Springs 2014 Vol 53 No1

ROBOTS

WIN

TE

R 2014

2001 Midwest Rd., Suite 106

Oak Brook, IL 60523-1335

Change Service Requested

Prsrt Std

US Postage

PAID

Michigan City, IN

Permit #3

THE INTERNATIONAL MAGAZINE OF SPRING MANUFACTURE A Publication of the Spring Manufacturers Institute / Vol. 53, No. 1NG MANUFACTURE

Robots and the Spring Industry 19

SMI Fall Business Meeting is a Winner 32

Comforting Earthquake Victims 47

2 / SPRINGS / Winter 2014

Passing the Gavel We all know the saying Time ies when you are having fun! It is hard

to believe my term as your leader has come to an end and that this is my nal Presidents Message. I can truly say it has been an honor and an extreme privilege to serve as your president during the past two years. I will always treasure and cherish this time.

Leading the SMI has been a richly rewarding experience in so many ways, but mostly because of the people. Ive been blessed to work with such great folks and to meet so many others around the nation and the world.

Over the past two years, we have developed a strategic plan with the help of a broad representative base of SMI members. The specic initiatives contained in this plan will help our members and the entire North American spring industry improve its global competitiveness. If you are an SMI member, I encourage you to attend our annual conventions and join one of the many operating committees who will help execute these specic strategic plans.

During my inauguration speech two years ago, I shared that beyond my rst two passions (my faith and my family), that my next two passions were manufacturing and relationships. During the past two years, together we have achieved all seven of my goals for the SMI under passion for manufacturing and four of my seven goals for the SMI under passion for relationships. Without a unied team of expert staff and dedicated volunteers, these goals could not have been met.

I want to express my heartfelt thanks to an incredible list of players who are responsible for the achievement of these goals and the ongoing success of the SMI. No organization can sustain excellence without a steady stream of dedicated, committed, hard-working volunteers; at the SMI it has been my pleasure to work with a wonderful executive committee, board of directors, committee chairs and committee members who together have helped to make excellent and sometimes challenging decisions to assure that our organization continues to reach for excellence in all that it does.

In addition to the great pleasure of working with all our wonderful volunteers, I want to extend a very special thank you to Lynne Carr, our executive director. Lynne is the glue that holds this organization together; in all my years of working and volunteering, I can honestly say I have never had the privilege of working with someone more dedicated, more committed and more loyal to an organization than Lynne is to the SMI. As members, we all benet from this!

By the time you read this, I will have just passed the gavel to our new SMI president Hap Porter. I am condent and enthusiastic about Hap leading SMI over the next two years, not only because he is such a wonderful person, but because of his great mind and strong leadership skills. As I step out of the limelight, I wish Hap and the SMI the very brightest of futures!

Forever Grateful,Steve

Steve MorelandPresident, Automatic Spring Products [email protected]

SMI Executive CommitteePresident: Steve Moreland, Automatic Spring ProductsVice President: Hap Porter, SEI MetalTekSecretary/Treasurer: Mike Betts, Betts CompanyImmediate Past President: Scott Rankin, Vulcan Spring & ManufacturingAt Large: Steve Kempf, Lee Spring

SMI Board of DirectorsTom Armstrong, Duer/Carolina Coil Torsten Buchwald, Kern-Liebers USA Ann Davey, John Evans Sons Mark DiVenere, Gemco Manufacturing Chris Fazio, Diamond Wire Spring Kurt Gillespie, Century Spring Richard Guimont, Liberty Spring Gene Huber Jr, Winamac Coil Spring Miko Kabeshita, Ark Technologies Charly Klein, Fox Valley Spring Bill Krauss, Vulcan Spring Don Lowe, Peterson Spring Bill Marcum, MW Industries Richard Rubenstein, Plymouth Spring Dan Sceli, Peterson Spring JR Strok, Mohawk Spring Bill Torres, Gibbs Wire and Steel Jeff Wharin, Bohne Spring

Springs Magazine StaffLynne Carr, Advertising Sales, [email protected]

Gary McCoy, Managing Editor, [email protected]

Dina Sanchez, Assistant Editor, [email protected]

Sue Zubek, Graphic Designer, [email protected]

Springs Magazine CommitteeChair, Richard Rubenstein, Plymouth Spring Reb Banas, Stanley Spring & Stamping Lynne Carr, SMI Raquel Chole, Dudek & Bock Ritchy Froehlich, Ace Wire Spring & Form Bud Funk, Fourslide Products Bill Marcum, MW Industries Brett Nudelman, International Spring Tim Weber, Forming Systems Europe Liaison: Richard Schuitema, Dutch Spring Association Technical Advisors: Loren Godfrey, Honorary Member Dan Sebastian, Honorary Member

Advertising sales - Japan Ken Myohdai, Sakura International Inc. 22-11 Harimacho1-Chome, Abeno-ku Osaka 545-0022 Japan Phone: +81-6-6624-3601 Fax: +81-6-6624-3602E-mail: [email protected]

Advertising sales - EuropeJennie Franks, Franks & Co.63 St. Andrew's Road Cambridge United Kingdom CB41DHPhone/Fax: +44-1223-360472 E-mail: [email protected]

Advertising sales - TaiwanRobert Yu, Worldwide Services Co. Ltd.11F-B, No 540, Sec. 1, Wen Hsin Rd. Taichung, TaiwanPhone: +886-4-2325-1784 Fax: +886-4-2325-2967 E-mail: [email protected]

Springs (ISSN 0584-9667) is published quarterly by SMI Business Corp., a subsidiary of the Spring Manufacturers Institute: 2001 Midwest Road, Suite 106, Oak Brook, IL 60523; Phone: (630) 495-8588; Fax: (630) 495-8595; Web site www.smihq.org. Address all correspondence and editorial materials to this address.The editors and publishers of Springs disclaim all warranties, express or implied, with respect to advertising and editorial content, and with respect to all manufacturing errors, defects or omissions made in connection with advertising or editorial material submitted for publication.The editors and publishers of Springs disclaim all liability for special or consequential damages resulting from errors, defects or omissions in the manufacturing of this publication, any submission of advertising, editorial or other material for publication in Springs shall constitute an agreement with and acceptance of such limited liability.The editors and publishers of Springs assume no responsibility for the opinions or facts in signed articles, except to the extent of expressing the view, by the fact of publication, that the subject treated is one which merits attention.

Do not reproduce without written permission.

Cover art created using images from: iStockphoto.com/3alexd

President's MessageFrom Steve Moreland

SPRINGS / Winter 2014 / 3

Intelligent Process& Quality Control

Since1893...

0)44)0

0)44..

0.

00000

5HPS*OHPU-LUJL4HJOPULZ

;\IL)LUKPUN-VYTPUN4HJOPULZ

>PYL:[YHPNO[LUPUN*\[[PUN

,UK>VYRPUN4HJOPULZ

>PYL)LUKPUN-VYTPUN4HJOPULZ

:WYPUN*VPSPUN-VYTPUN4HJOPULZ


Contents

FEATURES

19 Robots and the Spring Industry By Gary McCoy

27 FlashbackIntroduction to Robotics

By G.C. Macri

32 SMI Fall Business Meeting is a Winner

35 SMI Hosts International Standards Organization (ISO) TC-227 Meeting in Nation's Capital

36 Peterson Spring Celebrates 100 Years

40 Heart and Soul By John Passante

45 JSSE Semi-Annual Lecture Meeting and Awards

47 Comforting Earthquake VictimsMichio Takeda

19

47

COLUMNS

13 Be Aware Safety TipsOSHA Inspections: How You Were Chosen and What to Expect

By Jim Wood

15 IST Spring TechnologyCautionary Tale: Stainless Steel Turns 100 Years Old

By Mark Hayes

DEPARTMENTS

2 Presidents MessagePassing the Gavel

7 Global Highlights

10 Regional Spring Association Report

51 Springmaker Spotlight Leading His Team to Victory:A Profile of Norm Rodriques and Springfield SpringBy Gary McCoy

57 Book Corner

59 Inside SMI

61 New Products

63 Advertisers Index

64 SnapshotJim Callaghan

27

51

SPRINGS / Winter 2014 / 5WWW.RKTRADINGUSA.COM 847-640-9771

CSX & CSX Hybrid From complicated to REALLY difcult spring making requirements, the Herdon CSX Series and CSX Hybrid Series make the difcult easy. Equipped as a standard 16-axis All Servo former they both signicantly reduce set-up times while increasing production rates. Couple that with rotary wire and multiple single and dual servo spinners the impossible suddenly becomes possible at an affordable price. No matter what level of spring making requirement youre being asked to perform, RK Tradings line of CSX and CSX Hybrid machines offer something for everyone and make the difcult easy.

CSX

CSX Hybrid

East Coast Service Center, 100 Benton St., Stratford, CT 06615Tel 203.386.0038 Fax 203.502.6681 www.zapp.com

For over 25 years, Zapp has been providing

the spring industry with the highest quality,

best performing products which far exceed

the industry standards. Our state-of-the-art

mill facility located in Dartmouth,

Massachusetts, offers a convenient supply

chain that insures continuity and reliability.

At Zapp, no matter how we slice it, our

precision quality and outstanding customer

service always shine through.


North AmericaOn November 1, 2013, Lapham-Hickey Steel

Corporation purchased the assets of Industrial Spring Steel. Industrial Spring Steel, located in Philadelphia, Pa., was founded in 1958 and is a supplier of high carbon tempered and annealed spring steel primarily throughout the East Coast.

Lapham-Hickey Steel is a family owned and operated full line service center that was founded in 1926 in Chicago, Ill. The acquisition of Industrial Spring Steel will strengthen Lapham-Hickeys presence and coverage on the East Coast, and as a leading provider of high carbon tempered and annealed spring steels throughout the country.

We couldnt be more excited to welcome Industrial Spring Steel their employees, customers and all partnerships to the Lapham-Hickey family, said Brian Hickey, who will assume the responsibilities of general manager for Industrial Spring Steel in Philadelphia. Lapham-Hickey has a rich history with the Spring Manufacturers Institute and its member companies and we look forward to increasing our service levels to this industry.

David Devoe, operations manager and general manager of Plymouth Spring Company, Inc. in Bristol, Conn., was presented with the annual Quality Recognition Award sponsored by the Hartford Section of the American Society for Quality (ASQ) in June.

Devoe was recognized for his contribution in helping establish Plymouth Springs Lean Journey in 2011 and his achievement results since. During that time, Plymouth Spring has increased their on-time delivery by 20 percent, while keeping reject rates below expectations, and at the same time increasing sales growth by 10 percent.

The Hartford Section of ASQ honors individuals and teams with this award annually for their contributions to their associations and businesses. The American Society for Quality is a 108,000-member professional association headquartered in Milwaukee, Wis. that advances individual, organizational, and community excellence worldwide through quality improvement, learning, and knowledge exchange.

More information on the Hartford Section of ASQ can be found on the sections website www.asqhartford.org.

Kern-Liebers Pieron (KLP) has manufactured precision springs and wire parts in Farmington Hills, Mich. for more than 10 years. On September 7, 2013, they celebrated the opening of a new 25,000 square foot facility near Grand River and Drake, only a few miles from their previous location. The new facility has doubled the production oor space as their previous building, and will allow for business growth into new markets. KLP is excited to be a continuing part of the Farmington Hills community, and proud to be producing quality products competitively in Michigan.

Chicago-based Rolled Metal Products has appointed Steven E. Pearce as general manager. Before joining Rolled Metal Products, Pearce served in a similar capacity for A.M. Castle and Ryerson, Inc., both major processors and distributors of metals. He previously held progressively more senior positions with a global manufacturing company. Pearce holds a bachelors degree in engineering from Lehigh University and a masters degree in business administration from the University of Chicago.

Im pleased to contribute my 30 years of management experience to leading Rolled Metal Products to the next level of business growth in our markets, said Pearce. We will succeed by offering excellent customer service and delivering high value and high quality to our customers at all times.

Vulcan Spring and Manufacturing Co., a leading designer and manufacturer of at steel springs and related assemblies for diverse global markets, has hired Jon Racis as its regional sales manager. Racis will be responsible for eastern U.S. sales for both Vulcans industrial and point of purchase markets.

Global Highlights

iStockphoto.com

/DNY59


Jon adds an exciting amount of drive and experience to our growing sales organization, said Don Jarvie, vice president of sales. He will help Vulcan Spring better serve our clients and to nd new opportunities that will align with Vulcans strengths.

Originally from Wilmington, Del., Racis earned his bachelors in sports management from Wilmington University. He comes to Vulcan Spring from Fastenal Industrial Supply in Delaware.

Connecticut Spring & Stamping (CSS), a manufacturer of precision parts for the aerospace, medical, rearms and defense industries worldwide, announces its capabilities for producing compression springs for rearms from shaped and stranded wire. CSS development and prototyping assistance for both military and commercial rearms helps OEMs accomplish the right spring design, and ensures the springs are durable enough to sustain repeated use.

Using its 70-year history and diverse expertise in developing stranded wire and shaped wire springs, and its knowledge of design formulae for spring rate and equivalent direct (tensile or compressive) stresses, CSS helps OEMs design recoil compression springs that can perform properly in the extremely limited space available in most rearms.

CSS services includes consultation on stranded versus shaped wire, careful selection of wire base material, assistance with wire manufacturing stranding specications to achieve accuracy, as well as extensive development and prototyping to assist the customer accomplish the right spring design.

For further information, please visit www.ctspring.com or call 860-677-1341.

Decatur, Ga.-based Newcomb Spring Corporation has named Daniel (Dan) Tetreault as the new general manager of its New England facility, Newcomb Spring of Connecticut. In this position, Tetreault will oversee day-to-day operations at the plant, lead new business development and assist customers in the manufacture of custom springs, wire forms and stamped metal parts. Tetreault was previously employed at WAFIOS Machinery Corporation, where he served as vice president.

My past experience has been a valuable asset here at Newcomb Spring of Connecticut, said Tetreault. I have an in-depth understanding of CNC, verti-slide and multi-slide forming machinery, and Ive been able to apply those skills so that Newcombs very modern machinery is utilized to its maximum potential.

Tetreault was appointed general manager at Newcomb Spring of Connecticut after a month-long transition period

Global Highlights

Ready,

to Roll,

Reel Time.

For over 25 years, RolledMetal Products has beenproviding JIT delivery service,quality metal and processes,expert technical support andhigh value to its respectedcustomers. With locations inthe Midwest and Northeast,we have all the advantagesyou expect from a leader inthe metal processing industry.

Bensalem, PA 19020800.638.3544215.244.7789 FaxRolledMetalProducts.com

Your Edge Is Our Roll


working with the facilitys previous general manager, Keith Porter, Jr. Porter is now general manager at Newcomb Spring of Carolina.

I m rea l ly enjoy ing my new pos i t ion , a nd t h e N e w c o m b S p r i n g organization, said Tetreault. I think my knowledge of machinery and past metal forming experience allows me to ef fect ively assist customers, while also giving me the ability to control shop

continuous service and been welcomed into the companys 25-year club. Half of the current 32 employees are members of this exclusive club. Q

Top: Brian Russell is pictured standing center with colleagues at Airedale Springs.

Left: Brian Russell, right, receives a parting gift from Airedale Springs commercial director Sean Parkinson.

Daniel Tetreault

oor activity with a hands-on approach. I look forward to providing Newcombs customers with the very best products and service.

A veteran of the U.S. Army, Tetreault received his Bachelor of Science degree in manufacturing engineering from Georgia Southern University. In addition to post-graduate business studies, he also received training in advanced metal form manufacturing in both the United States and Germany.

InternationalBrian Russell has retired after a 44-year career with

Airedale Springs in Haworth, West Yorkshire.Russell, of Oxenhope, joined the company as a

chargehand instructor in 1969, becoming chief instructor a year later with overall responsibility for the training of the companys apprentices. In 1978, he was promoted to training superintendent and in 1980 his role was extended to cover to the supervision of the heavy springmaking department.

In 1983, Brian reverted to having sole responsibility for company training, and three years later, while still maintaining an overview on training issues, his primary role was meeting the needs of Airedale Springs smaller customers through his work in the custom spring department.

Chairman Tim Parkinson said Russell was regularly praised by customers for the personal service he provided and the way he always went that extra mile.

Parkinson commented, Brian is a unique character. He trained the majority of our current staff and many others who over the years have gone on to work in other companies within the area. While he has retired after 44 years of dedicated service, he will certainly never stop being part of the Airedale Springs family.

The company, which last year moved into a new purpose built factory completing a 3.5m investment, is renowned for longevity of service among its workforce.

Since Airedale Springs was founded 68 years ago, a total of 44 employees have completed 25 years of

Global Highlights


WCSMA Closes Out 2013

CASMI Holds SpringWorld Dinner

T h e W e s t C o a s t S p r i n g Manufacturers Association (WCSMA) closed out 2013 with three events. The group held its annual outing to see the Los Angeles Angels of Anaheim on August 3. The group held a tailgating party in the parking lot of Angel Stadium of Anaheim prior to the start of the event.

The WCSMA bi-annual Tabletop Expo was held on Thursday, October 24 at the Holiday Inn in La Mirada, Calif.

The groups golf outing and dinner was held on November 14 at Skylinks in Long Beach.

For more information, visit the WCSMA Facebook page or www.wcsma.us.

Looking toward October 2014, the Chicago Association of Spring Manufacturers (CASMI) held its SpringWorld 2014 Kickoff dinner on Thursday, October 17, 2013 at the Donald E. Stephens Convention Center in Rosemont, Ill.

CASMI executive director Tom Renk said SpringWorld 2014 will feature several new innovations to enhance the experience for attendees and exhibitors. SpringWorld 2014 will be held at Donald E. Stephens Convention Center October 810.

The SpringWorld 2014 kickoff dinner featured a presentation by SMI president Steve Moreland, who said international competition is a reality in todays spring marketplace. He shared his experience of traveling to Europe and learning more about

the composit ion of the worldwide spring market.

After Morelands presentation, special guest speaker, Nick H a l l e y, a r e t i r e d U.S. Army Brigadier General, talked about leadership and the war against radical Islam.

In regards to the subject of leadership, Halley said leaders must improve their leadership quota. He advised that leaders must be good listeners and lead by example all the time.

He concluded his remarks with information from his book, Terrorism The Target is You! The War Against Radical Islam.

CASMI c losed out it s 2013 schedule with its member dinner/holiday party on December 12 at The Great Escape in Schiller Park, Ill.

For more information, visit www.casmi-springworld.org.

iStockphoto.com

/Scott Hirko

Regional Spring Association Report


NESMA Christmas Celebration and Recognition Dinner

By Ted White, Hardware ProductsThe New England Spring and

Metalstamping Association (NESMA) had a record turnout of 166 people for its annual Christmas Dinner on December 5, 2013. George Fournier, the president of NESMA, greeted attendees with a few light hearted

and jocular comments and welcomed several honored guests, including Susan Sadecki, CEO of The Main Street Community Foundation, and Joyce Mowrey and Steven Hanecak from Bristol Technical School.

Thanks was g iven to Cindy Scoville from the Central Connecticut

Chamber of Commerce who ably assists NESMA, and her associates Mary Kuharski and Reiny Malsheske for helping organize the dinner.

The main purpose of the event was to celebrate Christmas and give special recognition to some NESMA members. But because this is one of

Avoid no-bids or timely set up on short runs. CenturySpring is a great source for filling low volume or

prototype demands. Our stock parts shipsame day at a very low minimum.

To learn more or to request a free stock springcatalog, inquire at [email protected] by calling us at (800) 237-5225 Mon-Fri6:00am - 4:30pm PST.

A WORLD OF SPRINGSAvailable in low volume quantities.

Compression Extension Die Disc DrawbarH-Clips Tapered Torsion Urethane

222 East 16th Street, Los Angeles, CA 90015ph 800-237-5225 fx [email protected] www.centuryspring.com/smi


only two general gatherings per year, NESMA used the opportunity to bring members up to date on recent efforts.

NESMA has been working to coordinate fragmented efforts to improve technical education in the Bristol area. Members were advised that this was a problem that neither the educators nor the legislators could solve. It is a problem that the entire membership needed to get involved with if they wanted to see workforce improvement.

It was pointed out that it is ludicrous for parents and educators to steer high school students only into college preparatory programs, when the reality is that some will attend college, graduate with $150,000 in debt, and end up unemployed. At the same time, the manufacturing industries in the area are screaming for educated technical employees.

Recognition was given to several individuals, including Joe Panella and

Regional Association Report

Bobby Cox from North American Spring Tool. Both Joe and Bobby have long been noted for their dedication to the spring industry while conducting their business in the most gentlemanly way. Mark DiVenere captured these many years of history in a most accurate way during his presentation of the award.

Bill Waseleski of Century Spring made the next presentation to Doug Johnson. Doug is a tireless individual who is involved in many efforts to create technical education and serves on many boards to advocate this. Doug, in a humorous acceptance speech, said that he had the unfortunate luck of sitting at a table with his two female superiors and his wife who were all telling him what to say and how to say it.

Bil l Lathrop then presented Loren Godfrey with an award for his professional accomplishments over the years. Now semi-retired, Loren is

still available to help springmakers through SMI when needed.

Bill Lathrop then presented the next award to yours truly for Diligent and Tireless Efforts to Improve the Recognition of the Spring Industry and NESMA. Consider ing the eminence of the other honorees I was not sure that I belonged in the same group. However it certainly meant an awful lot to me to be honored by my peers and to be included in such a well-respected group.

To conclude the festivities George Fournier once aga in caut ioned NESMA members that the problem of future manufacturing employees was all ours and that it would be in our best interests to collaborate and begin solving the problem together.

For more information on NESMA, visit www.nesma-usa.com. Q

&$60,LVSURXGWRFKHHUIRUDOORIWKH&KDPSLRQVRIWKH6SULQJ0DQXIDFWXULQJ,QGXVWU\0DQXIDFWXUHUVDQG

6XSSOLHUV

:HUH3URXGWR%HRQ


Jim Wood is an independent regulations compliance consultant to the Spring Manufac-turers Institute (SMI). A certified instructor of the OSHA Out-Reach Program, Wood conducts seminars, plant Safety Audits and In-House Safety Trainings. These programs help com-panies create safer work environments, limit OSHA/Canadian Ministry of Labor violations and insurance costs, and prepare for VPP or SHARP certification. He is also available for safety advice and information by phone at 630-495-8588 or via e-mail at [email protected].

OSHA Inspections: How You Were Chosen and What to ExpectBy Jim Wood

Be Aware Safety Tips

It is a misconception that OSHA picks companies at random. It is true, however, that they conduct inspections without advance notice. OSHA focuses their inspection resources on the most hazardous workplaces in the following order of priority:

1. Imminent Danger Situations hazards that could cause death or serious physical harm receive top priority. Compliance ofcers will ask employers to correct these hazards immediately, or remove endangered employees.

2. Fatalities and Catastrophes incidents that involve a death or the hospitalization of three or more employees come next. Employers must report such catastrophes to OSHA within eight hours.

3. Complaints allegations of hazards or violations also receive a high priority. Employees may request anonymity when they le these complaints.

4. Referrals of hazard information from other federal, state or local agencies, individuals, organizations or the media receive consideration for inspection.

5. Follow-ups checks for abatement of violations cited during previous inspections are also conducted by the agency in certain circumstances.

6. Planned or Programmed Inspections inspections aimed at specic high-hazard industries, or individual workplaces that have experienced high rates of injuries and illnesses, also receive priority.

When an OSHA inspector appears at your front door, the rst thing you should do is ask for his/her credentials, which include both a photograph and a serial number. If you have any doubt about their identity, call the local OSHA area director and get conrmation that the person is indeed an inspector.

Opening Conference The compliance ofcer will explain why OSHA selected your workplace for inspection and describe the scope of the inspection, walk around procedures, employee representation and employee interviews. The employer then selects a representative to accompany the compliance ofcer during the inspection. An authorized representative of the employees, if any, also has the right to go along. In any case, the compliance

ofcer will consult privately with a reasonable number of employees during the inspection.

Walk around Following the opening conference, the compliance ofcer and the representatives will walk through the portions of the workplace covered by the inspection, inspecting for hazards that could lead to employee injury or illness. The compliance ofcer will also review worksite injury and illness records and posting of the ofcial OSHA poster.

During the walk around, compliance ofcers may point out some apparent violations that can be corrected

iStockphoto.com

/oytun karadayi


immediately. While the law requires that these hazards must be cited, prompt correction is a sign of good faith on the part of the employer. Compliance ofcers try to minimize work interruptions during the inspection and will keep condential any trade secrets they observe.

Closing Conference After the walk around, the compliance ofcer holds a closing conference with the employer and the employees representative to discuss the ndings. The compliance ofcer discusses possible courses of action an employer may take following an inspection, which could include an informal conference with OSHA or contesting citations and proposed penalties. The compliance ofcer also discusses consultation and employee rights.

Results OSHA must issue a citation and proposed penalty within six months of the violations occurrence.

Citations describe OSHA requirements allegedly violated, list any proposed penalties and give a deadline for correcting the alleged hazards. Violations are categorized as other than serious, serious, willful, repeat and failure to abate. Penalties may range up to $7,000 for each serious violation and up to $70,000 for each willful or repeat violation. Penalties may be reduced based on the employers good faith, inspection history, and the size of the business. For serious violations, OSHA may also reduce the proposed penalty based on the gravity of the alleged violation. No good faith adjustment will be made for alleged willful violations.

Appeals When OSHA issues a citation to an employer, it also offers the employer an opportunity for an informal conference with the OSHA area director to discuss citations, penalties, abatement methods, abatement dates or any other information pertinent to the inspection. The agency and the employer may work out a settlement agreement to resolve the matter and to eliminate the hazard.

Alternatively, employers have 15 working days after receipt of the citation and proposed penalties to formally contest the alleged violations and/or penalties by sending a written notice to the area director. OSHA forwards the contest to the Occupational Safety and Health Review Commission for independent review. Alternatively, citations, penalties and abatement dates that are not challenged by the employer or settled, become a nal order of the Occupational Safety and Health Review Commission.

Jims Regulatory Tip:Designate a key management employee that is well

versed in OSHA inspection procedures to accompany the compliance ofcer during every step of the inspection. This employee should ask the compliance ofcer to explain every alleged violation found and record all information about the alleged violation. At the end of the day your representative should have a duplicate list of everything cited by the compliance ofcer. The best rule when accompanying the compliance ofcer is ask questions, give truthful answers to questions asked, but volunteer nothing. Q

Join the best welcome to the worlds leading trade fair for the wire and cable industry! To find comprehensive information about the latest innovations in wires and cables, manufacturing machinery and equipment, look no further! It is all on display at the worlds most important exhibition the meeting point for international experts, specialists and global market leaders. A focal point at wire 2014: The growing importance of copper wires in automotive engineering, telecommunications and electronics.

An important date in your calendar your visit to wire 2014 in Dsseldorf!

Meeting point: wire 2014 in Dsseldorf!

join the best7 11 April 2014Dsseldorf, GermanyInternational Wire and Cable Trade Fair

www.wire.de

Wire, Cable,Fibre Optic,Wire Productsand Machinery

FastenerTechnology

Mesh Welding Machinery

Spring Making

For show information: Messe Dsseldorf North America 150 North Michigan Avenue

Suite 2920 _ Chicago, IL 60601Tel. (312) 781-5180 _ Fax (312) 781-5188

[email protected] _ www.mdna.comFor hotel and travel arrangements: TTI Travel, Inc.

Tel. (866) 674-3476 _ Fax (212) 674-3477


IST Spring Technology

Mark Hayes is technical advisor to the Insti-tute of Spring Technology (IST) in Sheffield, England. He is also the principal trainer for the spring training courses that the Institute offers globally. Readers are encouraged to contact IST with comments about this cautionary tale, and with subjects that they would like to be addressed in future tales - e-mail [email protected]

Cautionary Tale:Stainless Steel Turns 100 Years OldBy Mark Hayes

Did you know stainless steel was invented 100 years ago in Shefeld, which is the headquarters town for IST? For those interested in more information on this important spring material, there is an excellent new book written by Shefeld metallurgist Dr. David Dulieu entitled Stay Bright. The book describes the history of stainless steel from it invention by Harry Brearley to its current use today.

The last cautionary tale discussed the oxide which forms naturally on stainless steel and how that oxide confers corrosion resistance. This prompted the idea that the various types of stainless steel should be described. They all have a layer of chromium oxide providing corrosion resistance. There are four distinct types of stainless steel. Two are excellent for spring production, but the other two are not.

The type of stainless steel invented by Harry Brearley contained 13 percent Cr (chromium) and 0.25 percent C (carbon), and becomes corrosion resistant after it has been hardened and tempered to a martensitic microstructure. At rst sight this might seem ideal for springs because it is corrosion resistant and has high strength.

Martensitic stainless steel is used for manufacturing knives and surgical instruments, industries for which Shefeld remains famous today. However, martensitic stainless steel has a fatal aw that makes it a very unlikely choice for making springs. It is not very corrosion resistant, so even a slight trace of corrosion which will cause this type of stainless steel to fail by stress corrosion cracking. That is the rst moral of this cautionary tale do not be tempted to use martensitic stainless unless you are certain that its corrosion resistance is good enough.

For springs, a stainless steel is needed that will repair its oxide lm in the event of slight corrosion before it fails. Stainless steel with 18 percent Cr and 8 percent Ni (nickel) has better corrosion resistance than the martensitic type. It has a microstructure of austenite, which needs to be cold worked to acquire spring strength. The microstructure is austenite prior to the start of the wire drawing process, but during wire drawing some of the austenite transforms to martensite, and this is what makes this grade slightly magnetic. The predominant microstructure remains austenite though, and this type of stainless steel is the most frequently used for springs everywhere in the world today.

The 18/8 stainless steel is usually called 302 or 304 type. There are two variants in common use. One is 316 type, which has 2 to 3 percent Mo (molybdenum) added for improved corrosion resistance, especially in salt environments. The other variant is 17/7PH (type 631), which has 1 percent Al (aluminium) added for precipitation hardening, and hence a strength level higher than 302 type.

Today, there are two other types of stainless steel, again both named for their microstructure. There is ferritic stainless steel, which has very good corrosion resistance, but not the high strength needed for springs. This is the type of stainless used for car exhausts.

Finally, there is duplex stainless steel, which has a duplex microstructure of ferrite and austenite, which is very corrosion resistant especially when molybdenum

iStockphoto.com

/DSGpro


(Mo) is an alloying element, and it may be drawn to high strength levels, hence conferring excellent spring properties. IST predicts that duplex stainless steel will gradually replace 316 as a spring material because it outperforms the latter with respect to corrosion resistance and strength levels.

All of these stainless steels contain at least 12 percent chromium. It is often said that their corrosion resistance is due to the formation of chromium oxide on their surface, something that happens naturally in air at room temperature. That is certainly true. However, the very

photoelectron spectrographic studies have shown that there is almost no Mo present in the oxide there is concentration of Mo below the oxide, but how does that help? This leads to the second moral of this cautionary tale the precise explanation for the corrosion resistance of stainless steels is, as yet, incomplete. This fact should keep metallurgists employed for some years to come. Q

Finally, there is duplex stainless steel, which has a duplex microstructure of ferrite and austenite, which is very corrosion resistant especially when molybdenum (Mo) is an alloying element, and it may be drawn to high strength levels, hence conferring excellent spring properties. IST predicts that duplex stainless steel will gradually replace 316 as a spring material because it outperforms the latter with respect to corrosion resistance and strength levels.

thin oxide on each type of stainless steel differs slightly, and, despite being only nanometers thick, is always made up of several oxide layers. Hence, there are differences in the corrosion resistance of the four types of stainless steel.

One thing that has always puzzled the industry is the fact that molybdenum (Mo) additions will invariably improve the corrosion resistance of stainless steels. So one might ask how the Mo affects the oxide, and X-ray

alloy wire international 205 Hallene Road, Warwick, RI 02886, USA

Call Toll Free: 1-866-482-5569fax: 401-384-6757email: [email protected]

www.alloywire.com

Inconel Phynox MP35N Hastelloy Monel

The leading brand alloy wire, are suppliers to designers of springsand engineered parts in any quantity from small to large...

...tailor made to fit your order perfectly.

Wire to resist intense corrosion and high temperatures.


$'75$',1*//&6SULQJ&RLOHUV:LUH%HQGHUV$XWR'HFRLOHUV6&$'$6\VWHPV

$'75$',1*//&6RXWK0DLQ6WUHHW5RFN&UHHN2KLR86$VDOHV#DGWUDGLQJOOFFRPZZZDGWUDGLQJOOFFRP


ROBOTSand the Spring Industry

he term robot conjures up a lot of images and ideas. Baby boomers might remember back to the days of Rosie, the household robot in the animated television show The Jetsons or HAL (Heuristically programmed ALgorithmic computer) 9000 in 2001: A Space Odyssey. While those types of robots are the lore of science ction, they bear little resemblance to the ones being used in industrial manufacturing settings such as the spring industry, where wire is coiled to make springs or bent to form wire parts. This article will attempt to take robots from the realm of TV, books and movies into practical applications for manufacturing.

T

A Fanuc M16 robot using dual Schunk PZN style grippers and ATI Robotic Tool Changer loads a part into the spindle of a Haas SL-20

lathe. The air blow nozzle is used to clear jaws of dirt and swarf prior to load.

Article photos provided courtesy of Productivity, Inc. and are used by permission.

By Gary McCoy


ISO 9001:2008FHUWLILHG

0$3(63,$12675,1*&203$1

Date post:	16-Nov-2015
Category:	Documents
Upload:	carlonewmann
View:	35 times
Download:	4 times

Springs 2014 Vol 53 No1

Documents