-o)% your too'ing need%G

You cou'd diide t-e &briction )or'd into t)o ty(e% o& %-o(. t-o%e t-t -e (reentie *intennce 3PM (rogr*, nd t-o%e t-t dont+ I& you -e )orked inenoug- %-o(% t-t (rctice PM, you 'ike'y kno) t-t e%tb'i%-ing good PM %y%te* i%)ort- it% )eig-t in go'd in t-e &or* o& u(ti*e+ A good PM %y%te* %trt% )it- yourinentory nd i% *tter o& co*(uteri0tion nd di%ci('ine+




T-e bigge%t %te( u%u''y i% getting %trted+ E:cu%e% &or not getting %trted re ?u%t t-t,e:cu%e%, nd it i% better to *oe &or)rd t-n to %it %ti''+ Wit- t-i% in *ind, under%tndt-t t-e %y%te* cn be %i*('e nd %tnd='one or it cn be ery deti'ed nd integrted+

9etting !tarted

Co*(uteri0ed inentory i% *u%t to %u((ort ny &briction ('nt+ T-e &ir%t %te( in%etting u( co*(uteri0ed too' inentory %y%te* i% bui'ding n in&or*tion dtb%e+ T-edtb%e *u%t inc'ude critic' in&or*tion.

• Prt nu*ber 3t-e end u%er% (rt nu*ber• 6ie nu*ber• 6eti' nu*ber 3t-e nu*ber o& t-e deti' o& t-e too' 'i%ted )it-=in die• Ty(e• 6e%cri(tion 3t-e too'% no*enc'ture• Order (oint <untity• Order <untity• Co%t• 6e'iery 3e%ti*ted de'iery ti*e

You *ig-t )nt to incor(orte ddition' &ie'd%, but t-e%e re *ini*u* re<uire*ent% &ort-e t%k+

lic0 to iew i&age larger @%ing (unc- nu*bering %y%te* t-t de%cribe% nd identi&ie% ec- (unc- cn be good%trtegy in orgni0ing your too'ing+ T-e key to %etting u( %ucce%%&u' %y%te* i% inc'udingenoug- in&or*tion to *ke t-e %y%te* u%e&u' but not %o *uc- deti' t-t it beco*e%oer)-e'*ing+

6ie 9i%ting or Ite* 9i%tingG Mny too'ing orgni0tion %c-e*e% e:i%t+ One co**on%c-e*e orgni0e% t-e too'ing by ec- die too'+ Anot-er orgni0e% t-e too'ing by too'

http://www.thefabricator.com/Images/1687/logical-numbering-system.pdf






de%cri(tion+ T-e *o%t co%t=e&&ectie ('n u%e% t-e too' de%cri(tion becu%e it (reent%du('iction o& co**on too'%, )-ic- -((en% )-en orgni0ing too'% by die %y%te*+

Mny &er t-e too' de%cri(tion %y%te* becu%e t-ey 'ike to -e bcku( too'ing in ot-er ('ce%+ T-e (rob'e* i% t-e bcku( too'ing i% gener''y unkno)n;t-t i%, youre not

re''y %ure i& you -e it nd )-ere it i%+ [uite bit o& 'ub'e ti*e i% %(ent, underurgent condition%, 'ooking &or too'ing+ In *o%t c%e%, it% none:i%tent+ Not u%ing t-e too'de%cri(tion %y%te* '%o cn be n e:cu%e &or not -ing better di%ci('ine+

Orgni0ing t-e too'ing by die %y%te* cn )ork, but u%u''y %uc- %y%te* i%nt deti'edenoug- to coer '' t-e b%e% nd i% *uc- *ore e:(en%ie i& it doe%+

Kee(ing it %i*('e )i'' be re)rding too+ 9et% 'ook t ('n orgni0ed by ite*de%cri(tion+ T-e re%on &or t-e re<uired dt 'i%ted (reiou%'y i% to o&&er t-e &i'tered%e(rtion by die &or re(orting (ur(o%e%+ It '%o identi&ie% co**on ite*% uti'i0ed in%eer' die% to %u((ort t-e re<uired inentory 'ee'%, % )e'' % ob%o'ete inentory % die%

re di%continued or trn%&erred to ot-er &ci'itie%+ 6edicted too'ing t-en cn &o''o) t-e%*e (t-+

Identi&ying Indiidu' Too'%+ T-e ne:t %te( i% identi&ying t-e indiidu' too'%+ Once gin,&brictor% u%e *ny %y%te*% nd de%cri(tion%+ 6edicted de%cri(tion% t-t cn be uti'i0edregrd'e%% o& t-e too'ing brnd (roide c'rity+ Be&ore creting nu*bering %c-e*e, you%-ou'd &*i'iri0e your%e'& )it- your %o&t)re% c(bi'itie% nd 'i*ittion%+ Cn itdi%tingui%- -y(-en &ro* n under%coreG I& it cnnot, t-e %o&t)re )i'' identi&y %i*i'rtoo' nu*ber% 3&or e:*('e, B'' 9ock Punc- 1""=S!"" M# P+#17 nd B'' 9ock Punc-=1""%!"" M# P+#17 % t)o uni<ue ite*%, een t-oug- it% t-e %*e too'+ It% *tter o&dei%ing %y%te* nd d-ering to it;gin, di%ci('ine i% t-e key+

Mny @%e% &or Indiidu' Too'%+ T-e &in' %tge o& co*(uteri0tion i% u%ing t-e dtb%e+T-roug- t-e ct'og o& bui't inentory you cn o&&er t-e inentory to ne) die bui'dgrou(% in your co*(ny+ A %(eci&iction cn re<uire t-t too'ing current'y inentoried be (re&erred+

You nd your co''egue% -e t-e o((ortunity to bui'd nd u%e 'ibrry o& too'ing+ T-i%'ibrry cn be u%ed to dro( CA6 dt direct'y into dr)ing to reduce de%ign ti*e %)e''+ You )i'' '%o gin (ro(er &or*t &or t-e no*enc'ture to be u%ed % de%cri(tionin t-e dtb%e &unction o& inentory+ T-i% i% t-e in&or*tion t-t cn t-en be %-red )it-die bui'der%+ T-e re%u't i% &e)er inentory ite*% nd 'rger (urc-%e <untitie% o& ite*%

t-t -e o'u*e di%count% &or &urt-er co%t reduction o((ortunitie%+

;ow to select t-e rig-t 7R6/RKER

for your application




onsider its capacity, ersatility, safety features, and

"uality

By i* Hog, Contributing Writer

nury $2, #""!

An iron)orker cn be n i*(ortnt nd er%ti'e *c-ine in *et' &bricting %-o(+[uite o&ten iron)orking i% t-e&ir%t %te( in t-e *nu&cturing (roce%%, nd one iron)orkerty(ic''y cn (roide enoug-&bricted *teri' to kee( u( to%een )e'der% or %%e*b'er% bu%y+

Since it% inention in t-e 'te$7""%, t-e iron)orker% *in%trengt- -% been it% bi'ity to (er&or* riety o& o(ertion%+ Itcn (unc- rnge o& *teri'%)it- (unc-e% o& riou% %i0e% nd %-(e%+ It '%o cn %-er rod, &'t br, ng'e, ndc-nne'+ In ddition, it cn notc- ng'e iron, (i(e, c-nne', nd &'t br+ Mnyiron)orker% re i'b'e )it- %(eci' too'ing to bend, %t*(, nd &or* too+

A% er%ti'e % t-e iron)orker i%, -o)eer, it i% (o%%ib'e to (urc-%e t-e )rong *c-ine ;or t 'e%t not t-e be%t *c-ine;&or your (('iction+ I*(ortnt con%idertion% &or

%e'ecting *c-ine inc'ude it% c(city, er%ti'ity, %&ety &eture%, nd <u'ity+T-e *teri' t-ickne%% you (roce%% )i'' indicte )-et-er to u%e n iron)orker or turret (unc- (re%%+ An iron)orker (unc-e% ('te u( to $ inc-, nd %o*eti*e% een t-icker+Ty(ic''y, turret (unc- (re%%e% re u%ed on %-eet *teri' $4 in+ nd t-inner+ Iron)orker%u%u''y re u%ed &or %-orter (roduction run% nd (('iction% &or )-ic- to'ernce% re not% critic'+

6eter*ining C(city

Iron)orker% ty(ic''y re rted by tonnge t t-e (unc- %ttion+ A 4"=ton iron)orker

%-ou'd (unc- $=in+ -o'e in $#=in+ *teri'F 2"=ton *c-ine %-ou'd (unc- $=in+ -o'e in!4=in+ *teri'F nd n 7"=ton *c-ine%-ou'd (unc- $=in+ -o'e in $=in+ *teri'3%ee Figure 1+

T-e &ir%t %te(, t-ere&ore, i% to deter*ine t-e*:i*u* *teri' t-ickne%% %o you cn

Figure 1




e%tb'i%- t-e tonnge rnge needed &or your (unc-ing (('iction+ E:*ine t-e %tee' rcknd t-e (roduct t-t you re &bricting+ 6eter*ine t-e *:i*u* -o'e di*eter to be (unc-edF t-e *:i*u* t-ickne%% o& t-e *teri' to be (unc-edF nd t-e *:i*u*t-ickne%% nd )idt- o& t-e c-nne', ng'e, nd rod to be %-ered or bent+

T-e *teri' or (rt )idt- ('y% (rt in your iron)orker %e'ection+ T-e t-rot de(t- o&n iron)orker (unc- %ttion %-ou'd be greter t-n -'& o& t-e (rt or *teri' )idt-+Mteri' 'engt-, -o)eer, re''y i% not n i%%ue+ An iron)orker cn (roce%% '*o%t ny*teri' or (rt 'engt-+

Becu%e *ny di&&erent ty(e% o& %tee' nd rnge% o& -rdne%% in *i'd %tee' e:i%t, it i%di%b'e to get *c-ine t-t i% t 'e%t #" (ercent 'rger t-n you t-ink your eerydyu%e re<uire% to oid getting *c-ine t-t i% too %*''+ Mo%t *c-ine% re rted &or*teri' )it- ten%i'e %trengt-% bet)een 2",""" nd 21,""" (ound%+

Mny *i'd %tee'% -e ten%i'e %trengt-% bet)een 1",""" nd 5",""" 'b%+ or -ig-er, nd

your *c-ine *y not -e t-e (o)er to (unc- t-e *teri' t t-e -ig-er end o& t-e-rdne%% 'ue%+ W-en (unc-ing -rd %tee', %uc- % %tin'e%% %tee', it i% better to incre%et-e e%ti*ted tonnge by 1" to $"" (ercent, de(ending on t-e grde o& %tee'+

Be)re Not '' ton% re creted e<u'+ A *etric ton ctu''y i% -eier t-n @+S+ ton3#,#"" 'b%+ er%u% #,""" 'b%++ A *c-ine rted &or *etric ton% %-ou'd be b'e to (unc- 'rger -o'e t-n *c-ine rted on t-e %*e nu*ber o& @+S+ ton%+ >or e:*('e, 7" ton%o& (re%%ure by @+S+ %tndrd% cn (unc- $=in+ -o'e t-roug- $=in+ *teri'F 7" *etricton% %-ou'd be b'e to (unc- $!!#=in+ -o'e t-roug- t-e %*e *teri' t-ickne%%+

Be %ure to co*(re t-e rting o& t-e *c-ine not on'y in ton%, but '%o t-e di*eter o& t-e

-o'e nd t-ickne%% o& *teri' it cn (unc-+ Iron)orker tonnge rting% cn ry &ro*iron)orker to iron)orker+

A%%e%%ing Ler%ti'ity Need%

A'' iron)orker% re e<ui((ed )it- &'t br %-er%+ T-e *in di&&erence% bet)een &'t br%-er %ttion% re t-e 'engt- nd t-e ((roc- o& t-e b'de to t-e *et'+ So*e iron)orker%u%e gui''otine, or &i:ed=rke=ng'e %-er, nd ot-er% u%e %ci%%or%=ty(e %-er 3%eeFigure 2+




T-e dntge o& t-e &i:ed=rke=ng'e %-er i% t-t t-eng'e o& t-e b'de % it((roc-e% t-e )ork re*in%con%tnt t-roug-out t-e cut,

%o*eti*e% o&&ering 'rgerc(city )it-out incre%ing*c-ine tonnge+ T-edi%dntge i% t-t )it-outt-e bi'ity to ry t-e rkeng'e, t-e di%tortion o& t-edro( (iece )i'' re*in t-e%*e t-roug-out t-e cut+

T-e dntge o& %ci%%or%=ty(e %-er i% t-t it cn ry

t-e rke ng'e o& t-e b'de+T-icker *teri' i% cut c'o%erto t-e (iot (oint, nd t-inner *teri' i% cut &rt-er &ro* t-e (iot (oint, )-ere t-e rkeng'e o& t-e b'de i% &'tter, t-ereby *ini*i0ing di%tortion+ Sci%%or% *c-ine% ty(ic''y-e 'onger &'t br %-er, %o*e u( to #4 in+ 'ong+

On %o*e iron)orker%, t-e rke ng'e o& t-e br %-er b'de i% d?u%ted by in%erting ndre*oing )edge=%-(ed %-i*% boe t-e %-er b'de+ T-i% *y re<uire %ub%tnti'*ec-nic' bi'ity nd %ub%tnti' ti*e+ A'%o, i& t-e %-i*% re not d?u%ted ec- ti*e*teri' t-ickne%% c-nge%, t-e *c-ine cou'd be d*ged+

Iron)orker% re i'b'e )itdi&&erent de%ign% to en-nce er%ti'ity+ >or e:*('e, t-e%ttion% on %o*e *c-ine% re (er*nent'y bui't in+ T-e%e *c-ine% o&&er (unc-ing%ttion%, ng'e %-er%, rod %-er%, notc-er%, nd %-ort &'t br %-er%+

I& you re %tructur' %tee' &brictor, you *y (re&er t-e%e *c-ine% becu%e t-e %ttion%coer t-e *?ority o& t-e *teri'% you (roce%% nd do not re<uire too'ing c-nge%+

I& you re gener' )e'ding, &briction, *intennce, nd %tructur' %tee' &brictor )-odoe% not kno) )-t cu%to*er )i'' bring in t-e door to*orro), you *y )nt niron)orker t-t o&&er% t-e c(bi'ity to d(t to '' cu%to*er need%+ Tb'eto( too'ingconce(t%, )-ic- (roide )ider riety o& too'ing, *y %uit your need%+

In ddition to ng'e %-er%, rod %-er%, notc-er%, nd &'t br %-er%, tb'eto( iron)orker%o&&er o(tion% %uc- % 'rger (re%% brke bending ttc-*ent%, tube %-er%, c-nne' %-er%, (i(e notc-er%, L notc-er%, (icket too'%, %<ure tube %-er%, nd riety o& %(eci'too'ing+ A't-oug- t-e%e *c-ine% cn u%e 'rger riety o& too'ing t-n t-o%e )it- bui't=in %ttion%, ti*e i% re<uired to %)itc- &ro* one o(ertion to t-e ne:t+

Addre%%ing S&ety I%%ue%

Figure 2

T-e dntge o& t-e &i:ed=rke=ng'e %-er i% t-t t-e b'de ng'e re*in% con%tnt t-roug-out t-e cut,

%o*eti*e% o&&ering 'rger c(city )it-out incre%ing*c-ine tonnge+ T-e dntge o& t-e %ci%%or%=ty(e%-er i% t-t it cn ry t-e rke ng'e o& t-e b'de,

t-ereby *ini*i0ing di%tortion+




S&ety i% n i*(ortnt &ctor )-en c-oo%ing n iron)orker+ Be %ure to c-oo%e niron)orker t-t *eet% ANSI B $$=1 %tndrd%+

E:*ine t-e gurding+ Be %ure it cn be d?u%ted do)n to )it-in $4 in+ &ro* t-e to( o&t-e *teri' to be (unc-ed, nd to t-e botto* o& t-e gurd or %tri((er 3t-i% i% n ANSI

%tndrd+ T-i% )i'' (reent o(ertor% &ro* ('cing ny (rt o& t-eir bodie% bet)een t-e*teri' being (unc-ed nd t-e %tri((ing *ec-ni%*+ A'' ot-er %ttion% %-ou'd o&&erco*('ete %&egurding % )e''+

Be)re o& *c-ine% )it- uto*tic uret-ne -o'd=do)n%+ Mo%t o(ertor% re'i0e t-ednger o& t-e b'de but do not e:(ect to be -urt by %&ety gurd% nd *y not )tc-t-e*+ Auto*tic uret-ne -o'd=do)n%, i& not d?u%ted (ro(er'y, '%o co*e do)n )it-*ny ton% o& &orce nd cn be dngerou% (inc- (oint%+

>or (roductiity % )e'' % %&ety, t-e *c-ine you c-oo%e %-ou'd o&&er n in&inite'yd?u%tb'e %troke contro' to *ini*i0e *c-ine *oe*ent, decre%e t-e nu*ber o& (inc-

(oint%, nd incre%e %troke% (er *inute nd (roduction+ T-i% i% e%(eci''y i*(ortnt in bending (('iction% nd &or %(eci' too'ing &or )-ic- t-e u(%troke *u%t be d?u%ted inddition to t-e do)n%troke+

E'ectric %troke contro'% o&&er dntge% oer *ec-nic' 'inkge contro'%+ E'ectric %trokecontro'% -e <uicker cyc'e ti*e% nd *ore (reci%e %to((ing becu%e t-ey u%e %)itc-e%t-t %end %ign'% to t-e contro' 'e '*o%t in%tnt'y+ Mc-ine% t-t u%e *ec-nic''inkge %troke contro'% *u%t be in *otion to cu%e t-e 'inkge to c'o%e t-e contro' 'e+A% t-e 'e c'o%e%, t-e *c-ine %'o)% do)n nd i% *ore di&&icu't to regu'te+

S&ety in%truction% %-ou'd inc'ude (ro(er 'ign*ent o& t-e (unc- nd die%+ Becu%e

(unc-e% re u%u''y -rdened to 17 /ock)e'', t-e (unc- )i'' not bend % it co''ide% )it- die+ I& it i% out o& 'ign*ent, it i% *ore 'ike'y to &'ke or een e:('ode, cu%ing %eriou%-r* to t-e o(ertor+

T-e (re&erred nd *o%t )ide'y u%ed *et-od o& 'igning t-e (unc- nd die i% %i*i'r tot-e )y (unc- (re%%e% -e been 'igned &or *ny yer%+ T-i% i% done by bringing t-e (unc- r* to t-e botto* o& t-e %troke nd in%t''ing t-e (unc- nd die% )it- t-e %trokedo)n+ T-i% )y, t-e (unc- 'redy -% been entered into t-e die, t-e 'ign*ent cn bec-ecked, nd gurd% *y be re('ced )it-out *c-ine *oe*ent+

A%%e%%ing [u'ity

In trying to deter*ine <u'ity, con%ider t-e %i0e o& t-e (iot (oint% nd be* %trengt- o&t-e %tee' t-t i% under (re%%ure+ Since your iron)orker (roduce% *ny ton% o& &orce, t-e&orce *u%t be generted nd trn%&erred t-roug- t-e (iot (oint% % )e'' % t-e be*+

Anot-er good indictor o& <u'ity i% -o) *uc- %-ock i% (roduced )-en t-e iron)orker (unc-e%+ E:ce%% %-ock, )-ic- cn be identi&ied by 'oud (o((ing or bnging noi%e % t-e (unc- goe% t-roug- t-e *teri', cou'd indicte t-e be* or %ide &r*e i% %tretc-ing nd




%n((ing bck into ('ce+ Continued %-ock cn cu%e )e'd% to brek, % )e'' % ot-er&i'ure%+ Hig-er=<u'ity *c-ine% contro' t-i% by incre%ing %ide &r*e, be*, nd (in%i0e+

T-e nu*ber o& gre%e (oint% '%o cn be n indictor o& <u'ity+ A't-oug- '' *c-ine%

-e gre%e (oint% on (iot (oint% nd guide %%e*b'ie%, %o*e *c-ine% -e ne:ce%%ie nu*ber o& gre%e (oint%;% *ny % #" or *ore+ @%u''y t-e%e ddition'gre%e (oint% -e been dded in n e&&ort to correct g''ing (rob'e*%+ It i% unre'i%tic toe:(ect o(ertor% to gre%e *ore t-n &ie or $" gre%e (oint%, nd *c-ine &i'ure org''ing *o%t 'ike'y )i'' occur+

T-e -ydru'ic %y%te* '%o %-ou'd be con%idertion+ You re buying t-e *c-ine &or t-eton% o& (re%%ure it (roduce%, not &or t-e *otor% -or%e(o)er rting+ So*e iron)orker% rede%igned t-roug- *ec-nic' dntge% to (roduce *ore tonnge )it- 'e%% -or%e(o)er,t-u% *king t-e *c-ine *ore e&&icient+ Mc-ine% )it- -ig-er=-or%e(o)er *otor%u%u''y o(erte t -ig-er -ydru'ic (re%%ure, or (ound% (er %<ure inc-, nd t-i%

incre%ed (re%%ure cn (roduce *ore )er on -o%e%, (u*(%, nd 'e%+Becu%e n iron)orker i% n i*(ortnt (rt o& *o%t %-o(%, )-en een one iron)orker brek% do)n, t-e negtie i*(ct on (roduction i% %igni&icnt, een (r'y0ing+ Be&ore (urc-%ing n iron)orker, tke t-e ti*e to n'y0e your need% nd cre&u''y %%e%% t-e<u'ity o& t-e iron)orker+ It )i'' be ti*e )e'' %(ent+

8i' oa! is 'ar1etin! director for 9cotc"'an: 7ndstries, $0 E. i!"wa+ $#, P"ilip,

9; 5<56<, p"one 605%5&%25#2, fax 605%5&%2#&&, e%'ail =i'"oa!(scotc"'an.co' ,

)e* site www.scotc"'an.co'. 9cotc"'an 7ndstries desi!ns and 'anfactresironwor1ers and saws for 'etal fa*ricators, 'ac"ine s"ops, and tec"nical sc"ools.

9etting &ore punc- life

%lternate tooling alloy and

coating reduce friction, -eat

*uildup

u'y $!, #""4

Augur Met' Product%, cu%to* &brictor inInde(endence Ken+, (er&or*% riety o& (roce%%e% &or *nu&cturer%+ W-i'e t-eco*(ny% c(bi'itie% inc'ude %-ering, cutting,&or*ing, )e'ding, nd &ini%-ing, c-ie& *ongt-e* i% %-eet *et' (unc-ing+

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One o& it% (roce%%e% ino'e% (unc-ing 51" %*'' -o'e% in !!=inc- by !2=inc- $"=guge%tin'e%% %tee' %-eet (ne'% u%ed in t-e *nu&cture o& 'rge co**erci' %e(rtor%+Becu%e %tin'e%% %tee' i% -rd nd br%ie, it -et% u( nd (ut% %tre%% on bot- t-e too'ingnd t-e (unc- (re%%+ Wit- it% (reiou% too'ing, t-e co*(ny )% 'i*ited to (unc-ing ?u%t$" to $1 (ne'% be&ore too' *intennce nd %-r(ening )ere re<uired+ Sto((ing t-e 'ine

to %-r(en (unc-e% o&ten cu%ed (roduction bott'eneck%+

On di&&erent o(ertion &or (er&orting co*(re%%or (ne'%,t)o "+51"=in+ round (unc-e% )ere in%t''ed %ide by %ide in turret %o t-t )-en one too' bec*e du'', t-e turret cou'd beinde:ed to t-e ne:t (unc- to continue (unc-ing )it-out%to((ing t-e *c-ine+ W-en bot- t-e (unc-e% bec*e du'',t-e *c-ine -d to be %to((ed nd t-e (unc-e% re*oed &or%-r(ening, t ti*e% di%ru(ting (rt &'o) t-roug- t-e ce'' o&&ie (re%%e%+

\Our (unc- (re%% o(ertor% do gret ?ob o& *intiningcon%tnt )ork &'o) t-roug- our (re%% de(rt*ent,] %id oeS-ot)e'', %enior (urc-%ing buyer+ \Pre*ture too'ing )erin t-e *idd'e o& (rt run i% di%ru(tie+ Our (rt run% rynd )e (unc- 'ot o& di&&erent *teri'% nd t-ickne%%e%,eeryt-ing &ro* 'u*inu* nd *i'd %tee' to %tin'e%% %tee'+So continuou% )ork &'o) *ini*i0ing (re%% do)nti*e &ortoo' *intennce i% c-''enge )e tke %eriou%'y nd try toi*(roe on becu%e it in&'uence% our <u'ity nd (roductiity+]

etting 9onger 9i&e >ro* Toug-er Punc-e%T-e co*(ny (er&or*ed tri' run u%ing Mte Preci%ion Too'ing% Stri((it (unc-e% *deo& 6urStee'^ in n e:i%ting guide %%e*b'y to %ee i& it cou'd i*(roe t-e -it count+

\We didnt -e to touc- t-e Mte (unc- unti' )e'' &ter (er&orting 4" o& t-e $"=guge%tin'e%% %tee' (ne'%,] %id (re%% o(ertor Pt W'ker+ \A'' 4" o& t-e (ne'% -d bet)een21" nd 51" -o'e% (unc-ed in t-e*+ T-e -o'e% re c'ener )it- 'e%% burr on t-e*+ And)ere getting t-ree to &our ti*e% t-e too' 'i&e )it- t-e ne) Mte (unc-e%+]

\Stin'e%% i% ery br%ie to (unc-, creting -ig- degree o& &riction nd -et in t-e

(unc- )-en it (enetrte% t-e *teri',] e:('ined Ti* Kru%, Mte %'e% re(re%enttie+\Stin'e%% du''% ordinry too'% ery <uick'y, e%(eci''y t -ig-er (re%% %(eed%+ Een i& you%'o) t-e *c-ine do)n, t-e br%ie e&&ect continue% nd )er% out t-e too' (re*ture'y+You 'o%e (roductiity t)o )y%;)it- 'o)er (re%% %(eed nd by -ing to *intin t-etoo'ing &re<uent'y+]

Figure 1

Augur Met' Product% (unc-e% -undred% o& -o'e%in %tin'e%% %tee' %-eet% &or

co**erci' %e(rtor%+Ho'ding (unc-ed (ne' i%oe S-ot)e'' 3'e&t, %enior

(urc-%ing buyer, nd PtW'ker 3rig-t, (re%%

o(ertor+




T-e ne) (unc-e% re%i%t t-e br%ie e&&ect% o& t-e%tin'e%% *teri' nd reduce -et bui'du( in t-e (unc-+In ddition to t-e 6urStee' (unc-e%, %(eci' too'coting c''ed M:i*^ )% u%ed to cot t-e (unc-+T-e coting bond% )it- t-e %ub%trte nd dd% bot-

durbi'ity nd 'ubricity+

Punc- Anto*y

In ddition to t-e 6urStee' (unc- nd M:i* coting,t-e too'% de%ign &&ect% (roductiity+ >or e:*('e, (unc- (oint% re *c-ined )it- $4=degree bck t(er toreduce &riction during t-e %tri((ing (-%e o& t-e (unc-ing cyc'e, )-ic- &urt-er e:tend% too' 'i&e+ A'%o,%'ug (u''ing i% 'ongti*e (rob'e* in t-e (unc-ing (roce%%, nd t-u% t-e u%e o& %(eci' die de%ign to

counter t-i% &oe i% u%e&u'+ 6uring (unc-ing t-e %'ug cn (u'' bck out o& t-e die nd t-en inter&ere )it- t-e ne:t (unc-ing cyc'e+ T-i% i% generic''y c''ed %'ug (u''ing+Mte% S'ug >ree die i% de%igned )it- %'ig-t-ourg'%% %-(e t-t cu%e% (re%%ure (oint t-t ct% 'ike one=)y door to kee( t-e %'ug&ro* (u''ing bck out o& t-e die+ Once t-e %'ug i% %<uee0ed t-roug- t-e (re%%ure (oint, iti% &ree to &'' do)n t-e %'ug c-ute % it %-ou'd nd )y &ro* )-ere it cou'd cu%e (rob'e*%+

@%ing t-e ne) (unc-e%, Augur %y% it )% b'e to incre%e (re%% %(eed by #" (ercent+S-ot)e'' dded t-t %)itc-ing to t-e ne) Mte too'ing ctu''y co%t $" (ercent 'e%% t-n

t-e o'd too'ing+ \W-en you dd u( t-e 'onger too' 'i&e, incre%ed (re%% out(ut, nd 'e%%do)nti*e &or too' %-r(ening, youe re''y i*(roed oer'' (roductiity nd (ro&itbi'ity on t-t ?ob+]

7s &etal roofing fa*rication rig-t for your

s-op'

;ow to ensure your roll for&ing operation is a good fit

By Pu' Wi''i*%A(ri' $", #""5




W-en deciding )-e-er or not to (roduce roo&ing (ne'%, you need to deter*ine your/OI, b%ed on i& you cn u%e e:i%ting e<ui(*ent or need ne) e<ui(*ent, t-e re<uired (ne' ((ernceF (o%%ib'e 'ine con&igurtionF nd *teri' -nd'ing o(tion%+

In recent yer% t-e *et' bui'ding indu%trie% -e gro)n %ub%tnti''y+ According to t-eMet' /oo&ing A''ince, t-e re%identi' *et' roo&ing *rket doub'ed it% *rket %-re&ro* ! (ercent to 2 (ercent in &ie yer%+ To tke dntge o& t-i% gro)t-, *ore&brictor% re incre%ing t-e er%ti'ity o& t-eir *nu&cturing c(bi'itie% by dding to

or e:(nding t-e *et' bui'ding (roduct% t-ey o&&er+

Be%ide% t-e *ore co**on'y (roduced *et' %tud%, &brictor% -e been dding *et'roo&ing nd cce%%orie% to t-eir current (roduct 'ineu(%+ T-e roo&ing (ne'% co*e in *nydi&&erent ty(e%, )it- t-e *ore co**on one% being /, A, A, corrugted, %tnding %e*,nd roo& deck% 3%ee >igure% 1, 2, and 3+

Figure 1,2,3 /oo&ing (ne'% co*e in *ny di&&erent ty(e%, )it- t-e *ore co**one one% being /3'e&tA,A,corrugted 3center,%tnding %e*, nd roo& decking 3rig-t+

E@isting or 6ew E"uip&ent'

W-en deciding )-et-er or not to (roduce t-e%e (ne'% eit-er % n e:(nded 'ine or ne) (roduct, you *u%t decide i& your return on ine%t*ent 3/OI *ke% %en%e &or your bu%ine%% *ode'+ T-e ru'e o& t-u*b i% i& you *u%t run t 'e%t 1"",""" 'iner &eet o& %-eet*et' to ?u%ti&y (urc-%ing ne), co*('ete ro'' &or*ing 'ine+

I& you -e n e:i%ting ro'' &or*ing 'ine nd re ('nning to run &e)er t-n 1"","""'iner &eet o& %-eet *et', you *u%t c'cu'te t-e current c(city o& your 'ine to %ee i& t-ene) co*(onent% cn be run on it+ You *ig-t be b'e to retoo' your e:i%ting 'ine, )-ic-cn be big co%t %ing%+




O& cour%e, t-e ty(e o& (roduct you re going to run nd it% re<uire*ent% 3nu*ber o& (%%e%, -ori0ont' %(cing, ro'' %(ce, nd %o on )i'' dictte )-et-er you cn run it one:i%ting e<ui(*ent+ Your too'ing endor% %-ou'd be b'e to -e'( you )it- t-i%deter*intion+

I& you do not -e n e:i%ting ro'' &or*ing 'ine or -e in%u&&icient c(city on yourcurrent e<ui(*ent, you )i'' need to (urc-%e ne), co*('ete 'ine+ Ne) 'ine% co*e in*ny con&igurtion%F %o*e re -ig-=%(eed, in=('nt *c-ine% )-i'e ot-er% re 'e%%c(it'=inten%ie &eed=to=%to( nd (ortb'e unit% &or %*''er &ootge re<uire*ent%+ T-e (ortb'e *c-ine% u%u''y re entry='ee', )it- c(citie% 'i*ited to t-e %*''er &ootgere<uire*ent% o& on=%ite &briction+

anel %ppearance

/oo& nd )'' (ne'% re -ig-'y i%ib'e D((ernceD co*(onent%+ Mo%t re &bricted&ro* (re(inted coi', %o cre *u%t be tken to oid d*ging t-e coi'% coting during

t-e ro'' &or*ing (roce%% 3%ee 'ed i*ge+ T-i% i% c-ieed by -ing enoug- ro'' too'ing (%%e% nd by c-ro*ed ro'' too'ing+

In ddition, ro'' &or*ing cn contribute to oi' cnning, )-ic- i% t-e )ine%% in t-e &'tre% o& roo&ing nd %iding (ne'%+ ener''y, t-e (eriod nd *('itude o& t-e )ede(end on t-e continuou% )idt- o& t-e &'t, %o t-t *u%t be *onitored c'o%e'y+ T-e (ne'%need to be %trig-t, e%(eci''y on t-e %ide% o& %tnding %e* (ne'%, %o t-t t-ey cn be ?oined+ T-ere&ore, &'re *u%t be *ini*i0ed+

/, A, A, nd ot-er (ne'% run on )ide ro'' &or*er% 344= to 47=inc-=)ide ro'' %(ce*i''% t-t (roduce (ne' )it- !2=in+=)ide coerge+ T-e *o%t co**on %tnding %e*

(ne' )idt-% re $# nd $7 in+, nd t-ere i% no center &or*ing+ To c-nge )idt-% <uick'y,you cn (roduce %tnding %e* (ne'% on du('e:=%ty'e *i''+ T-e (ne'% '%o cn be runon conention', r&t=%ty'e ro'' &or*er%+ Portb'e *i''% -e *de big inrod% in t-i%*rket, becu%e contrctor% cn (roduce (ne'% on=%ite, oi' cnning nd '', nd (ut t-e*rig-t on t-e roo&+

Line onfigurations

Pne' ro'' &or*ing 'ine% cn be con&igured in cou('e o& di&&erent )y%+

One i% %trt=%to( 'ine+ T-e *teri' %trt% *oing by r*(ing u( to %(eed nd t-endece'erte% nd %to(% )-en it i% ti*e to cut+ T-i% ty(e o& 'ine ty(ic''y i% ine:(en%ieoer'', becu%e you do not -e to &'y t-e cuto&& die+ Ho)eer, %ince t-e 'ine -% to %to(,tot' t-roug-(ut i% 'i*ited+ T-e 'ine *ig-t run t to( %(eed o& $"" &eet (er *inute, butt-e erge 'ine %(eed &or t-e dy *ig-t be on'y 2" >PM+

A continuou% ro'' &or*ing 'ine run% con%tnt'y+ Ho)eer, t-e oer'' co%t u%u''y i%-ig-er t-n on %trt=%to( 'ine, becu%e you *u%t dd &'ying cuto&& con&igurtion+




Wit- eit-er o& t-e%e con&igurtion%, you cn dd (recut%-er die or (o%tcut die 3%eeFigure 4+ Mo%t ne) (ne' 'ine% -e (recut die+ Precut die% u%e co**on %ttionryor &'ying cuto&& %et &or t-e *:i*u* )idt-, )-ic- (roide% er%ti'ity+ Een co**on%tcker cn be (('ied+ You cn c-nge (rt )idt-% 3%uc- % &ro* !2=in+ to #4=in+coerge )it- %i*('e %tock guide d?u%t*ent nd coi' c-nge nd no die c-ngeout+

Figure 4 Mo%t ne) (ne' 'ine% -e (recut %-er die 3to(, )-ic- u%e co**on %ttionry or&'ying cuto&& %et &or t-e *:i*u* )idt-+ Ty(ic''y, you )i'' get better oer'' (ro&i'e)it- (o%tcut die 3botto* becu%e you e'i*inte %o*e o& t-e ddition' &'re t-t cnoccur during (recutting+ 6e(ending on t-e (ne' ty(e, (o%tcut die *ig-t re<uire diein%ert c-ngeout or co*('ete die c-ngeoer+

6e(ending on t-e (ne' ty(e, (o%tcut die *ig-t re<uire die in%ert c-ngeout orco*('ete die c-ngeoer+ W-en running (recut (roduct%, you need to be cre&u' not todd &'re on t-e ingoing nd outgoing end% o& t-e *teri'; co**on occurrence on (recut 'ine%+

Wit- (o%tcut die, you )i'' ty(ic''y get better oer'' (ro&i'e becu%e you e'i*inte%o*e o& t-e ddition' &'re t-t cn occur during (recutting+ A'%o, de(ending on t-e (ne' (ro&i'e nd t-e ro'' too'ing de%ign, you *ig-t be b'e to u%e co**on cuto&& die by%i*('y c-nging t-e *teri' %tri( )idt-+ >or unco**on %-(e%, cutting b'de or entiredie c-ngeoer *ig-t be re<uired+

/o'' too'ing c-nge i% n i%%ue becu%e t-e %et% -e 'ot o& ro''%+ /&ting, doub'e=)idero'' &or*er%, t)o=(rt ro'' &or*er%, nd *c-ine% )it- co*bintion too' %et% cn -e'(*ini*i0e t-e *c-ine do)nti*e+ Ho)eer, *king t-e ro'' &or*ing %y%te* *oreco*('e: to decre%e do)nti*e u%u''y incre%e% t-e oer'' *c-ine co%t+

<aterial ;andling ptions

To &urt-er cu%to*i0e your 'ine, you cn dd di&&erent *teri' -nd'ing o(tion% t t-e&eeding end+ T-ere re *ore o(tion% t-n ty(ic' uncoi'er 3in continuou%=&eed 'ine or-nd=&eeding %-eet% 3in (recut 'ine+ You cn u%e coi' cr%, coi' u(ender%, turn%ti'e%, nd%tcking %y%te*% to -e'( decre%e c-ngeoer ti*e+ [uick coi' c-nge i% i*(ortnt, becu%e t-e &%ter you cn &eed ne) *teri'% nd di&&erent co'or% o& coi'% into t-e ro''&or*ing 'ine, t-e *ore (ne'% you cn run oer''+




T-e *o%t co**on c-oice &or t-e e:it end o& (ne' ro'' &or*ing *i'' -% been dro(%tcker+ Anot-er o(tion i% *gnetic %tcker+ W-i'e it co%t% *ore, it ino'e% 'e%%*intennce+

Addition' bui'ding (roduct% t-t cn be ro'' &or*ed on dedicted *c-ine% re %o&&it%,

&%ci, gutter gurd%, nd dri( edge%+ Mo%t o& t-e%e 'end t-e*%e'e% to being (roduced on (recut or (o%tcut ro'' &or*ing 'ine%, )it- t-e %*e bene&it% nd 'i*ittion% % (ne'*nu&cturing+

>or n in=de(t- n'y%i% o& *et' roo&ing (ne'% &or your %(eci&ic (('iction, it% be%t tocontct ro'' &or*ing e<ui(*ent *nu&cturer+

/orn out roll for&ing tooling and no

drawings'

Reerse:engineer it

By Stee Ebe' nd /ier City /o'' >or*Inc+, Contributing Writer Mrc- #1, #""4

You *y -e &ound your%e'& %ying, DIneed to *ke n engineering c-nge to*y ro'' &or* too'ing, but I dont -e t-ero'' too'ing de%ign% or dr)ing%+D Mybe

you -e (roduct c-ngeF or t-e too'ingi% )orn out, c-i((ed, or brokenF or yourco*(ny ?u%t need% to i*(roe t-etoo'ing+

W-en you re &ced )it- t-i% %itution, you -e to %trt t t-e beginning, b%ic''y, ndreer%e=engineer t-e co*('ete %et o& ro'' &or* too'ing+

/ecut or /e('ce Too'ingG

6e(ending on cou('e o& &ctor%, t-e ro'' &or* too'ing *y be recut nd dro((ed, or

decre%ed, in di*eter to e'i*inte )er+ T-e &ir%t con%idertion i% t-e ertic' rnge o&your ro'' &or* e<ui(*ent+ T-e ertic' rnge 3center% i% t-e di%tnce bet)een t-e to(%(ind'e nd t-e botto* %(ind'e, nd on *o%t *c-ine% it i% d?u%tb'e 3%ee Figure 1+ A'rge ertic' rnge ''o)% &or recutting o& t-e ro'', but ery %*'' ertic' rnge doe%not ''o) &or di*eter c-nge%, )-ic- *en% t-e ro'' too'ing *u%t be re('ced )-en it beco*e% )orn+




T-e %econd con%idertion i% %(ind'e )er+ I& t-e ro'' &or*too'ing -% been run )it-out key% in it, t-e bore% o& t-e ro''too'ing *y be )orn *ore t-n t-e %(eci&iction% ''o), )-ic-*en% t-e bore% *u%t be re('ced or reconditioned+ 3Key% ret-e %<ure (iece% o& co'd=ro''ed %tee' t-t re in%erted into t-e

key)y% o& t-e ro'' too'ing nd t-e %(ind'e% to (reent t-e ro''too'ing &ro* %(inning on t-e %(ind'e%+ I& t-e bore% reoer)orn becu%e t-ey )ere ''o)ed to %(in on t-e %(ind'e o&t-e ro'' &or*er, t-ey )i'' -e to be ground, t-en -rd=c-ro*ed,nd ground gin to c-iee t-e (reci%ion &it re<uired bet)eent-e bore on t-e ro'' too'ing nd t-e %(ind'e% on t-e ro'' &or*er+

You need to gt-er % *uc- in&or*tion bout your ro'' &or*too'ing nd e<ui(*ent % (o%%ib'e be&ore you cn get %trted+Me%ure nd record.

•

Hori0ont' center%+• Lertic' center% 3*ini*u* nd *:i*u*+• S(ind'e di*eter 3key)y %i0e+• /o'' %(ce 3b%e to center'ine o& botto* %(ind'e+

Too'ing Mteri'

It i% i*(ortnt to kno) )-t %tee' grde t-e ro'' &or* too'ing )%*de o& origin''y+ In t-e (%t *ny %et% o& ro'' &or* too'ing )ere*de out o& too' %tee'% t-t )ou'd c%e=-rden on'y )-en -et=treted, *ening t-t t-e -rdened %ur&ce )% on'y bout $_`!#

inc- dee(+ /o'' &or* too'ing con%tructed t-i% )y cnnot be recutF it-% to be re('ced+ I& t-e ro'' &or* too'ing i% *de out o& too' %tee't-t cn be t-roug-=-rdened, t-e c-nce% o& being b'e to recut itre better+

Too'ing Con%truction

ItaGG% '%o i*(ortnt to kno) -o) your current ro'' &or* too'ing i% bui't+ Mny ti*e% ro'' &or* too'ing i% bui't in )y t-t ''o)% it to be recut e%i'y+ A ro'' too'ing %et t-t i% bui't )it- *ny %('it% orindiidu' (iece% i% better=%uited &or recutting t-n %et t-t -%

one=(iece ro'' con%truction 3%ee Figure 2+ One=(iece ro'' con%truction doe% not ''o) &ore%y c-nge%, nd i& c-nge or )er in t-e ro'' &or* too'ing i% e:ten%ie, re('ce*ent i%re<uired+

Product 6r)ing

Figure 1

Me%ure*ent% *u%t betken t t-e ertic'center%, -ori0ont'

center%, %(ind'edi*eter, *d ro''

%(ce+

Figure 2

S('it contruction i% better=%uited &or

recutting t-n one= (iece con%truction+




T-e ro'' de%igner reie)% t-e (roduct dr)ing nd &in' (ro&i'e to generte t-e ne) ro''&or* too'ing dr)ing+ Once t-e de%igner -% t-i% in&or*tion, -e cn deter*ine t-e (rctic'ity o& c-nging t-e ro'' &or* too'ing+

At t-i% (oint t-e ro'' &or* too'ing -% to be %-do)=gr(-ed nd *e%ured 3%ee

introductory p-oto+ Ec- (%% nd ec- ro'' *u%t be (ut into n o(tic' co*(rtor t-t (ro?ect% n i*ge %c'ed $" ti*e% t-e origin' %i0e onto %creen+ T-i% i*ge -% to betrced by -nd to e:*ine t-e current condition o& t-e ro'' &or* too'ing nd co*(red tot-e (roduct dr)ing+

Ty(ic''y t-i% cn be done in bout )eek, de(ending on t-e %i0e o& t-e ro'' &or* too'ingnd t-e nu*ber o& &or*ing (%%e%+ Co*(nie% t-t o&&er t-i% %erice cn )ork )it- t-ecu%to*er to *ini*i0e t-e *ount o& 'o%t (roduction ti*e by doing &e) (%%e% o& ro''&or* too'ing t ti*e+

A&ter t-e %-do)=gr(- trcing i%

co*('ete, t-e ro'' di*eter, ro'' )idt-,ng'e%, nd bore %i0e -e to be*e%ured nd recorded+ T-i% in&or*tioni% u%ed in con?unction )it- t-e trcing to

dee'o( t-e CA6 &i'e% &or ec- ro'' nd &or*ing (%%+ At t-i% (oint t-e ro'' de%igner '%o 'ook% tt-e trcing to deter*ine t-e *ount o& )er nd-o) *uc- t-e ro'' di*eter% -e to bedecre%ed to e'i*inte t-e )er or c-i(% in t-e

ro'' &or* too'ing+ I& %o*e o& t-e ro''% re )orn*ore t-n t-e ot-er%, t-e de%igner *y e'ect tore('ce &e) ro''% rt-er t-n recut t-e entire%et+

Once '' t-i% in&or*tion i% co''ected nd t-edeci%ion i% *de to recut or re('ce t-e ro''&or* too'ing, t-e de%igner u%e% CA6 to dr)t-e ro'' &or* too'ing &'o)er 3%ee Figure 3+

A&ter t-e &'o)er (ttern i% deter*ined, t-e ro''de%igner in(ut% t-e dt &ro* t-e trcing% ndt-e *e%ure*ent% into t-e CA6 %y%te* to (roduce t-e ro'' &or* too'ing de%ign+ T-e *t-dt generted )i'' be u%ed in t-e CNC turningcenter% to recut or *ke ne) ro''% % needed3%ee Figure 4+

Figure 3

Figure 4

T-e CA6 dr)ing% t-t re dee'o(ed *u%t %-o)*e%ure*ent%, %(ec%, nd deti'% &or ec- (%%+




I& t-e ro'' &or*er -% ddition' %ttion%, u%u''y e:tr (%%e% cn be dded t %trtegic%(ot% t-t cn -e'( reduce )er, i*(roe (rt <u'ity, or reduce (roduction (rob'e*%+ >ore:*('e, i& 'ot o& &or*ing i% being done bet)een (%%e% 1 nd 2, n e:tr (%% cn bedded bet)een t-e%e (%%e% to -e'( %'o) do)n t-e &or*ing+ T-e%e ty(e% o& ide% cn -e'(i*(roe (roduction i%%ue% nd (rt <u'ity+

Au:i'iry Too'ing or >i:ture%

I& you -e dded %ide ro'' %tnd%, %u((ort%, or %trig-tener% to )ork in con?unction )it-t-e ro'' &or* too'ing, t-e ro'' de%igner need% to -e % *uc- in&or*tion bout t-e* % (o%%ib'e %o t-ey cn be *de to &it i& ny c-nge% or re('ce*ent% re needed+

Obiou%'y, 'ot o& ti*e nd e&&ort go into reer%e=engineering %et o& ro'' &or* too'ingnd re(roducing t-e de%ign+ Ho)eer, once t-e de%ign i% co*('ete, (er&or*ing nengineering c-nge, re('cing or recutting d*ged too'ing, or du('icting %et o&too'ing )i'' be e%ier t-e ne:t ti*e+

Die Basics 1A15 art C7

By Art Hedrick, Contributing Writer October 8, #""5

T-i% rtic'e continue% t-e di%cu%%ion o& bending in %t*(ing o(ertion%+ It &ocu%e% on

rotry nd reer%e @ bending nd ddre%%e% t-e dntge% nd di%dntge% o& rotry bending+ 6e%cri(tion% o& nd 'ink% to t-e &ir%t $1 (rt% in t-i% %erie% cn be &ound t t-eend o& t-i% rtic'e+

Prt L o& t-i% %erie% bout %t*(ing die &und*ent'% de%cribed %eer' bending*et-od%;)i(e, coin re'ie&, (iot, nd L bending+ It '%o di%cu%%ed %(ringbck nd -o)to co*(en%te &or it )-en u%ing t-e%e *et-od%+ T-i% rtic'e &ocu%e% on ot-er bending (roce%%e%+ Kee( in *ind t-t t-e key to %ucce%% i% to de%ign t-e bending (roce%% %o t-t itcn be e%i'y, <uick'y, nd %&e'y d?u%ted to ''o) &or *teri' rib'e%+

Rotary Bending

/otry bending (er-(% i% one o& t-e *o%t (o(u'r nd e&&ectie )y% o& creting (reci%ion bend+ /otry bender%, '%o kno)n co**erci''y % /edy Bender% or Accu=Bend^ bender%, -e *ny dntge% oer conention' )i(e bending *et-od%+ >ir%t,'et% e:*ine -o) t-ey )ork+

/otry or rocker bender% con%i%t o& &oundtion b'ock, o&ten re&erred to % t-e %dd'e+T-e %dd'e -% %(ring='oded L=%-(e co*(onent c''ed t-e rocker+ T-i% rocker rotte%

http://www.thefabricator.com/ToolandDie/ToolandDie_Article.cfm?ID=1698





bout it% center'ine nd (er&or*% t-e bending ction+ It ct% % bot- -o'ding (d nd t-e bending *ec-ni%*+

A't-oug- t-i% ty(e o& bender cn be in%t''ed in '*o%t ny direction )itre%(ect to t-er* tre', it *o%t co**on'y i% &%tened to t-e u((er die %-oe+ A% t-e bender *oe%

do)n, t-e rocker *ke% contct )it- t-e %-eet *et'+ One contct (oint ct% % -o'ding (d, )-i'e t-e o((o%ite contct (oint rotte%, creting t-e bending ction+ A&ter t-e bendi% co*('eted nd on t-e (re%%% return %troke, t-e %(ring &orce% t-e rocker to return bck toit% origin' or id'e (o%ition 3Figure 1+

Figure 1

%dantages+ /otry bending -% %o*e dntge% oer ot-er *et-od%+ T-e *o%tdntgeou% &eture i% t-e %i*('icity o& d?u%t*ent+ C-nge% in t-e bend ng'e cn be*de %i*('y by %-i**ing or grinding t-e -eig-t o& t-e %%e*b'y+ 6oing %o tke% ery'itt'e ti*e, nd ti*e i% *oney+

/otry bender% cn bend % *uc- % $#" degree% nd re )e''=%uited to bending -ig-=%trengt- *teri'+ One co*(ny in S)eden -% %ucce%%&u''y creted t)o 8"=degree return bend% in %tee' )it- yie'd %trengt- o& 87" *eg (%c'%+ T-i% trn%'te% into %tee' t-t by@+S+ %tndrd% -% yie'd %trengt- o& *ore t-n $4#,""" (ound% (er %<ure inc- 3PSI; &ie ti*e% %tronger t-n 'o)=crbon %tee'+ Atte*(ting to *ke %uc- bend in

conention' )i(e=bending o(ertion *o%t certin'y )ou'd be i*(o%%ib'e+

Anot-er dntge i% t-t, un'ike conention' )i(e bending, rotry bender% re<uire*uc- 'o)er &orce% to crete t-e bend+ Any)-ere &ro* 4" (ercent to 7" (ercentreduction in &orce cn be e:(ected+ T-i% *ke% t-i% *et-od ide' &or (roducing 'ong,-ey=guge, 'rge (rt%, %uc- % truck nd %e*i &r*e ri'%+




You cn e:(ect 'e%% -o'e di%tortion in rotry bending+ Con%ider -o'e t-t i% (ierced in &'t b'nk nd 'ter bent into ertic' )''+ 6uring conention' bending, t-i% -o'e cn be %ub?ected to gret de' o& ten%ion, )-ic- cu%e% t-e -o'e to di%tort+ Becu%e rocker bender% &o'd t-e *et' round t-e (unc-, -o'e di%tortion i% e'i*inted 3Figure 2+

Figure 2

In%erting rocker% )it- %(eci' -rd ('%tic c''ed 6e'rin cn *ke t-e* non*rking,)-ic- i% de%irb'e )-en bending co%*etic=<u'ity %tin'e%% %tee' or (re(inted *teri'%+

/otry bender% cn u%ed to bend u( or do)n+ T-ey '%o cn be ('ced on c* %'ide%+

Disadantages+ 6e%(ite t-e *ny dntge%, rotry bender% do -e %o*edi%dntge%+ >ir%t, t-ey cn be <uite e:(en%ieF -o)eer, con%ider t-e dntge% o&t-e reduction in do)nti*e nd &ru%trtion+ Oer'', t-ey o&ten (y &or t-e*%e'e% in %-ort (eriod o& ti*e+




Figure 3 Poor Cndidte &or /otry Bending

A'%o con%ider t-t you *o%t 'ike'y )i'' not need n e:tern' (d, )-ic- reduce% die co%t+O&ten t-e true co%t o& de%igning nd bui'ding conention' )i(e bending die i% *uc-

greter t-n t-e rocker bender+ 6ont con&u%e co%t )it- 'ue+ In *y o(inion, rotry bender% re )ort- eery (enny+

Becu%e t-e%e bender% -e *oing (rt%, t-ere i% ri%k o& g''ing u( nd &i'ing torotte+ T-i% cn be (reented by (eriodic''y c'ening nd 'ubricting t-e*+

/e*e*ber t-t rotry bender% cn be u%ed &or %trig-t='ine bending on'y+ Aoid u%ingt-e* to bend %(eci'=%-(ed tri* 'ine% t-t do not ''o) &or %i*u'tneou% (unc- contct+Ang'ed corner% re not good cndidte% &or rocker bender% 3Figure 3+

Oer'', I -ig-'y reco**end u%ing rotry bender% &or ((ro(rite (('iction%+ T-ey re

i'b'e co**erci''y &ro* &e) re(utb'e %u(('ier%+

Reerse 8 Bending

/eer%e @ bending i% uni<ue but e&&ectie )y o& obtining eit-er 8"=degree bend or bend )it- %'ig-t negtie ng'e+ T-i% (roce%% uti'i0e% -ig-=(re%%ure (d )it- n in%ertt-t cn be d?u%ted in -eig-t by %-i**ing or grinding it+ T-e in%ert cu%e% t-e (rt to bo) u()rd in t-e center o& t-e (unc- )-ere oid -% been creted+ /i%ing or'o)ering t-e in%ert c-nge% t-e %eerity o& t-e bo)+ Kee( in *ind t-t t-i% bo) *u%t becreted )it- t-e (re%%ure e:erted by t-e (d+ T-i% o&ten re<uire% t-e u%e o& -ig-=(re%%ureg% %(ring%+

A&ter t-e bo) -% been creted, t-e (d *oe% do)n)rd nd t-e bend% re e%tb'i%-ed+@(on (unc- re*o', t-e (rt -% tendency to %(ring bck in t-e center, )-ic- cu%e%t-e bend% to Dtoe in+D T-i% *et-od )ork% )e'' )it- *teri'% t-t e:-ibit gret de' o&%(ringbck+ I& t-e *et' (er*nent'y de&or*% in t-e center bo)ed re, it *y benece%%ry to (u%- t-e (rt bck &'t in order to c-iee 8"=degree ng'e 3 Figure 4+




Figure 4 /eer%e @ Bending Proce%%

/e*e*ber t-t t-e true key to bending %ucce%% i% to de%ign t-e too' in %uc- &%-ion t-tit cn be <uick'y, %&e'y, nd ccurte'y d?u%ted )itre%(ect to eer=c-nging inco*ing

rib'e%+ Aoid u%ing t-e grinding nd )e'ding (roce%% )-eneer (o%%ib'e+

Die Basics 1A15 art 7C

By Art Hedrick, Contributing Writer une $#, #""5

>ineb'nking nd /IP&'o) re co'd *et' e:tru%ion (roce%%e% u%ed to (roduce )-t((er to be b'nked (rt%+ T-e%e (roce%%e% re 'terntie% to c%ting, &orging, nd*c-ining+ T-i% rtic'e e:('in% t-e%e (roce%%e%+ 6e%cri(tion% o& nd 'ink% to t-e &ir%t $!

(rt% in t-i% %erie% cn be &ound t t-e end o& t-i% rtic'e+A't-oug- &ineb'nking nd /IP&'o) o&ten re ctegori0ed % *et' cutting o(ertion%,t-ey *ore c'o%e'y re%e*b'e co'd *et' e:tru%ion (roce%% t-t crete% )-t ((er% to be b'nked (rt+ T-e (roce%%e% cn be de&ined %i*('y % *et-od% in )-ic- (rt i% s>eeed &ro* t-e %tri(+

Figure 1 /e%u't% o& Conention' Cutting

@n'ike (rt% *de )it- conention' *et' cutting *et-od%, t-e (rt% *de u%ing&ineb'nking nd /IP&'o) -e 'itt'e or no &rcture 0one 3Figure 1+ In ot-er )ord%,t-e%e (rt% ((er to -e %*oot-, %<ure *c-ined edge%+

T-e%e (roce%%e% '%o cn (roduce (rt% )it- ery c'o%e &'tne%% nd di*en%ion'to'ernce% nd roug-ne%% o& bout # to ! *, )-ic- *en% t-t, in *ny c%e%, (o%t(roce%%ing o(ertion% %uc- % grinding nd *i''ing cn be e'i*inted+




Prt% co**on'y *de u%ing &ineb'nking nd /IP&'o) inc'ude ger% nd (rt% t-tre<uire c'o%e &'tne%% to'ernce% or %<ure cut edge+ T-e%e (roce%%e% '%o cn (ierce-o'e% )itdi*eter% % %*'' % one=t-ird o& t-e *et'% t-ickne%% nd ery c'o%e to t-e (rt% edge+

Be&ore t-e%e *et-od% )ere i'b'e, t-e *et' -d to be %-ed in one or %eer'%-ing o(ertion% to c-iee %*oot- cut edge+ S-ing in die o&ten (roduce% %'ier%nd debri% t-t cn crete too' (rob'e*% nd (roduct de&ect%+

Fine*lan0ing

Inented in S)it0er'nd in t-e $8#"%, &ineb'nking, un'ike conention' %t*(ing*et-od%, uti'i0e% %(eci' tri('e=ction -ydru'ic (re%% c''ed &ineb'nking (re%%+>ineb'nking re<uire% t-e u%e o& e:tre*e=(re%%ure (d%+ T-e%e -ig-=(re%%ure (d% -o'dt-e *et' &'t during t-e cutting (roce%% nd kee( t-e *et' &ro* ('%tic''y de&or*ingduring (unc- entry+

In &ineb'nking (re%%e%, L=ring i% incor(orted into one o& t-e -ig-=(re%%ure (d%+ T-i%L=ring '%o i% co**on'y re&erred to % %tinger or i*(inge*ent ring+

Be&ore t-e (unc- contct% t-e (rt, t-e L=ring i*('e% t-e *et'+ It %urround% t-e (rt (eri*eter nd &unction% bot- to tr( t-e *et' &ro* *oing out)rd nd (u%- t-e *et'in)rd to)rd t-e (unc-+ T-i% ction reduce% t-e ro''oer t-t occur% t t-e (rt% cutedge+ @%ing -ig-=(re%%ure (d% co*bined )it- t-e %tinger ring nd c'o%e c'ernce%kee(% t-e *et' &ro* &rcturing nd crete% %*oot- edge 3Figure 2+ Becu%e t-e (rt i%-e'd e:tre*e'y tig-t bet)een t-e -ig-=(re%%ure (d% during cutting, (rt di%tortion i%*ini*'+

Figure 2 >ineb'nking Proce%%




@n'ike conention' cutting o(ertion% t-t u%e ((ro:i*te'y $" (ercent o& t-e *et'%t-ickne%% &or t-e cutting c'ernce, &ineb'nking o(ertion% u%u''y u%e c'ernce% 'e%%t-n "+"""1 in+ (er %ide+ T-i% %*''=c'ernce re<uire*ent co*bined )it- -ig- (re%%ure'%o contribute% to t-e &u''y %-ered (rt edge+

Once gin, dont con&u%e &ineb'nking )it- cutting o(ertion+ It% not cuttingo(ertion t ''F it i% *ore 'ike co'd e:truding (roce%%+ T-e %'ug 3(rt i% (u%-ed ore:truded &ro* %tri( -e'd %o tig-t'y bet)een -ig-=(re%%ure -o'ding ('te% nd (d% t-t t-e*et' cnnot bu'ge or ('%tic''y de&or* during t-e (roce%%+ T-e%e -ig-=(re%%ure (d% &it (reci%e'y round '' cutting co*(onent%+ >ineb'nking cn be u%ed to (roduce (rt% %t-ick % "+1 in+ &ro* riety o& *et'%+

9R7flow

Not to be con&u%ed )it- &ineb'nking, t-e /IP&'o) (roce%% doe% not u%e %tinger ori*(inge*ent ring to %to( out)rd *et' *oe*ent but re'ie% %o'e'y on -ydru'ic''y

(('ied (re%%ure to t-e b'nk+ T-e (re%%ure i% (('ied t-roug- (reci%ion=guided (re%%ure (d%+

Figure 3 /IP&'o) PrtSource. Eb)y Cor(+

T-ink o& t-e /IP&'o) (roce%% % %i*i'r to co*(ound b'nking+ Ho)eer, un'ike co*(ound b'nking o(ertion, /IP&'o) u%e% ery %*'' cutting c'ernce% bet)eenec- o& t-e cutting co*(onent%+ T-i% %*'' c'ernce, co*bined )it- -ig- b'nk -o'ding

(re%%ure% nd (reci%ion c'ernce% bet)een '' *oing co*(onent%, (roduce% %*oot-=edged (rt t-t cn be -e'd to ery tig-t di*en%ion' to'ernce% 3Figure 3+

Once gin, kee( in *ind t-t /IP&'o) i% not *et' cutting (roce%% but co'de:truding (roce%%+ T-e cutting %ection% do not -e cutting %-er ground on t-e*+

It i% di&&icu't to te'' t-e di&&erence bet)een (rt t-t )% &ineb'nked nd one *deu%ing t-e /IP&'o) (roce%% ?u%t by 'ooking t t-e*+ @n'ike &ineb'nking, /IP&'o) doe%




not re<uire tri('e=ction (re%%+ Becu%e it u%e% -ydru'ic cy'inder% *ounted in t-e die,t-e (roce%% i% be%t=%uited to -ydru'ic ction (re%%+

Bot- &ineb'nking nd t-e /IP&'o) (roce%% no) re being u%ed to (roduce *ny (rt% (reiou%'y *de by *ore co%t'y (roce%%e%, %uc- % c%ting, &orging, nd *c-ining+

Becu%e ot-er *inor &or*ing o(ertion% cn be co*bined )it- t-e%e %(eci' (roce%%e%,t-ey bot- 'end t-e*%e'e% to *ny geo*etrie%+ Kee( in *ind t-t ec- (roce%% -% it%o)n dntge% nd di%dntge%+

G?7Pflow i% regi%tered trde*rk o& EBwa+ Corp.

Die Basics 1A1 :: art 777

By Art Hedrick, Contributing Writer A(ri' $", #""5

Pinc-, brekout, nd %-i**y tri**ingre cutting *et-od% o&ten u%ed in%t*(ing o(ertion%+ T-i% rtic'e, )-ic-i% continution o& %erie% on die b%ic%,di%cu%%e% t-e%e (roce%%e%+ 6e%cri(tion%o& nd 'ink% to t-e &ir%t $# (rt% in t-i%%erie% cn be &ound t t-e end o& t-i%rtic'e+

Lriou% %(eci'ty *et' cutting *et-od%

re u%ed in %t*(ing o(ertion%+ A*ongt-e* re (inc-, brekout, nd %-i**y+

Pinc- Tri**ing

Pinc- tri**ing i% %(eci' *et-od in )-ic- t-e ertic' )''% o& dr)n or %tretc-ede%%e' re cut by (inc-ing t-e *et' bet)een t)o -rdened too' %tee' die %ection%+ In *o%tc%e%, t-e c'ernce bet)een t-e die %ection% i% % 'itt'e % (o%%ib'e 3Figure 1+

@n'ike conention' *et' cutting (roce%%, no %-ering or &rcturing tke% ('ce in (inc- tri**ing+ Ite*% %uc- % dee(=dr)n cn% o&ten re (inc- tri**ed+

A't-oug- (inc- tri**ing i% ery (o(u'r *et-od, becu%e t-e *et' b%ic''y i% (inc-ed o&&, ery %-r( burr u%u''y re*in% on t-e (rt 3Figure 2+ T-i% burr *u%to&ten be re*oed by tu*b'ing t-e (rt% in tub contining br%ie%+

Figure 1Pinc- tri**ing die de%ign




Pinc- tri**ing '%o ('ce% gret 'odon t-e %ide% o& t-e die %ection%, )-ic-re%u't% in -ig- )er+ Mo%t (inc-tri**ing o(ertion% re<uire gret de'o& *intennce+

Brekout Tri**ing

Brekout tri**ing i% %(eci'ty *et' tri**ing (roce%% in )-ic- t-e *et' i% &orced to&rcture or brek &ree &ro* t-e e%%e'% &'nge+ I& you re ccu%to*ed to conention'cutting o(ertion%, t-i% (roce%% *o%t certin'y *y 'ook -rebrined to you+ @n'ike conention' *et' cutting (roce%%, t-e 'o)er die %ection -% 41=degree ng'e ground onit% edge+ T-i% ng'e -% t)o b%ic &unction%. &ir%t, to ''o) t-e cu( to &u''y ne%t in t-e'o)er die, nd %econd,+ to &orce t-e &'nge to bend u()rd %'ig-t'y+

T-e cutting c'ernce '%o i% *uc- greter in brekout tri**ing t-n t-e c'ernce

co**on'y u%ed in conention' cuttingo(ertion%+ T-i% ddition' c'erncecu%e% 'eerge ction, but doe% not''o) &or t-e *et' to be bent into ertic' )''+ Ho)eer re%t %%ured, t-i% (roce%% )ork% )e'', e%(eci''y &or *et'%t-t %eere'y )ork -rden 3Figure 3+

Brekout tri**ing tke% dntge o&t-e *et'% )ork -rdening nd reducedt-ickne%% in gien 'oc'i0ed 0one+ T-i%

*et-od )ork% be%t &or round or :i'%y**etric' dr)n (rt%+

>or brekout tri**ing to )ork e&&ectie'y, t-e dr)n cu( *u%t be (ro(er'y (re(red &ort-e (roce%%+ T-e in%ide rdiu% on t-e cu(% &'nge *u%t be reduced to ded %-r( corner be&ore u%ing t-i% *et-od+ T-i% i%c-ieed by dr)ing t-e cu( dee(er int-e dr)ing o(ertion or co*(re%%ing it bck oer ded %-r( corner on t-e die%ection 3Figure 4+ 6oing %o reduce%t-ickne%% in t-e rdiu% nd ''o)% )ork-rdening to tke ('ce+

A&ter t-e cu( -% been (re(red (ro(er'y,it cn be introduced into t-e brekouttri**ing (roce%%, in )-ic- t-e cu(&'nge )i'' be &orced u()rd, cu%ing t-e*et' to *rea1 t t-e ded %-r( corner3Figure #+ Becu%e t-e cu( &'nge i%

Figure 2/e%u't o& (inc- tri**ing

Figure 3

Brek out tri**ing

Figure 4

Creting %*'' rdiu%




round, % it i% (u%-ed u()rd it i% &orced into rdi' co*(re%%ion+ T-i% co*(re%%ion)ork% to your dntge by &orcing t-e cu( to be &rctured out o& t-e &'nge+

Brekout tri**ing doe% not (roduce burr % 'rge %t-t (roduced by (inc- tri**ing+ A'%o, becu%e t-e

'od% on t-e too' %tee' %ection% re *ini*', t-e diere<uire% 'e%% &re<uent *intennce+ Ho)eer kee( in*ind t-t t-i% *et-od cn be u%ed on'y in %itution% in)-ic- t-e *et' *u%t be cut t t-e inter%ection o& t-e&'nge nd t-e cu(% ertic' )''+

S-i**y Tri**ing

S-i**y tri**ing i% uni<ue *et' tri**ing (roce%%in )-ic- %erie% o& %(eci''y de%igned c*% re u%edto &orce t-e (rt to *oe %ide to %ide+ @n'ike

conention' c* tri**ing, t-e (rt doe% not re*in %ttionry, but rt-er *oe%-ori0ont''y in t-e die+ It *oe% in %uc- % &%-ion t-t it cn be tri**ed true to t-e%ur&ce o& t-e e%%e'+ Tri**ing 8" degree% or tre to srface re%u't% in *uc- c'enercut nd con%iderb'y 'o)er burr% t-n (inc- tri**ing+

A gret dntge o& %-i**y die% i% t-t t-ey cn cut t-e entire (eri*eter o& (rt in %ing'e (re%% %troke+ @n'ike conention' (inc- tri**ing, %-i**y tri**ing o(ertion i%not re%tricted to %trig-t 'ine cut%+>eture% %uc- % notc-e%, cured cut%, %)e'' % riou% ot-er cut% cn be *de+Mny co**on ite*% %uc- % cigrette

'ig-ter% nd gun %-e''% re *de u%ingt-e %-i**y tri**ing (roce%%+

S-i**y tri**ing o(ertion% '%o cn bede%igned to cut *et' % t-ick % "+#1"in+ nd, un'ike conention' (inc-tri**ing, cn kee( t-e origin' *et't-ickne%% in t-e tri**ed re+ Not 'ikeconention' cutting o(ertion%, %-i**ydie% re<uire (re%%ure %y%te* %uc- % (re%% cu%-ion or nitrogen g% *ni&o'd 3Figure

$+

W-ic- *et' cutting o(ertion die de%ign engineer c-oo%e% i% b%ed on *ny &ctor%,inc'uding ''o)b'e burr -eig-t, (rt% o'u*e%, *et' ty(e nd t-ickne%%, nd tri* 'inegeo*etry+ No %ing'e tri**ing o(ertion i% be%t &or '' %cenrio%+ T-e ne:t rtic'e in t-i%%erie% )i'' continue t-e di%cu%%ion o& *et' cutting+

Die Basics 1A15 art 77

Figure #

Figure $

Prt% tri**ed )it- %-i**y tri* die 7'a!es cortes+ of @lcan /ool Corporation




By Art Hedrick, Contributing Writer >ebrury $!, #""5

Prt I o& t-i% %erie% coering %t*(ing die &und*ent'% de&ined %'ug (u''ing nddi%cu%%ed %o*e under'ying re%on% t-t it occur%+ T-i% rtic'e de%cribe% %o*e *et-od% &or

re%o'ing %'ug (u''ing (rob'e*%+ 6e%cri(tion% o& nd 'ink% to t-e &ir%t $" (rt% in t-i%%erie% cn be &ound t t-e end o& t-i% rtic'e+

S'ug (u''ing, )-ic- occur% )-en %cr( *et';t-e %'ug;%tick% to t-e (unc- &ce u(on)it-dr)' nd co*e% out o& t-e button, or 'o)er *tri:, i% %eriou% (rob'e* t-t cnd*ge (rt% nd die%+ Lriou% *et-od% cn -e'( reduce t-e occurrence o& %'ug (u''ing+

%ir Cents

Putting ir ent% in cutting nd (iercing %ection% *o%t 'ike'y )i'' not co*('ete'y %to(cutting %'ug% &ro* (u''ing, but it% good %trt+ T-i% i% becu%e tr((ed ir t-t crete%

cuu* (ocket% i% *?or cu%e o& %'ug (u''ing+ It i% good die=bui'ding (rctice to dri''ir ent% in '' cutting (unc-e% )-eneer (o%%ib'e, e%(eci''y i& t-ey re (iercing (unc-e%+

!pring ins

Figure 1 S(ring E?ector% nd Air Lent%I*ge% courte%y o& 6yton Progre%%




A co**on, (o(u'r *et-od &or (reenting %'ug% &ro* (u''ing i% to u%e (ierce (unc-)it- %(ring='oded e?ector (in+ Ho)eer, t-i% *et-od i% e&&ectie on'y i& t-e (unc- i%'rge enoug- to cce(t %(ring (in+

T-e %(ring='oded (in (u%-e% %'ug% &ro* t-e (unc- (oint nd into t-e *tri:+ Kee( in

*ind t-t to *:i*i0e t-e %(ring (in% e&&ectiene%%, it *u%t be cco*(nied by n irent+ T-i% cn be c-ieed by dri''ing n oer%i0ed -o'e &or t-e (in nd ''o)ing t-etr((ed ir to e%c(e round t-e %(ring (in+

S(ring (in% )ork )e'' in 'rge die% contining 'rge (ierce (unc-e%, but t-ey do not 'endt-e*%e'e% )e'' to %*''=die, -ig-=%(eed o(ertion%+ Mny co**erci' (unc-*nu&cture% cn (roide t-e%e ty(e% o& (unc-e% &or you+ So*e co**erci''y i'b'e (unc-e% een -e %(eci' )ire retiner t-t ''o)% t-e *intennce tec-nicin tode(re%% t-e %(ring (in, 'ock it in ('ce )it- %(eci' retention (in, nd grind t-e (unc-)it- t-e %(ring de(re%%ed+ T-i% c(bi'ity ''o)% t-e (unc- to -e t-e %*e *ount o&%(ring tre' % ne) (unc- 3Figure 1+

Reduce t-e unc-:to:Die learance

A't-oug- reducing t-e cutting c'ernce %-orten% t-e 'i&e o& t-e (unc- nd *tri:, it -e'(%*ini*i0e %'ug (u''ing+ T-i% i% becu%e reducing cutting c'ernce &orce% t-e %'ug inco*(re%%ion during cutting+ A&ter t-e cutting i% co*('eted, t-e %'ug deco*(re%%e% in t-e*tri: &or n inter&erence &it+

>or %-ort=ter* run% nd 'o)=(roduction (rt%, reducing t-e c'ernce *y be yourn%)erF -o)eer, &or -ig-=(roduction die%, it i% reco**ended t-t you u%e n engineeredcutting c'ernce co*bined )it- n 'ternte *et-od &or %'ug retention+

!pecial Die 7nserts, Buttons, and <atri@ %lterations

Mny co**erci''y i'b'e in%ert% orbutton% cn -e'( ddre%% %'ug (u''ing (rob'e*%+So*e co**on co**erci' n*e% re D%'ug -ugger%D or D%'ug=contro' button%D 3Figure

2+




Figure 2 Co**erci' S'ug Contro' Button%

A %'ug=contro' button con%i%t% o& t)o %*'' %'ot% *c-ined t n ng'e in ec- %ide o& t-e*tri:+ T-e%e %'ot% cu%e burr to be generted on t-e %'ug+ T-e burr i% &orced do)n)rdt n ng'e, )edging t-e %'ug in t-e *tri:+

A %'ug=-ugger button -% brb% in t-e *tri: t-t i*('e t-e*%e'e% into t-e %'ug+ Bot- o&t-e%e *et-od% )ork )e'' nd re -ig-'y reco**ended+

A reer%e=t(ered Dbe'' *out-D button '%o )ork% )e''+ Mo%t die button% -e be''*out- t(er *c-ined into t-e*, )it- t-e -o'e di*eter incre%ing to)rd t-e botto* o&t-e button+ A't-oug- it *y %ee* %trnge to u%e button )it- -o'e in t-e *tri: t-t

get% %'ig-t'y %*''er % it ner% t-e c'ernce o(ening, t-i% i% n e&&ectie %'ug retention*et-od+ T-e reer%e t(er -o'd% t-e %'ug% in co*(re%%ion in t-e *tri:+ Kee( in *ind t-tin *o%t (iercing o(ertion%, "+"""1 inc- to "+""$ in+ i% *ore t-n %u&&icient t(er+ Too*uc- t(er nd co*(re%%ion cn cu%e t-e *tri: to %('it 3Figure 3+

Figure 3 A'ternte S'ug Contro' Button%




Cacuu& 8nits

Co**erci''y i'b'e cuu* unit% cn be incor(orted in your (iercing o(ertion+T-e%e unit% crete cuu* nd (u'' t-e %'ug do)n)rd into t-e *tri:+ In (inc-, try %i*('e )et nd dry cuu*+ In *y e:(erience, it )ork% &ir'y )e''+ Ho)eer, kee( in

*ind t-t t-e%e cuu*% ty(ic''y re not *ent to run &or -our% nd -our%+ Een t-e-ig-er=<u'ity *ode'% burn u( <uick'y+

t-er 7deas

A't-oug- it *y be %o*e)-t crude, u%ing )e'd %(tter tec-ni<ue on t-e in%ide o& button cn be re'tie'y e&&ectie %'ug=(u''ing re*edy+ Co**erci''y i'b'e de(o%it*c-ine% )ork be%t to e:ecute t-i% (('iction+ T-e%e %(eci' de(o%it *c-ine% de(o%ittiny brb% on t-e in%ide o& t-e button+ T-e%e brb% i*('e t-e*%e'e% into t-e %'ug nd-e'( (reent it &ro* (u''ing u()rd+

T-e%e (ortb'e (('iction *c-ine% -e %igni&icnt dntge% oer ordinry )e'd%(tter+ >ir%t, t-ey cn de(o%it tung%ten or ndiu* crbide on t-e button %ur&ce, )-ic-decre%e% button )er nd incre%e% %'ug=retention 'i&e+ Second, t-e de(o%it% cn be *deccurte'y )it- % 'itt'e -et % (o%%ib'e+ T-i% -e'(% to reduce too' %tee' nd buttond*ge+ 6e(o%it *ount% cn be cre&u''y contro''ed+

Kee( in *ind t-t ec- cutting nd (iercing o(ertion *y re<uire di&&erent %'ug (u''ing*et-od+ T-e key i% to re*e*ber t-t one (u''ed %'ug i% one too *ny+ Een %ing'e (u''ed %'ug cn re%u't in e:ten%ie die d*ge+ 6ont ri%k ignoring t-e i%%ue. An ounce o& (reention i% )ort- (ound o& cure

Future articles in t-is series will coer

specialty cutting &et-ods, suc- as pinc-,

*rea0out, and s-i&&y tri&&ing, as well

as tric0s for piercing &ultiple layers and

on angular suDie Basics 1A15 art

By Art Hedrick, Contributing Writer October $", #""2

T-i% rtic'e, Prt o& %erie% coering %t*(ing die &und*ent'%, begin% n in=de(t-'ook t t-e *et' cutting (roce%%+ It coer% (iercing nd cutting c'ernce nd di%cu%%e%%o*e co**on (iercing *i%conce(tion%+ 6e%cri(tion% o& nd 'ink% to t-e &ir%t nine rtic'e%in t-i% %erie% cn be &ound t t-e end o& t-i% rtic'e+




Cutting i% t-e *o%t %eere *et')orking (roce%% t-t tke% ('ce in die nd %-ou'dnt betken 'ig-t'y+

Cutting B%ic%

Cutting *et' re<uire% gret &orce+ >or e:*('e, it tke% ((ro:i*te'y 57,""" 'b%+ o& (re%%ure to cut $"=in+=di*eter b'nk &ro* "+$""=in+=t-ick *i'd %tee'+ Con%e<uent'y, t-e (unc-, die, nd (re%% *u%t b%orb oer)-e'*ing %-ock+

Oer%-ocking t-e (re%% nd die co*(onent% u%u''y i% )-t cu%e% t-e* to &i' (re*ture'y+ I& you )ork in %-o( t-t b'nk% -ey *et'%, you kno) )-t I *en+ Youcn -er nd feel t-e (re%% %-ock+ 6oing eeryt-ing you cn to reduce t-e unnece%%ry'oding nd %-ocking i% i*(ortnt+ >ctor% %uc- % cutting c'ernce nd %-er ng'e%contribute %igni&icnt'y to t-e *ount o& &orce re<uired+ T-ey '%o &&ect t-e *ount o&%-ock t-t i% generted+

Piercing Mi%conce(tion%I& you (rtici(ted in too' nd die ((rentice%-i(, you (robb'y )ere tug-t t-e&o''o)ing ru'e% &or (iercing (unc-e%.

• T-e (unc- deter*ine% t-e -o'e %i0e+• T-e cutting c'ernce ')y% %-ou'd be een 3e<u' round t-e (unc-+• $" (ercent o& t-e *et'% t-ickne%% i% good cutting c'ernce &or ec- %ide o& t-e

(unc-+

T-e%e re good %trting !idelines &or cutting, but t-ey rent entire'y true+ 9et% e:*ine

ec- *i%conce(tion+

-e punc- deter&ines t-e -ole si.e ;A't-oug- t-e (unc- (roduce% -o'e t-t i% eryc'o%e to it% ctu' di*eter, 'tering t-e c'ernce bet)een t-e (unc- nd t-e button3%o*eti*e% re&erred to % t-e *tri: '%o &&ect% t-e -o'e %i0e+ T-e %i*('e trut- i% t-t -o'e cn be *de %'ig-t'y 'rger or %*''er t-n t-e (unc- di*eter by incre%ing ordecre%ing t-e cutting c'ernce+ T-i% i% becu%e o& t-e )y t-t t-e *et' de&or*% be&oret-e cutting ctu''y tke% ('ce+

T-ink o& t-e *et' t-t youre cutting % Si''y Putty or rubbery ('%tic+ I& t-e c'ernce bet)een t-e cutting (unc- nd t-e button i% in%u&&icient, it )i'' cu%e t-e *et' to

co*(re%% or bu'ge out )y &ro* t-e (unc- be&ore t-e cutting tke% ('ce+ A&ter t-e %'ugi% creted, t-e *et' gri(% t-e (unc- %ide%+ T-i% incre%ed &riction bet)een t-e %ide% o& t-e (unc- nd t-e *et' ri%e% t-e *ount o& &orce nece%%ry to %tri( or (u'' t-e (unc- &ro*t-e *et'+

T-e in%u&&icient c'ernce bet)een t-e (unc- nd t-e button *en% t-t greter &orce i%needed to crete t-e -o'e+ Inde<ute c'ernce '%o incre%e% t-e 'od on t-e edge% o& t-e (unc- nd t-e *tri:, )-ic- cu%e% (re*ture edge brekdo)n+




A&ter t-e (unc- i% re*oed, t-e *et' t-t once )% co*(re%%ed deco*(re%%e% ndco''(%e% round t-e oid re 3t-e -o'e+ T-e re%u't i% -o'e t-t i% %*''er t-n t-e (unc-% di*eter 3Figure 1+

Figure 1

In%u&&icient Cutting C'ernce

I& t-e c'ernce bet)een t-e (unc- nd button i% incre%ed, t-e *et' i% (u''ed in)rd in%'ig-t ten%ion into t-e button+ A&ter t-e %'ug i% creted, t-e *et' (u''% )y &ro* t-eedge% o& t-e (unc-, re%u'ting in -o'e t-t i% %'ig-t'y 'rger t-n t-e (ierce (unc-+

Incre%ing t-e cutting c'ernce '%o reduce% t-e cutting &orce needed to crete t-e -o'e+In ddition, becu%e t-e -o'e i% %'ig-t'y 'rger t-n t-e (unc-, t-e &orce needed to %tri( t-e*et' &ro* t-e (unc- i% gret'y reduced 3Figure 2+

Figure 2

@%ing Incre%ed Cutting C'ernce

Kee( in *ind t-t c-nging t-e c'ernce doe% not &&ect t-e -o'e %i0e to gret e:tent; bout "+""$ in+ to "+""# in+ A't-oug- it *ig-t %ee* %*'', t-i% c-nge cn reduce t-e&riction generted during (unc- )it-dr)' %igni&icnt'y nd e:tend t-e (unc- 'i&e+

-e cutting clearance always s-ould *e e"ual around your punc-es ;Once gin,un'e%% you re (iercing on'y round -o'e%, t-i% %tte*ent i% not entire'y true+

Cutting c'ernce% %-ou'd c-nge round t-e (unc- (eri*eter )itre%(ect to t-e (unc-geo*etry+ 9et *e e:('in u%ing t-i% e:*('e. I& you re (iercing %<ure -o'e, you *ynotice t-t t-e corner% o& t-e (unc-e% re t-e &ir%t re% to brek do)n+ Once t-e corner% brek do)n, t-e entire (unc- *u%t be %-r(ened+ Eer )onder )-y t-e corner% brek




do)n &ir%tG It% becu%e t-i% i% t-e re t-t i% %ub?ected to t-e -ig-e%t cutting 'od%+ Lery%i*('y, )-ereer t-ere i% %*'' rdi' &eture in cut 3not-ing i% )or%e t-n ded%-r( corner, t-e co*(re%%ie &orce% )i'' be greter+

E:ce%%ie co*(re%%ion cn be co*(en%ted &or by incre%ing t-e cutting c'ernce in

re% )it- %*'' rdi' &eture% or %-r( corner%+ Incre%ing t-e c'ernce in t-e%e re%-e'(% to incre%e (unc- nd button 'i&e nd reduce t-e (robbi'ity o& 'rge corner burr+ Agood ru'e o& t-u*b i% to incre%e t-e c'ernce in t-e corner% to ((ro:i*te'y $+1 ti*e%t-e nor*' c'ernce+ An een better %cenrio i% to oid ded %-r( corner% )-eneer (o%%ib'e 3Figure 3+

Figure 3

Incre%ing Cutting C'ernce% in Corner%

1A percent of t-e &etals t-ic0ness is a good cutting clearance for eac- side of t-e

punc- ;Once gin, t-i% %tte*ent i%nt ')y% true+ W-i'e $" (ercent i% by &r t-e *o%t (o(u'r cutting c'ernce u%ed, it *o%t certin'y i% not ')y% t-e ide' cutting c'ernce+

Cutting c'ernce% cn rnge &ro* % 'itt'e % "+1 (ercent u( to % *uc- % #1 (ercent o&t-e *et'% t-ickne%% (er %ide+ A*ong t-e *ny &ctor% t-t deter*ine t-e be%t cuttingc'ernce re t-e *et'% t-ickne%% nd -rdne%% nd t-e (unc- %i0e nd geo*etry+ >ore:*('e, t-e ide' cutting c'ernce &or (iercing "+1""=in+=di*eter round -o'e in %-eet o& "+$""=in+=t-ick !"" %erie% %tin'e%% %tee' i% bout $! (ercent o& t-e *et'%t-ickne%% (er %ide, or "+"$! in+ (er %ide+ T-i% c'cu'te% to tot' c'ernce o& "+"#2 in+

Ho)eer, c-nging &ro* "+1""=in+=di*eter (unc- to "+$""=in+=di*eter (unc-re<uire% *ore cutting c'ernce, &ro* $! (ercent to #" (ercent (er %ide+ T-i% i% becu%et-e %*''er (unc- -% %*''er rdiu%, nd co*(re%%ie &orce% congregte t t-e %*''e%trdi' &eture o& cut 3?u%t % in t-e rectngu'r (unc- e:*('e noted boe+

Met' ty(e '%o &&ect% cutting c'ernce %e'ection+ Hrder, -ig-er=%trengt- *teri'%re<uire *ore cutting c'ernce, )-i'e %o&ter *et'%, %uc- % 'u*inu*, re<uire %*''ercutting c'ernce%+

A% you cn %ee, *et' cutting i% %'ig-t'y *ore co*('icted t-n o&ten (erceied+@nder%tnding t-e *ny rib'e% nd -o) t-ey &&ect t-e cutting (roce%% re key+




T-e ne:t rtic'e in t-i% %erie% )i'' continue t-e di%cu%%ion bout cutting+ To(ic% to becoered in t-e ne:t nd %ub%e<uent rtic'e% inc'ude *et-od% &or (reenting %'ug (u''ingnd (unc- brekgeF %(eci'ty cutting *et-od%, %uc- % (inc-, brekout, nd %-i*tri**ingF nd trick% &or (iercing *u'ti('e 'yer% nd (iercing on n ngu'r %ur&ce+

Die Basics 1A15 art 7By Art Hedrick, Contributing Writer Augu%t 7, #""2

T-i% in%t''*ent in t-e 6ie B%ic% $"$ %erie% (ick% u( )-ere Prt LIII 'e&t o&& inde%cribing t-e *ec-nic' (ro(ertie% nd be-ior' c-rcteri%tic% o& *et'% u%ed in%t*(ing o(ertion%+ A*ong t-e to(ic% di%cu%%ed re %trin, %(ringbck, %tre%%, %tretc-di%tribution, n 'ue, r 'ue, nd %ur&ce to(ogr(-y+

Editors NoteA /"is articlePart 7 of a series co-erin! sta'pin! die fnda'entals contines t"e discssion of 'ec"anical properties as well as *e"a-ioral c"aracteristics

of 'etals. Part VIII expanded pon Part VII s o-er-iew of 'etals sed in sta'pin!. Part

VI explained specialt+ die co'ponents. Parts IV and Part V co-ered co''on sta'pin!

die co'ponents. Part III discssed se-eral different prodction 'et"ods sed to prodce

sta'ped parts. Part II co-ered -arios for'in! operations, and Part I explained w"at adie is and descri*ed se-eral 'etal cttin! operations.

Figure 1Strin nd T-ickne%% 6i%tribution

Prt LIII o& t-i% %erie% di%cu%%ed %o*e o& t-e %(eci&ic *ec-nic' (ro(ertie% o& *et'%; ducti'ity, e'ongtion (ercentge, ten%i'e nd yie'd %trengt-, nd -rdne%%;nd -o) toderie t-e%e (ro(ertie%+ T-i% rtic'e de%cribe% ot-er i*(ortnt *ec-nic' (ro(ertie%, %)e'' % &e) be-ior' c-rcteri%tic%+








http://www.thefabricator.com/Articles/Stamping_Exclusive.cfm?ID=1141

















Strin

Strin cn be de&ined %i*('y % *e%urb'e de&or*tion o& t-e *et'+ In ot-er )ord%,*et' *u%t be D%trinedD in order to c-nge it% %-(e+ Strin% cn be (o%itie 3(u''ing t-e*et' (rt, or ten%ion or negtie 3(u%-ing t-e *et' toget-er, or co*(re%%ion+ Strin%

'%o cn be (er*nent 3('%tic or recoerb'e 3e'%tic+ T-e re%u't o& e'%tic %triningco**on'y i% re&erred to % %(ringbck, or e'%tic recoery+

/e*e*ber, eery *et' ty(e )nt% to return to it% origin' %-(e )-en it% de&or*ed+ T-e*ount t-e *et' %(ring% bck i% &unction o& it% *ec-nic' (ro(ertie%+ W-en engineer%re&er to (rt re% t-t re D-ig- %trin,D t-ey ty(ic''y re re&erring to re% t-t -e been %ub?ected to %ub%tnti' %tretc- or co*(re%%ion+ Figure 1 %-o)% %i*u'tion i*geo& (rt t-t -% been %tretc-ed+ Ec- co'or re(re%ent% di&&erent ty(e nd *ount o&%trin+ So*e o& t-e %trin% re (o%itie nd ot-er% re negtie+

Stre%%

Stre%% i% %i*('y t-e re%u't o& %trining t-e *et'+ W-en %ub?ected to %tre%%, *et' incur%intern' c-nge% t-t cu%e it to %(ring bck or de&or* nonuni&or*'y+ Tr((ed %tre%%e%)it-in (rt o&ten re%u't in 'o%% o& &'tne%% or ot-er geo*etric c-rcteri%tic%+ A'' cut or&or*ed (rt% incur %tre%%+

Stretc- 6i%tribution

Stretc- di%tribution i% ery i*(ortnt*ec-nic' (ro(erty+ A *et'% %tretc-di%tribution c-rcteri%tic% contro' -o)

*uc- %ur&ce re o& t-e %tretc-ed *et'i% (er*nent'y de&or*ed+ Stretc-di%tribution i% deter*ined (ri*ri'y byc-ecking t-e *et'% t-ickne%% )-en it%de&or*ed in ten%ion during t-e ten%i'ete%ting (roce%%+ T-e *ore uni&or* t-et-ickne%% di%tribution, t-e better t-e%tretc- di%tribution+ Stretc- di%tribution'%o i% (rti''y e:(re%%ed in t-e *et'% n 'ue+ Figure 2 %-o)% di&&erent %tretc-di%tribution re%u't%+ T-e red re% o& t-e %*('e te%t cou(on re(re%ent re% t-t -e been %tretc-ed+

n L'ue

To under%tnd n 'ue, ot-er)i%e kno)n % t-e )ork or %trin -rdening e:(onent, you*u%t under%tnd t-t eery ti*e *et' i% e:(o%ed to (er*nent de&or*tion, )ork-rdening occur%+ It% t-e %*e t-ing t-t -((en% )-en you bend cot -nger bck nd&ort-+ A% you bend t-e -nger, it get% -rder nd -rder to bend+ It '%o beco*e% *oredi&&icu't to bend it in t-e %*e ('ce+ T-i% incre%e in %trengt- i% t-e re%u't o& )ork or

Figure 2

Stretc- 6i%tribution Ten%i'e Te%t




%trin -rdening+ Ho)eer, i& you continue to bend t-e -nger in t-e %*e %(ot, it )i''eentu''y &i'+

Ironic % it *y %ee*, *teri'% need to )ork=-rden to c-iee bot- good %tretc-bi'itynd %tretc- di%tribution+ Ho) t-ey )ork=-rden i% t-e key+ T-e n 'ue o& *teri' cn

be de&ined &und*ent''y % t-e *et'% %tretc-bi'ityF -o)eer, it '%o i% n e:(re%%ion o& *teri'% %tretc- di%tribution c-rcteri%tic%+

Per-(% one o& t-e *o%t i*(ortnt *ec-nic' (ro(ertie% to con%ider i& t-e %t*(ed (rtre<uire% gret de' o& %tretc-, t-e n 'ue i% e:(re%%ed nu*eric''y in nu*ber% &ro*"+$"" to "+!"" nd u%u''y i% crried out t)o or t-ree deci*' ('ce%+ T-e -ig-er t-enu*ber, t-e greter t-e *et'% %tretc-bi'ity nd %tretc- di%tribution+ Hig-er=%trengt-*et'%, %uc- % %(ring %tee', -e ery 'o) n 'ue%, )-i'e *et'% %uc- % t-o%e u%ed &or*king oi' (n% nd ot-er dee(=&or*ed (rt% u%u''y e:-ibit -ig-er n 'ue%+

T-e *et'% n 'ue '%o i% key *ec-nic' 'ue u%ed in creting &or*ing 'i*it

digr*%+ 3T-i% )i'' be di%cu%%ed in %ub%e<uent (rt% o& t-i% %erie%+r L'ue

T-e *et'% r 'ue i% de&ined *et''urgic''y % t-e ('%tic %trin rtio+ To under%tnd t-i%conce(t, you *u%t c'er'y kno) t-e di&&erence bet)een %tretc-ing nd dr)ing+Stretc-ing i% *et' &or*ing (roce%% in )-ic- t-e *et' i% &orced into ten%ion+ T-i%re%u't% in n incre%e in %ur&ce re+ Ite*% %uc- % *o%t uto*obi'e -ood% nd &ender%re *de u%ing t-i% (roce%%+

6r)ing i% t-e di%('ce*ent o& *et' into city or oer (unc- by *en% o& ('%tic

&'o) or &eeding t-e *et'+ Ite*% %uc- % 'rge cn%, oi' (n%, nd dee(=&or*ed (rt%u%u''y re *de u%ing t-i% (roce%%+

Figure 3

P'%tic Strin /tio r L'ue

T-e *et'% r 'ue cn be de&ined %i*('y % t-e *et'% bi'ity to &'o)+ It '%o i%e:(re%%ed nu*eric''y u%ing 'ue &ro* $ to #, )-ic- u%u''y i% crried out t)o deci*' ('ce%+ T-e greter t-e r 'ue, t-e *ore dr)b'e t-e *et' 3Figure 3+

T-e *et'% r 'ue i% not uni&or* t-roug-out t-e %-eet+ Mo%t *et'% -e di&&erent r'ue% )itre%(ect to t-e *et'% ro''ing direction+ Te%ting &or *et'% r 'ue re<uire%ten%i'e te%ting in t-ree di&&erent direction%;)it- t-e ro''ing direction, gin%t t-e ro''ing




direction, nd t 41 degree% to t-ero''ing direction+ T-e te%t re%u't%u%u''y re erged nd e:(re%%ed %t-e r br, or erge o& t-e r 'ue%+

6i&&erence% in t-e ('%tic %trin rtiore%u't in erring o& t-e *et' )-en being dr)n+ >or e:*('e, )-endr)ing round %-e'' &ro* round b'nk, t-e re%u't% )i'' be ner %<ure botto* on t-e &'nge o& t-e cu(+ T-i%e&&ect 3Figure 4 i% cu%ed bydi&&erent *ount% o& *et' &'o) )it-re%(ect to t-e *et'%

Sur&ce To(ogr(-y

A *et'% %ur&ce to(ogr(-y, de&ined %i*('y % t-e *et' %ur&ce &ini%-, i% creted*in'y during t-e *et' ro''ing (roce%%+ Sur&ce to(ogr(-y i% n i*(ortnt *et'c-rcteri%tic+ W-en being dr)n, *et'% o&ten re<uire %ur&ce &ini%- t-t -% t-e bi'ityto -o'd 'ubricnt+ Sur&ce to(ogr(-y i% deter*ined )it- *e%uring too' c''ed (ro&i'o*eter+

T-i% )r(% u( t-e di%cu%%ion o& %-eet *et' c-rcteri%tic%+ T-e ne:t rtic'e in t-i% %erie%)i'' &ocu% on *et' cutting+

By Art Hedrick, Contributing Writer

A(ri' $$, #""2A't-oug- *ny *et'% re u%ed in %t*(ing, '' &'' into one o& t)o b%ic ctegorie%; &errou% nd non&errou%+ A'' *et'% -e certin c-rcteri%tic% t-t *u%t be con%idered)-en deter*ining )-ic- %t*(ing die%, (roduction (roce%%e%, nd e<ui(*ent to u%e+ T-i%rtic'e introduce% t-e *o%t b%ic *et'% nd t-eir (ro(ertie%+

Editor% Note. T-i% rtic'e;Prt LII o& %erie% coering %t*(ing die &und*ent'%;i%n oerie) o& *et'% u%ed in %t*(ing+ art C7 e:('ined %(eci'ty die co*(onent%+arts 7C nd C coered co**on %t*(ing die co*(onent%+

art 777 di%cu%%ed %eer' di&&erent (roduction *et-od% u%ed to (roduce %t*(ed (rt%+art 77 coered riou% &or*ing o(ertion%, nd art 7 e:('ined )-t die i% ndde%cribed %eer' *et' cutting o(ertion%+

Preiou% rtic'e% in t-i% %erie% &ocu%ed on %t*(ing die% nd (roduction *et-od%+ T-i%rtic'e di%cu%%e% %t*(ing *teri'%;bot- &errou% nd non&errou%+

Figure 4

Erring Cu%ed by 6i&&erence% in t-e Met'% rL'ue

















To (roce%%, de%ign, nd bui'd %ucce%%&u' %t*(ing die, it i% nece%%ry to &u''yunder%tnd t-e be-ior' c-rcteri%tic% o& t-e %(eci&ic *teri' to be cut nd &or*ed+>or e:*('e, i& you re &or*ing 1""" %erie% 'u*inu* nd you &o''o) t-e %*e (roce%%you u%e &or dee( dr)ing %tee', t-e o(ertion *o%t 'ike'y )i'' &i';not becu%e'u*inu* i% bd, it% ?u%t di&&erent &ro* %tee'+

Ec- *et' -% it% o)n uni<ue *ec-nic' c-rcteri%tic%+ T-e *et' ty(e t-t t-e die i%&or*ing nd cutting o&ten deter*ine% t-e too' %tee' t-t *u%t be u%ed, % )e'' % -o)*ny o(ertion% re re<uired+ In ddition, di&&erent *et' ty(e% re<uire di&&erent'ubricnt%, (re%% %(eed%, nd c(citie%+ Becu%e %t*(er% re end u%er% o& *et'%, t-i%rtic'e &ocu%e% on %e'ecting nd under%tnding t-e end=(roduct be-ior on'y nd not t-e*et'=*king (roce%%+

T)o Met' Ty(e%

A't-oug- t-ere re 'iter''y t-ou%nd% o& *et'% t-t cn be %t*(ed, '' &'' )it-in t)o

b%ic ctegorie%; ferros nd nonferros+ >errou% *et'% contin iron, nd non&errou%*et'% re t-o%e )it-out iron+ Stee' i% c'%%ic &errou% *et' becu%e it i% deriede%%enti''y &ro* iron ore+ A'u*inu*, -o)eer, contin% no iron nd i% c'%%i&ied % non&errou% *et'+

Wit- t-e e:ce(tion o& &e) e:otic %(eci'ty *et'%, &errou% *et'% re *gnetic ndnon&errou% *et'% re non*gnetic+ Becu%e non&errou% *et'% do not contin iron, t-eyre 'e%% 'ike'y to deteriorte t-roug- o:idtion or ru%ting+ So*e co**on'y %t*(ednon&errou% *et'% re 'u*inu*, br%%, bron0e, go'd, %i'er, tin, nd co((er+

A'u*inu* i% ery (o(u'r *et' &or (('iction% in )-ic- %trengt-, )eig-t, nd

corro%ion re%i%tnce re &ctor%+ A'u*inu* i% ((ro:i*te'y one=t-ird t-e )eig-t o& %tee'+A't-oug- -undred% o& ''oyed %tee'% e:i%t, ('in crbon %tee' i% by &r t-e *o%t co**on'y%t*(ed &errou% *et'+

Stee' B%ic%

Crbon i% b%ic e'e*ent o& t-e %tee'*king (roce%%+ In it% r) &or*, crbon cou'd bede%cribed % c-unk o& co' or (enci' 'ed+ A (iece o& co' buried *i'e or %o benet-t-e %ur&ce o& t-e ert- nd %ub?ected to inten%e -et nd (re%%ure &or bout t-ou%ndyer% yie'd% )-tG A di*ond+ A di*ond i% not-ing *ore t-n (ure, co*(re%%ed crbon+3Ye%, DCrbon i% gir'% be%t &riend+D u%t *ke %ure t-t it% ntur', -ig-'y co*(re%%ed

crbon t-t you re giing -er+>ro* t-i% b%ic kno)'edge o& crbon, it i% e%y to deduce t-t t-e *ore crbon (re%ent int-e %tee', ty(ic''y t-e %tronger nd 'e%% &or*b'e it )i'' be+ >or e:*('e, too' %tee' u%edin *nu&cturing die% contin% &r *ore crbon t-n t-e %-eet *et' being (roce%%ed+Kee( in *ind t-t t-e crbon content o& (rticu'r *et' doe% not &u''y deter*ine t-e*et'% *ec-nic' (ro(ertie%+ Crbon content i% on'y one &ctor+




A''oy%

An ''oy i% -o*ogeneou% co*(ound or *i:tureo& t)o or *ore *et'% t-t en-nce% t-e *et'%c-e*ic', *ec-nic', or (-y%ic' (ro(ertie%+

W-en co*bined, t-e *et'% *u%t be co*(tib'end re%i%t %e(rtion under nor*' condition%+>or e:*('e, t)o co**on ''oy% dded to %tee' re c-ro*e nd nicke'+ C-ro*e i% ery-rd nd re%i%t% o:idtion, nd %o doe% nicke'+ Adding c-ro*e nd nicke' to %tee' (roduce% %tin'e%% %tee'+ T-e%e dded ''oy% enb'e t-e %tin'e%% %tee' to re%i%t o:idtion+

I& you -e (urc-%ed %tin'e%% %tee' &'t)re recent'y, you *y -e noticed di&&erentgrde% re i'b'e+ T-e%e grde% u%u''y re de%ignted % good, better, nd be%t+ T-e*in di&&erence in t-e <u'ity de(end% (ri*ri'y on t-e ''oy content+ T-e nu*ber% t-tyou %ee on t-e (ckging, %uc- % $77 or $7$", re&er to t-e (ercentge o& c-ro*iu* 3$7 (ercent nd nicke' 37 (ercent or $" (ercent in t-e %tin'e%% %tee'+ C-ro*iu* i% kno)n

&or it% %tin re%i%tnce, nd nicke' i% kno)n &or it% -ig- 'u%ter nd %-ine+ Hig-er ''oynu*ber% *en -ig-er <u'ity nd co%t+

A''oy% cn be introduced into bot- &errou% nd non&errou% *et'%+ Mny 'u*inu* ''oy%re i'b'e tody+ A ery co**on %tee' ty(e u%ed in t-e uto*otie indu%try i% -ig-=%trengt-, 'o)=''oy %tee' 3HS9A+ A''oy% re co*bined )it- *ediu* crbon %tee' to giet-e *et' good 'od=crrying bi'ity ndre%onb'e &or*bi'ity+ T-e%e *ec-nic' (ro(ertie% *ke HS9A good cndidte &or&r*e ri'% nd ot-er uto*otie %tructur' (rt% t-t re<uire %trengt-+

T-e nu*ber o& ''oyed *et'% u%ed in%t*(ing re &r too nu*erou% to *ention int-i% rtic'e+ T-e t-ing to re*e*ber i% t-t''oyed *et'% re co*bintion or *i:tureo& t)o or *ore *et'% t-t crete ne) *et')it- %(eci' c-rcteri%tic%+

P'in Crbon Stee'

P'in crbon %tee' cn be de&ined % (ure %tee', *ening t-t it contin% no intention''y

dded ''oy%+ P'in crbon %tee';*ong t-e *o%t (o(u'r %tee' ty(e% u%ed in %t*(ingtody;u%u''y i% %%igned &our=digit nu*ber, %uc- % $""2, $"#", $"1", nd $"7"+ Todeter*ine t-e %tee'% crbon content, %i*('y ('ce n i*ginry deci*' ('ce bet)eent-e &our digit% nd red t-e '%t t)o digit% % (ercentge o& $ (ercent+ >or e:*('e,$"$" %tee' contin% $0 $D$00 o& $ (ercent crbon, or "+$" crbon 3%ee Figure 1+

T-e *ore crbon in t-e %tee', t-e -rder it )i'' be to cut nd &or*+ Met'% )it- incre%edcrbon cn be -rdened &urt-er by -eting t-e* to critic' te*(erture nd coo'ing

Figure 1

Figure 2




t-e* <uick'y in t-e (ro(er <uenc-ing *ediu*+ Proce%%ing -rder *et'% re<uire% die%*de &ro* toug-er, *ore )er=re%i%tnt too' %tee'%+ A'%o, greter &orce i% needed to cutnd &or* t-e *et'+ Kno)ing t-e *et'% crbon content cn -e'( you *ke betterdeci%ion bout t-e ((ro(rite too' %tee' nd (re%% c(city+ Figure 2 %-o)% &e) ty(ic'(('iction% )itre%(ect to t-e %tee'% crbon content+

T-i% rtic'e coered ery b%ic *et' ty(e% nd (ro(ertie% on'y+ T-e ne:t rtic'e in t-i%%erie% )i'' di%cu%% t-e *ec-nic' c-rcteri%tic% o& di&&erent *et'% in *ore deti'+ It '%o)i'' e:('in -o) t-e *et' %e'ection &&ect% t-e die (roce%%ing *et-od nd die *teri'%+

By Art Hedrick, Contributing Writer >ebrury 5, #""2

In=die t((ing unit%, rotry bender%, (ierce nut unit%, HY6/OCAM%, nd t-red=&or*ing (unc-e%button% re *ong t-e %(eci'ty die% t-t cn -e'( reduce t-e nu*ber o&re<uired o(ertion% nd co%t% to (roduce -o'e% in %t*(ed (rt%+ T-i% rtic'e di%cu%%e%

t-e%e co*(onent% nd t-eir (('iction%+ Editors NoteA /"is articlePart @7 of a series co-erin! sta'pin! die fnda'entals discsses specialt+ die co'ponents. Parts IV and V co-ered co''on sta'pin! die

co'ponents. Part III discssed se-eral different prodction 'et"ods sed to prodce

sta'ped parts. Part II co-ered -arios for'in! operations, and Part I explained

w"at a die is and descri*ed se-eral 'etal

cttin! operations.

Preiou% rtic'e% in t-i% %erie% di%cu%%ed

co**on %t*(ing die co*(onent%+ T-i%rtic'e &ocu%e% on 'e%% co**on %(eci'tyco*(onent% &ound on'y in certin die%,*o%t o& )-ic- re i'b'e &ro* riou%%u(('ier%+

In=die T((ing @nit%

Mny die% (roduce (rt% t-t contin-o'e% or e:tru%ion% t-t )i'' be t((ed or t-reded to -o'd &%tener+ T-e%e -o'e% o&tenre t((ed in t-e die rt-er t-n in %e(rte, o&&'ine o(ertion+

In=die t((ing unit% u%e %erie% o& -e'i:=%ty'e %-&t% nd ger% to trn%&er 'iner *otion3(re%% r* into rotry *otion+ T-e *ec-nic' rotry *otion cn be (re%% r*=drien, orit cn be creted by %(eci' e'ectronic %ero=drie *otor%+ Be%ide% *oing do)n)rd, t-et( %(in% nd crete% t-e t-reded -o'e+

@n'ike regu'r cutting t(, n in=die t((ing unit u%e% %(eci' ro'' &or*ing t(%+ In%tedo& re*oing c-i(%, ro'' &or*ing t(% grdu''y de&or* t-e *et' into t-e %-(e o&

Figure 1

Inidie T((ing @nit% 7'a!e cortes+ of ;anl+ 7EM.
















t-red+ @%ing %tndrd cutting t( in n in=die t((ing unit )ou'd crete cutting c-i(re*o' (rob'e*+

Becu%e t-e )ork -rden% during t-e *et' de&or*tion (roce%%, n in=die t((ed -o'e%%trengt- cn be %i*i'r to %tndrd cut

t-red% %trengt-+ T-e di&&erence i% co%t; u%ing n in=die t((ing unit in%ted o& no&&'ine t((ing (roce%% cn reduce co%t%%igni&icnt'y 3%ee Figure 1+

/otry Bender%

/otry bender%, o&ten re&erred to %rocker bender%, re %(eci'ty *et' bending unit% t-t &eture rotry ction= (roducing L=grooed cy'inder+ T-i%

cy'inder i% %(ring 'oded nd %ecured into %(eci' retiner c''ed %dd'e+ A% t-edie c'o%e% nd t-e cy'inder *ke% contct)it- t-e %-eet *et', it rotte% bout it%center'ine nd crete% t-e bend+ /otry bender% cn be u%ed to crete %trig-t='ine bend% on'y+

@n'ike conention' *et' bending e<ui(*ent, rocker bender% re<uire no ddition' (re%%ure (d+ /ocker bender% cn be e%i'y d?u%ted nd re<uire 'e%% &orce t-nconention' bending *et-od%+ W-en in%erted )it- %(eci' -rd ('%tic, t-ey renon*rking nd cn oerbend t-e *et' to crete n cute or 'e%% t-n 8"=degree ng'e+

T-ey '%o cn crete doub'e bend% 3Figure 2+Pierce Nut @nit%

>%tener%, %uc- % %cre)%, nut% nd riet%, cn be in%erted into %t*(ed (rt in riou%)y%+ @%ing (ierce nut unit current'y i% co**on *et-od+ T-i% %(eci' *ec-nic'unit 3Figure 3 bot- (ierce% -o'e nd &%ten% t-reded nut to t-e %t*(ed (rt+

Figure 3

Figure 2

7'a!e cortes+ of ;anl+ 7EM




Pierce Nut In%t''tion @nit 7'a!e cortes+ of Mltifastener Corp.

Pierce nut unit% cn &eed &%tener% in %eer' di&&erent )y% nd cn be incor(ortede%i'y in (rogre%%ie, 'ine, nd trn%&er die%+ @n'ike t((ing, in )-ic- t-e -o'e re'ie% on

t-e *ount o& t-red engge*ent t-t cn be c-ieed by t-e %(eci&ic e:tru%ion 'engt-, (ierce nut unit% cn )ork )it- riety o& nut %i0e%, %trengt-%, nd t-red %erie%+

Pierce nut unit% cn be u%ed in '*o%t ny -o'e=(iercing o(ertion nd re ery (o(u'r in bot- t-e uto*otie nd ot-er indu%trie%+

HY6/OCAM%

Actited by (re%% r*=drien -ydru'ic cy'inder%, HY6/OCAM% 3Figure 4 (ierce-o'e% nd crete %(eci' &or*% in die re% t-t re incce%%ib'e u%ing %tndrd c*%+@%ing HY6/OCAM% cn reduce t-e nu*ber o& %t*(ing o(ertion% nece%%ry, % )e''

% t-e die co%t+

Figure 4

HY6/OCAM A%%e*b'y 7'a!e cortes+ of ?ead+ /ec"nolo!+.

T-e drie unit cn be ('ced '*o%t ny)-ere benet- t-e (re%% r* nd cn be u%ed toctite one o& %eer' c*%+ Becu%e t-e%e c*% run on -ydru'ic%, t-ey cn c-iee gret &orce+ HY6/OCAM% '%o cn be d?u%ted e%i'y to &ine=tune t-e ti*ing to e:ecute%(eci'ty cutting nd &or*ing o(ertion%+

T-red=&or*ing Punc-e%Button%

T-red=&or*ing (unc-e% nd button% 3Figure # bot- (ierce nd &or* t-e *et' into %(eci' %-(e+ T-e %(eci''y %-(ed (ierced -o'e &unction% to -o'd riety o& %cre)% ndincre%e% t-e &orce nece%%ry to (u'' t-e %cre) out o& t-e %-eet *et'+




Figure #

7'a!e cortes+ of ;anl+ 7EM.

T-e (unc-e% nd button% cn be incor(orted into %tndrd b'' 'ock retiner%, or t-ey cn be t-e -eded ty(e+ Becu%e t-e *et' %i*('y i% being (ierced nd &or*ed, no (re%% %(eedreduction i% nece%%ry+

Ho'e% creted )it- %(eci' t-red=&or*ing (unc-e% nd button% -e i*(roed -o'dingbi'ity oer (utting %cre) into &'t (iece o& %-eet *et'+

Met' cutting nd &or*ing *et-od% re irtu''y end'e%% nd 'i*ited on'y by t-ei*gintion+ Ec- die -% it% o)n %(eci' &unction+ To 'i%t '' co**erci''y i'b'e ndcu%to*=*de die co*(onent% i'b'e )ou'd be ner'y i*(o%%ib'e+

Prt LII o& t-i% %erie% )i'' di%cu%% %-eet *et' (ro(ertie%+

By Art Hedrick, Contributing Writer October $$, #""1

St*(ing die% cn co*(ri%e *ny co*(onent%+ T-i% rtic'e di%cu%%e% t-e b%icco*(onent%, inc'uding die ('te%, %-oe%, die %et%, guide (in%, bu%-ing%, -ee' b'ock%, -ee' ('te%, %cre)%, do)e'%, nd key%+

T-i% rtic'e; art 7C o& %erie% coering %t*(ing die &und*ent'%;e:('in% t-e (ur(o%e nd co*(o%ition o& co**on %t*(ing die co*(onent%+ art 777 di%cu%%ed%eer' di&&erent (roduction *et-od% u%ed to (roduce %t*(ed (rt%+ art 77 coeredriou% &or*ing o(ertion%, nd art 7 e:('ined )-t die i% nd de%cribed %eer'*et' cutting o(ertion%+

W-i'e *ny %(eci'ty co*(onent% cn be u%ed in *nu&cturing die%, *o%t die% contincertin co**on co*(onent%+

6ie P'te%, S-oe%, nd 6ie Set%










6ie ('te%, %-oe%, nd die %et%re %tee' or 'u*inu* ('te%t-t corre%(ond to t-e %i0e o&t-e die+ T-ey %ere % t-e&oundtion &or *ounting t-e

)orking die co*(onent%+ T-e%e (rt% *u%t be *c-ined %o t-tt-ey re (r''e' nd &'t )it-in critic' to'ernce+ T-e*c-ining *et-od% re *i''ingnd grinding+ A't-oug-grinding i% t-e *o%t (o(u'r, *i''ed %ur&ce no) cn be obtined t-t i% % ccurte % ground %ur&ce+

Mo%t die %-oe% re *de &ro* %tee'+ A'u*inu* '%o i% (o(u'r die %-oe *teri'+A'u*inu* i% one=t-ird t-e )eig-t o& %tee', it cn be *c-ined ery <uick'y, nd %(eci'

''oy% cn be dded to it to gie it greter co*(re%%ie %trengt- t-n 'o)=crbon %tee'+A'u*inu* '%o i% gret *et' &or %-ock d%or(tion, )-ic- *ke% it good c-oice &or b'nking die%+

T-e u((er nd 'o)er die %-oe% %%e*b'ed toget-er )it- guide (in% crete t-e die %et+ T-e'o)er die %-oe o&ten -% *c-ined or &'*e=cut -o'e% t-t ''o) %'ug% nd %cr( cretedin t-e die to &'' &ree'y t-roug- t-e die %-oe onto t-e (re%% bed+ T-e -o'e% '%o *y %ere% c'ernce% &or g% %(ring% nd ot-er die co*(onent%+

T-e die %-oe t-ickne%% i% b%ed on -o) *uc- &orce cn be e:(ected during cutting nd&or*ing+ >or e:*('e, coining die, one t-t co*(re%%e% *et' by %<uee0ing it bet)een

n u((er nd 'o)er die %ection, re<uire% *uc- t-icker die %-oe t-n %i*('e bendingdie 3Figure 1+

uide Pin% nd Bu%-ing%

uide (in%, %o*eti*e% re&erred to % guide (o%t% or (i''r%, &unction toget-er )it- guide bu%-ing% to 'ign bot- t-e u((er nd 'o)er die %-oe% (reci%e'y+ T-ey re (reci%ion=groundco*(onent%, o&ten *nu&ctured )it-in "+"""$ in+ A't-oug- nu*erou% %(eci'ty*ounting *et-od% cn be u%ed to in%t'' t-e%e co*(onent%, t-ere re on'y t)o b%ic ty(e%o& guide (in% nd bu%-ing%;&riction (in% nd b'' bering=%ty'e (in%+

>riction (in% re (reci%ion=ground (in% t-t re %'ig-t'y %*''er t-n t-e guide bu%-ing%in%ide di*eter+ Pin% re *de &ro* -rdened too' %tee', )-i'e bu%-ing% o&ten re *de&ro* or 'ined )it- %(eci' )er=re%i%tnt *teri' c''ed 'u*inu*=bron0e+ T-e'u*inu*=bron0e *y contin gr(-ite ('ug% t-t -e'( to reduce &riction nd )er t-toccur to t-e (in% nd bu%-ing%+

>riction (in% '%o -e'( to -ee' t-e die %-oe% nd (reent t-e* &ro* *oing &ro* %ide to%ide+

Figure 1

Lriou% die %et ty(e%






cutting nd &or*ing (roce%%+ T-ey re e%(eci''y i*(ortnt i& t-e generted &orce i% one=direction'+ Too *uc- &orce generted &ro* one direction on'y cn cu%e t-e guide (in% tode&'ect, )-ic- re%u't% in *i%'ign*ent o& critic' cutting nd &or*ing co*(onent%+

Mo%t -ee' b'ock% -e %tee' -ee' ('te%, nd t-e -ee' b'ock on t-e o((o%ite %-oe -%

)er ('te *de &ro* 'u*inu* bron0e or %o*e ot-er di%%i*i'r *et'+ T-e ('te%e'ection (roce%% i% critic'+ @%ing t)o o((o%ing ('te% *de o& t-e %*e *et' ty(e cnre%u't in -ig- &riction, -et, nd eentu''y g''ing or co'd )e'ding o& t-e )er ('te%+

Hee' b'ock% cn be u%ed to -ee' t-e die in ny or '' direction%+ Bo: -ee'% o&ten re u%edto -ee' t-e die in '' direction% 3Figure 3+

Scre)%, 6o)e'%, nd Key%

Scre)% &%ten nd %ecure t-e )orkingco*(onent% to bot- t-e u((er= nd

'o)er=die %-oe%+ T-e %ocket -ed c(%cre) i% t-e *o%t (o(u'r &%teneru%ed in %t*(ing die%+ T-i% -rdenedtoo' %tee' %cre), o&ten re&erred to % nA''en -ed %cre), o&&er% %u(erior-o'ding (o)er nd %trengt-+

6o)e'% re -rdened, (reci%ion=ground (in% t-t (reci%e'y 'octe t-edie %ection or co*(onent in it% (ro(er'oction on t-e die %-oe+ A't-oug-

do)e'% -e *uc- -ee'ing bi'ity, t-eir *in &unction i% to 'octe t-e die %ection (ro(er'y+Key% re %*'', rectngu'r b'ock% o& (reci%ion=ground %tee' t-t re in%erted into *i''ed (ocket in t-e die %-oe% nd %ection% c''ed key)y%+ Key% 'octe nd -ee' die %ection%nd co*(onent% 3Figure 4+

W-i'e t-e%e re t-e *o%t co**on, ot-er co*(onent% cn be u%ed in *nu&cturing%t*(ing die%+ T-e%e )i'' be di%cu%%ed in Prt L o& t-i% %erie%+

By Art Hedrick, Contributing Writer 6ece*ber $!, #""1

St*(ing die% co*(ri%e *ny co*(onent%+ Continuing t-e di%cu%%ion o& co**on%t*(ing die co*(onent% begn in Prt IL o& t-i% %erie%, t-i% rtic'e &ocu%e% on (d%,inc'uding %tri((er, (re%%ure, nd dr)ingF t-e *et-od% u%ed to %ecure t-e*;%(oo'%,%-ou'der bo't%, kee(er%, nd retiner%F nd %(ring%;g%, coi', nd uret-ne+

Editors NoteA /"is articlePart @ of a series co-erin! sta'pin! die fnda'entals contines t"e discssion a*ot co''on sta'pin! die co'ponents t"at *e!an in Part IV .

Figure 4

Key%, do)e'% nd %cre)%






Part III discssed se-eral different prodction 'et"ods sed to prodce sta'ped parts.

Part II co-ered -arios for'in! operations, and Part I explained w"at a die is and

descri*ed se-eral 'etal cttin! operations.

Mny %(eci'ty co*(onent% cn be

u%ed in die%, but t-e *o%t co**on'yu%ed re die ('te%, %-oe%, die %et%,guide (in%, bu%-ing%, -ee' b'ock%, -ee' ('te%, %cre)%, do)e'%, nd key%;''o& )-ic- )ere e:('ined in art 7C

o& t-i% %erie%+ T-i% rtic'e &ocu%e% onot-er co**on co*(onent%;(d%,retiner%, nd %(ring%+

Pd%

A (d i% %i*('y (re%%ure='oded ('te, eit-er &'t or contoured, t-t -o'd%, contro'%, or%tri(% t-e *et' during t-e cutting nd &or*ing (roce%%+ Seer' ty(e% o& (d% re u%ed in%t*(ing die%+ 6e(ending on t-eir &unction, (d% cn be *de &ro* %o&t 'o)=crbon %tee'or -rdened too' %tee'+ Contoured (d% *u%t &it ery c'o%e'y to t-e *ting die %ection+Preci%ion re<uire*ent% deter*ine )-et-er t-e (d% re (o%itioned )it- guide (in% nd bu%-ing% or 'e&t unguided+

Stri((er Pd% P'te%+ Stri((er (d% re &'t or contoured, %(ring='oded ('te% t-t (u'', or strip, t-e *et' o&& t-e cutting (unc-e%+ W-en it% cut, *et' ntur''y tend% to co''(%eround t-e body or %-nk o& t-e cutting (unc-e%F t-i% i% e%(eci''y true during (iercing+T-e %tri((er (d %urround% t-e cutting (unc-e% nd *ount% to t-e u((er die %-oe+ A% t-e

(unc- e:it% t-e 'o)er die, t-e %(ring='oded (d -o'd% t-e *et' do)n &'u%- )it- t-e'o)er die %ection, )-ic- ''o)% t-e cutting (unc-e% to )it-dr) &ro* t-e %-eet *et' or (iece (rt+

O&ten %tri((er (d% re in%erted )it- %*'' b'ock o& %tee' c''ed pad window+ T-i% (d)indo) u%u''y i% %*'' nd 'ig-t)eig-t nd cn be re*oed e%i'y to ''o) t-e die*intennce tec-nicin to re*oe t-e b'' 'ock=%ty'e (ierce (unc- &ro* t-e retiner)it-out re*oing t-e entire %tri((er (d+ Stri((er (d% '%o &unction to -o'd t-e *et' &'tor to t-e de%ired %-(e during t-e cutting (roce%% 3Figure 1+

ressure ads lates+ 6uring t-e )i(e bending (roce%%, t-e *et' *u%t be -e'd do)n

tig-t'y to t-e 'o)er die %ection be&ore t-e &or*ing (unc- contct% t-e *et'+ Pre%%ure (d% *u%t (('y &orce t-t i% t 'e%t e<ui'ent to t-e bending &orce+ Mo%t (re%%ure (d% u%e -ig-=(re%%ure coi' or g% %(ring% 3>igure $+ W-en 'oded )it- ery -ig-= (re%%ure %(ring%, contoured or &'t (d% '%o cn &or* %-eet *et'+ T-e%e (d ty(e% o&tenre re&erred to % power pnc"es 3Figure 2+

Figure 1














Figure 2 Figure 3

Draw ads+ 6r) (d% contro' *et' &'o) during t-e dr)ing (roce%%+ In dr)ing, t-e*ount o& (re%%ure, or do)n)rd &orce, e:erted on t-e %-eet *et' deter*ine% -o) *uc-

*et' i% ''o)ed to &'o) nd enter t-e dr) die city+ Too *uc- (re%%ure *y %to( t-e*et' &ro* &'o)ing nd cu%e %('ittingF too 'itt'e do)n)rd &orce *y ''o) e:ce%% *et'to &'o) in)rd nd cu%e 'oo%e *et' or )rink'ing+

6r) (d%, o&ten re&erred to % *inders or *lan1 "olders u%u''y re *de &ro* -rdenedtoo' %tee'+ T-ey cn be &'t or contoured, de(ending on t-e (iece (rt %-(e+ Mo%tdr)ing die% u%e %ing'e dr) (dF -o)eer, in %(eci' c%e%, %o*e u%e t)o 3Figure 3+

S(oo'%, S-ou'der Bo't%, nd Kee(er%

S(oo'%, %-ou'der bo't%, nd kee(er% re u%ed to &%ten (d% to t-e die %-oe% )-i'e

''o)ing t-e* to *oe u( nd do)n+ T-ey re %ecured to eit-er t-e to( or botto* die%-oe )it- %cre)% nd o&ten do)e'% &or (reci%ion 'oction+ O& '' o& t-e co*(onent% u%ed&or %ecuring (d%, %(oo'% re t-e *o%t co**on, e%(eci''y in 'rger die% 3>igure $ ndFigure 4+

Figure 4

/etiner%




/etiner% -o'd or %ecure cutting or &or*ing die co*(onent% to bot- t-e u((er nd 'o)erdie %-oe%+ One o& t-e *o%t (o(u'r retiner% i% b''='ock retiner, -ig-=(reci%ion,ccurte'y *nu&ctured die co*(onent t-t %ecure% nd 'ign% bot- cutting nd &or*ing (unc-e%+ It u%e% %(ring='oded b'' bering to 'octe nd %ecure t-e (unc-e%, )-ic-&eture (reci%e'y *c-ined teardrop or *all seat + T-e %(ring='oded b'' bering 'ock%

into t-e terdro( %-(e nd (reent% t-e (unc-e% &ro* co*ing out o& t-e retiner+

Figure #

T-e dntge o& b''='ock retiner% i% t-t t-ey ''o) t-e die *intennce tec-nicin tore*oe nd rein%t'' (unc-e% <uick'y+ T-e (unc- i% re*oed by de(re%%ing t-e %(ring='oded b'' bering nd (u''ing u( on t-e (unc-+ S(eci'ty retiner% '%o cn be *de to-o'd nd 'ign irregu'r (unc- %-(e%, % )e'' % -eded=%ty'e (unc-e% nd (i'ot (in%3Figure #+

S(ring%

S(ring% %u(('y t-e &orce needed to -o'd, %tri(, or &or* *et'+ Mny di&&erent %(ring% reu%ed in %t*(ing die%+ S(ring %e'ection i% b%ed on *ny &ctor%, inc'uding t-e re<uired&orce nd tre', t-e %(ring% 'i&e e:(ectncy, nd, o& cour%e, co%t+ A*ong t-e *o%t (o(u'r re g% %(ring%, )-ic-, )-en &i''ed )it- nitrogen, cn %u(('y gret de' o&&orce+ T-ey '%o -e n e:ce''ent 'i&e e:(ectncy+

Figure $




Ot-er ty(e% re coi' nd uret-ne %(ring%, o&ten c''ed 'ars"'allow %(ring% 3Figure $+Coi' %(ring% re ery (o(u'r )-en re%onb'e *ount o& &orce i% needed nd budgetcon%trint% re (re%ent+ @ret-ne %(ring%)ork )e'' in %-ort=run or (rototy(e%t*(ing o(ertion%+ T-ey '%o re

ine:(en%ie+

T-e ne:t (rt o& t-i% %erie% )i'' coereen *ore co**on %t*(ing dieco*(onent%

By Art Hedrick, Contributing Writer April 11, 2005

When I conduct conferences, it isn't unusual to have one or twoattendees who are new to the stamping die and pressworkingworld. ome are !oung new hires tr!ing to learn a"out stamping,and others are individuals who have "een transferred from adifferent department and thrown to the wolves in the stampingdepartment.

#his article is the first in a series intended to introduce "eginner toolmakers, die maintenance technicians, engineers, and press techniciansto stamping. #he series will define a die as well as a stamping operation. It will also discuss cutting and forming operations, componentsand functions, and different methods used to stamp parts.

What Is a tamping $ie%

A stamping die is a special, one&of&a&kind precision tool thatcuts and forms sheet metal into a desired shape or profile.#he die's cutting and forming sections t!picall! are madefrom special t!pes of hardena"le steel called tool steel.$ies also can contain cutting and forming sections madefrom car"ide or various other hard, wear&resistantmaterials.

tamping is a cold&forming operation, which means that noheat is introduced into the die or the sheet materialintentionall!. owever, "ecause heat is generated fromfriction during the cutting and forming process, stampedparts often e(it the dies ver! hot..

$ies range in si)e from those used to makemicroelectronics, which can fit in the palm of !our hand, tothose that are 20 ft. s*uare and 10 ft. thick that are used to make entire automo"ile "od! sides.

#he part a stamping operation produces is called a piece part +see Figure 1. -ertain dies can make more than one piece part per c!cleand can c!cle as fast as 1,500 c!cles +strokes per minute. orce from a press ena"les the die to perform.

ow /an! $ie #!pes (ist%

#here are man! kinds of stamping dies, all of which perform two "asicoperations3 cutting, forming, or "oth. /anuall! or ro"oticall! loadeddies are referred to as line dies. 4rogressive and transfer dies are full!automated.

-utting

-utting is perhaps the most common operation performed in a stampingdie. #he metal is severed "! placing it "etween two "!passing tool steelsections that have a small gap "etween them. #his gap, or distance, iscalled the cutting clearance.

-utting clearances change with respect to the t!pe of cutting operation"eing performed, the metal's properties, and the desired edge conditionof the piece part. #he cutting clearance often is e(pressed as a percentage of the metal's thickness. #he most common cutting clearanceused is a"out 10 percent of the metal's thickness.

er! high force is needed to cut metal. #he process often introduces su"stantial shock to the die and press. In most cutting operations, themetal is stressed to the point of failure, which produces a cut edge with a shin! portion referred to as the cut "and, or shear, and a portioncalled the fracture )one, or "reak line +see Figure 2.

Figure 1

Figure 2#!pical -ut dge of a tamped 4art

Figure 3

#rimming




#here are man! different cutting operations, each with aspecial purpose. ome common operations are6

Trimming3#he outer perimeter of the formed part or flatsheet metal is cut awa! to give the piece part the desiredprofile. #he e(cess material usuall! is discarded as scrap+see Figure 3.

Notching37suall! associated with progressive dies, notching is a process in which a cutting operation is performed progressivel! on theoutside of a sheet metal strip to create a given strip profile +see Figure 4.

Blanking3A dual&purpose cutting operation usuall!performed on a larger scale, "lanking is used in operationsin which the slug is saved for further pressworking. It also isused to cut finished piece parts free from the sheet metal.#he profiled sheet metal slug removed from the sheet "!this process is called the "lank, or starting piece of sheetmetal that will "e cut or formed later +see Figure .

!iercing38ften called perforating, piercing is a metalcutting operation that produces a round, s*uare, or special&shaped hole in flat sheet metal or a formed part. #he maindifference "etween piercing and "lanking is that in "lanking,the slug is used, and in piercing the slug is discarded asscrap. #he cutting punch that produces the hole is called

the pierce punch, and the hole the punch enters is calledthe matri( +see Figure ".

#ancing3In lancing, the metal is sliced or slit in an effortto free up metal without separating it from the strip. 9ancingoften is done in progressive dies to create a part carrier called a fle( or stretch we" +see Figure $.

%hearing3hearing slices or cuts the metal along a straight line. #his method commonl! is used to produce rectangular and s*uare"lanks +see Figure &.

4art II of this series will discuss forming dies and stamping processes.

'educing (cra), in*entory co(t( +ith coil o)timiation (o-t+are

.a/imie material u(age

By #loyd Wol- April 10, 200:

-oil optimi)ation software is a valua"le tool that fa"ricators can use to attack the pro"lems of high scrap and highinventor!. It offers the a"ilit! to *uickl! and easil! make sound decisions regarding the purchase and use of master coil

Figure 4;otching




si)es. <! using computers and speciali)ed optimi)ation algorithms, fa"ricators can minimi)e manual selection of coilsi)es.

peciali)ed coil optimi)ation software anal!)es the parts to "e made and determines the optimal coil si)es +widths to purchase and maintain ininventor!. /ulticut "lanking line photo courtes! of =ed <ud Industries, =ed <ud, Ill.

/etal fa"rication is one of the most competitive industries in the 7.. a"ricators are alwa!s looking for new wa!s to decreasemanufacturing costs to maintain profita"ilit! and a competitive edge. Identif!ing and implementing cost&reduction opportunities often meanthe difference "etween long&term survival and plant closure.

/an! companies report that raw steel can represent as much as :0 percent of total manufacturing costs. #herefore, reducing scrap andinventor! costs are at the center of man! cost&reduction efforts. ven the smallest reduction in these costs can have a huge impact on thecompan!'s financial "ottom line.

peciali)ed coil optimi)ation software helps anal!)e the parts to "e made and determine the optimal coil si)es +widths to purchase andmaintain in inventor!.

The Coil Handling !roce((

/aster coils that fa"ricators purchase from mills and service centers t!picall! are from >0 to :2 inches wide +see Figure 1. #he mastercoils are decoiled and processed through a series of cut&to&length or multicut "lanking operations to !ield rectangular "lanks.

Figure 1 /aster coils >0 to :2 inches wide are processed through a series of cut&to&length or multicut "lanking operations to !ield rectangular "lanks.

#he process "egins when a master coil is loaded onto a cut&to&length or multicut "lanking line. As the coil is unrolled, the length is sheared,or cut to length. #he "lanks generated from the cut&to&length operation are sent to a manual shear, where the coil's width is cut in asecondar! shearing operation. #he rectangular "lanks generated from these operations are then sent to the fa"rication, welding, paint, andassem"l! departments to create the finished part.

If the coil is on a multicut "lanking line +a cut&to&length line with slitter "lades, the "lank's width also is slit at the same time the length is"eing cut.

#he difference "etween the width of the master coil and the sum of the "lank widths across the coil is scrap. It is dumped into a scraphopper and resold for onl! a few pennies per pound.

-utting from master coils can result in inefficient material utili)ation, "ecause, t!picall!, hundreds of rectangular fa"ricated parts?each withuni*ue dimensions?must "e cut from onl! a few master coil si)es. #o make the math even more comple(, each part has its own productionre*uirements6 ome parts ma! "e produced in ver! high volumes?more than 100,000 pieces annuall!. 8ther parts ma! "e needed in ver!low volumes?as few as 100 pieces annuall!. A coil si)e that utili)es material efficientl! for one part num"er often is inefficient for anotherpart num"er.

or e(ample, four 12&in.&wide parts placed across a @&in.&wide coil results in 100 percent material utili)ation and 0 percent scrap. owever,four 10&in.&wide parts placed across the same @&in.&wide coil results in a"out 1: percent scrap. #hree 15&in.&wide parts placed across the@&in.&wide coil results in more than B percent scrap.

.any Coil(, .any Foil(

8ne method some fa"ricators use to reduce scrap is to increase the num"er of different master coil si)es that the! purchase and maintainin inventor! to increase the chance of ma(imi)ing material utili)ation. 7nfortunatel!, this method of scrap reduction conflicts with Cust&in&time+DI# manufacturing and low coil inventor! goals. With man! different coil si)es in inventor!, each coil's usage is reduced. Also, thisincreases inventor! carr!ing costs, "ecause the coils tend to sit idle in inventor! for e(tended time periods. 4urchasing and maintainingnumerous different coil si)es also force more fre*uent setups and changeovers on the cut&to&length line. #his is "ecause the more coils thatare in inventor!, the less likel! that the coil re*uired for the ne(t shop order will "e the same as the coil re*uired for the last.

In addition, purchasing man! coil si)es reduces the purchasing power of volume discounts.

Another method some companies use to reduce material costs is to purchase standard&si)e master coils, t!picall! >0, @, B0, and :2 in.wide. #hese are common si)es, readil! availa"le from man! suppliers. Accordingl!, the! are sold for several cents per pound less than theEspecialEmaster coil si)es. owever, in some instances, this method can "e penn!&wise and dollar&foolish, "ecause man! parts ma! not fitefficientl! into these standard coil si)es. If 5 percent can "e saved on the purchase price per pound, then an e(tra 2 percent or > percent




scrap might "e accepta"le. <ut does it make sense to save 5 percent on the purchase price per pound with a scrap rate that is 10 percentto 15 percent higher than it would "e with special master coil si)es%

.anual Calculation(

a"ricators tr! to minimi)e the amount of scrap the! produce "! selecting coil si)es that "est fit the part si)es. owever, for the largenum"er of different part si)es that most fa"ricators produce, a nearl! infinite num"er of solutions could "e considered as to which coil si)es?and com"inations of those si)es?Fwould provide the lowest overall scrap.

electing the most desira"le coil si)es t!picall! means rel!ing on personal e(perience or a set of comple( manual calculations using

spreadsheets. #hese calculations can take several da!s or even months to perform, especiall! when a different set of calculations must "eperformed for each uni*ue material specification +gauge, grade, chemistr!, and so on. 7nfortunatel!, during that time, product line and mi(changes ma! render those results invalid. Also, without having knowledge of comple( optimi)ation algorithms, fa"ricators ma! "ase theircalculations on invalid assumptions.

urther complicating manual calculations are that purchase prices and part rotation often var! as the coil width changes, "ecause apremium is charged for narrower coils, while discounts are provided for wider coils.

econd, if grain direction does not matter, each part can "e considered "oth with&the&grain and rotated. #his factor alone more thandou"les the num"er of possi"le solutions.

0)timiation %o-t+are

peciali)ed coil optimi)ation software can help fa"ricators attack the pro"lems of high scrap and high inventor!. #he software anal!)esforecast production re*uirements for a set of parts, manufacturing constraints, and material and manufacturing costs. It determines theoptimal coil si)es +widths to purchase and maintain in inventor!, and it shows how to cut parts with lower scrap, lower cost, and fewer coilsi)es.

Figure 2 #he parts data"ase stores part "lank information?such as part num"er, width, length, forecast demand, and rotata"ilit!? for each material

specification.

<ecause of powerful optimi)ation algorithms, the software can effectivel! consider the cost of ever! possi"le com"ination of coil si)es that

can "e used?more than could ever "e considered manuall!. It finds the optimal coil si)es, thus reducing scrap loss and the num"er ofdifferent master coil si)es.

Ty)ical 0)timiation !roce((

#he user starts an optimi)ation stud! "! providing parts and constraint information for the material t!pe to "e optimi)ed.

#he parts data"ase +see Figure 2 is a spreadsheet&like window where part "lank information is stored for each material specification.Information t!picall! includes part num"er, width, length, forecast demand, and rotata"ilit!. #his ma! "e entered directl! "! the user, copiedand pasted from other software, or imported from other s!stems via file transfer.

Figure 3 #he costs and constraints data"ase is where e*uipment limits, material costs, and manufacturing costs are specified.

#he costs and constraints data"ase +see Figure 3 is where e*uipment limits, material costs, and manufacturing costs are specified.*uipment constraints include ma(imum and minimum coil widths, the *uantit! of slitter "lades, and edge&trim allowance. 7sing a materialcost ta"le, the user can specif! the purchase price per pound for var!ing ranges of coil widths, along with the reim"ursement for scrap.




-osts for material handling and la"or also can "e "roken out. -onstraint information needs to "e set up onl! once for various materialspecifications and does not re*uire modification for each optimi)ation stud!.

8nce that data is input, the user starts the optimi)ation routine. #he software automaticall! determines the optimal master coil si)es in lessthan five minutes, t!picall! +see Figure 4. A"out halfwa! through the optimi)ation process, the optimal coil si)es are displa!ed. #he usercan continue with the optimal master coil si)es, or other si)es ma! "e entered to facilitate Ewhat ifEscenarios.

When the calculations are finished, the optimi)ation results can "e reviewed "oth on&screen and in printed reports. #he cost and scrapsummar! report provides summar! information such as total scrap, total cost, and total weight for different master coil si)es.

Figure 4 $uring the optimi)ation routine, the software automaticall! determines the optimal master coil si)es. 8ther si)es ma! "e entered to facilitate Gwhat if3

scenarios.

or e(ample, if onl! one coil si)e were selected, what would "e its width% What would "e the scrap rate% What would "e the overall cost% Iftwo coil si)es were selected, what would "e the width and volume of each, the overall scrap rate, and overall cost% aving more coil si)eswill result in less scrap, "ut other, intangi"le costs would also increase at the same time, offsetting the material savings. If adding anadditional coil si)e saves an e(tra H25,000 per !ear in scrap, that pro"a"l! makes sense. <ut if the savings were onl! an additional H500per !ear, then the additional, intangi"le inventor! costs would pro"a"l! far e(ceed the material savings.

7sing the cost and scrap summar!, it is fairl! eas! to decide on the solution containing the optimal num"er of master coil si)es to use,considering scrap, material costs, and inventor! all together.

8nce the num"er of master coil si)es is decided, a part assignment report can "e viewed on&screen or printed. #his report shows whichparts are assigned to which master coil for the selected solution, and the corresponding num"er of pieces cut across the coil width. #hisreport t!picall! is used "! the engineering department to update "ills of materials and routings in the compan!'s manufacturing softwares!stem.

Ty)ical n*e(tment, %a*ing(, and 0ngoing !eriodic Analy(i(

#he initial investment in coil optimi)ation software t!picall! is from H15,000 to H25,000 per manufacturing location?depending on thenum"er of users, the amount of user training, and the need for an! customi)ation. 8ngoing annual costs for software maintenance andsupport are t!picall! 15 percent to 20 percent of the initial investment. $epending on the annual steel tonnage the compan! needs, material

costs, and the part mi(, annual savings t!picall! are from H>0,000 to H200,000. <ecause operating costs and material costs tend toincrease over time, annual savings t!picall! increases too.

<ecause the mi( of parts can change each !ear, as older product lines are discontinued and new product lines and changes are introduced,the optimal coil si)es also ma! change. <arring an! maCor product changes, t!picall! a compan! will use the optimi)ation software to re&evaluate master coil si)es a"out once each !ear to see how an! changes in part mi( have affected the optimal coil si)es. If part demandand mi( have changed significantl!, different coil si)es likel! will "e recommended.

If a !ear from now the results from a new optimi)ation stud! show that changing two of the four coil si)es for a material specification !ieldsa H25,000 savings, then it pro"a"l! makes sense to change those si)es. If, however, changing the si)es would produce onl! a H2,500savings, meaning that the part mi( has not changed much and the prior coil si)es still EfitEthe parts fairl! well, then it ma! make sense tosimpl! keep the current si)es, "ecause there will "e some cost associated with the time and effort to switch. n

#ea*ing the lab behind Au(tralian (tudent( mo*e (tam)ing re(earch to the)lant

By .ichael Carde+Hall, !eter Hodg(on, and Noel .iller, Contributing Writer( April 2@, 2001

tamping #echnolog! for Automotive /anufacturing 4rocesses +#A/4 is a novel t!pe of research program developed in Australia. #heuni*ue aspect of this program is that research is conducted for industr! inside actual companies&&a radical departure from traditionalresearch, which t!picall! involves e(perimentation in la"oratories. #his research model is well&suited to the manufacturing industr!,particularl! in Australia, where small and medium&si)e companies are predominant.

#he ;eed for Assistance

#A/4 was launched in mid&1: as a colla"orative venture "etween two Australian universitiesJ#he Australian ;ational 7niversit! and$eakin 7niversit!&&and ord /otor -ompan!, along with three of its suppliers, <4 teel 9td., -astrol 4t! 9td., and Imag Australia. #heprogram was created to address some specific needs of the colla"orating partners in the general areas of stamping and sheet metalforming.

As man! other stamping professionals throughout the world do, these partners perceived stamping as a "lack art and "elieved thatpro"lems e(perienced with new or ongoing parts could "e solved onl! "! e(perts with man! !ears of e(perience. While this had "een the






1. Improvement in processNincrease intechnical knowledge "ase in the plant.#his is a ke! outcome. ach thesisgenerated "! the students must have anappendi( of how the results will "eadopted "! the industr! partner.4roCects completed to date havereduced lu"ricant and die coating costs,increased practical understanding offorming "ake&hardena"le steels,ena"led viewing of the deep&drawingprocess as a s!stem, and more.

2. ;ew emplo!ees. #o date, all of thegraduates either have "een emplo!ed"! the partner companies or have goneto supplier organi)ations uponcompletion of their proCects.

>. 4u"lication of academic works. #heindustrial partners recogni)e theacademic partnersM need to pu"lishscholarl! articles. /uch of the work thatis not of a sensitive nature has "eenpu"lished in international Cournals orpresented at conferences. In addition to"eing presented at pu"lic conferences,the work carried out within #A/4 isregularl! reported to the industrial

partners' glo"al head*uarters in the7.. through various technical stamping forums.

While proCect results have significantl! improved understanding of the stamping process in the plant, the most significant outcome has "eenthe development of a knowledge capture and dissemination s!stem called impress. #his s!stem initiall! was developed "! researchengineers in conCunction with the student proCects as a wa! to use proCect results as useful tools in the plant +see Figure 1.

$eveloped in close cooperation with staff and students in the plant, the s!stem now forms the "asis of a wider knowledge&capture s!stemfor stamping operations. It has "een designed to allow knowledge and methods from student proCects to "e incorporated in a modularfashion

Figure 18ne significant proCect result has "een the development of a knowledge capture and disseminations!stem called impress, which initiall! was developed "! research engineers in conCunction with the

student proCects as a wa! to use proCect outcomes as useful tools in the plant.

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