“Now, with tool changes occurring multiple times per day in many cases, metalformers cannot accept long changeovers,” says Dixon. “That’s too damaging to their productivity and profitability.” Referencing the above-mentioned example, “Consider a 15,000-lb. tool that a human never has to touch. The automation brings safety gains while increasing efficiency across the board. The press line maintains continuous production as opposed to idling while humans load the next tool. We are seeing a dramatic increase in metalformers asking about QDC.”
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2) Robotic Part Loading/Unloading
“Robots commonly are used to automate repetitive tasks and those that would be boring and tiresome to humans,” Dixon says. “The types of robots used vary depending on the application, cycle-time requirements and other specific metalformer needs.”
While traditionalists may believe that robotic part handling requires a fully functional six-axis industrial robot flying around a fully guarded cell, new robot technology offers simplicity and cost savings.
“The recent introduction of collaborative robots, or cobots, provide a lower-cost alternative for applications with less demanding cycle-time requirements,” says Dixon. Although introduced a number of years ago, cobots recently have become more accepted among the manufacturing community.
When to Automate? The Rules Have Changed
A host of factors determine whether to automate a press line and to what extent. This isn’t news. What is news: Automation makes sense in more situations than it used to.
“Most people associate automation with increased speed and throughput, which mostly is true, but automation provides benefits beyond that,” says Josh Dixon, director of sales and marketing for Beckwood Press Co. He notes that safety factors such as repetitive motion, ergonomics and the need to transport heavier weights are, and always will be, prime drivers for automation.Automation traditionally has been applied to processes with well-defined work rules and little variation in parts and procedures. But new technology advancements allow automation to better accept variability.
“Some process variability can be overcome through the use of vision systems, sensors and other quality-control devices incorporated into the automation,” Dixon says, while noting that at some point excessive variability will negatively impact ROI. “Also, presses can better interact with automation add-ons, allowing for more seamless and effective integration than ever before. Press builders such as Beckwood deliver presses with compatibility and the ability to expand built in.”
Another factor that demands a new look at automation options is cost.
“Manufacturers still tend to think that automation often is too expensive,” says Dixon. “What might have been too expensive five years ago is worth checking out again. Increased competition within the industry has resulted in decreased costs, and technology gains have allowed for more ROI-friendly automation than in the past.” This, too, requires metalformers to re-examine automation in their press lines.
3) Part-Transfer Systems for Progressive Dies
Many metalformers are seeking automated transfer systems for parts, particularly within progressive dies, reports Dixon.
“Each station performs different functions, and automated transfer allows a part to travel quickly through multiple steps within the progressive die,” he explains. “With a linear transfer system, you can move a part efficiently through die stations, allowing the press to cycle as quickly as possible. Automated systems can transfer each part in a single motion, thus providing quick transfer and press-cycle times. Many metalformers continue to rely on hand-transfer, but automated transfer can boost productivity significantly while improving operator safety.”
4) Quality ControlAnother area of demand among metalformers is press-line quality-control, with automated systems integrated into a press itself.
“The increasing image quality of industrial cameras generates a clearer view of part details by vision systems,” Dixon says. “Presses today can be equipped with vision systems that closely monitor parts as they exit the press, checking dimensions and looking for cosmetic defects or checking that a part is properly oriented for processing in a secondary operation. These automated quality-control systems are unbiased, repeatable, and can check parts in milliseconds without increasing production time.”
5) Machine Monitoring and Reporting
Though not normally considered as automation, machine monitoring and reporting most definitely can increase press-line productivity.
“Metalformers require more control over their processes than ever before,” says Dixon. “To get that control they need data, but gathering data is not enough.”
He believes that mountains of data without context cause many metalformers to fall off of the Industry 4.0 and IoT bandwagon.
“A machine can provide any kind of data that you want,” Dixon explains, “but how you analyze and react to that information is what’s important. Press builders such as Beckwood partner with control providers to supply smart machines that not only compile but analyze data and report the information in digestible formats that can result in quick action from plant management."
Machines can track many things including productivity, part quality and downtime.
“For example,” says Dixon, “on a Beckwood press, downtime data could include operator-supplied reasons for downtime as well as machinery production logs over a specified period of time. Results are sent proactively to management where the data are analyzed to uncover the source of the inefficiency such as material shortage, inefficient operators, maintenance issues, etc. It’s not just numbers in an Excel file; it’s actionable intelligence.”
Such information pays dividends in many ways.
“How do you justify to your boss the need to automate die changes?” Dixon asks. “It’s much easier if you have a year’s worth of data showing 800 hr. of lost production due to die changes, as in the case of our QDC example.”
Predictive maintenance is another area where smart machines shine.
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“Take the case of a heated platen press,” Dixon offers. “These presses employ multiple electric heating rods with elements that periodically must be replaced. Traditionally, the operator would only become aware of a faulty element by performing temperature checks on a platen or recognizing that part quality was diminishing. That’s an inefficient, reactive way of discovering an issue. From there, the operator would contact the maintenance department, which would have to troubleshoot to find the cause, then contact the machine OEM for a replacement part. It’s a long, drawn-out process.”
A predictive-maintenance system, like Beckwood’s PPM, offers Dixon, eliminates that lengthy process.
“Using integrated machine intelligence such as this, presses can pinpoint the issue, notify the operator, maintenance personnel and machine OEM, and identify the replacement part needed,” says Dixon. “This streamlines maintenance issues and increases machine uptime.” MF
See also: Beckwood Press Company
Updated 10/28/
Metal stamping has revolutionized the manufacturing industry, enabling the production of high-quality metal components with remarkable efficiency. As a cornerstone of modern manufacturing, the metal stamping process has become critical for creating precise metal parts that meet the ever-growing demands of various sectors.
From the intricate components in automobiles and aircraft to the essential parts in electronics and medical devices, metal stamping plays a vital role in precision manufacturing processes for products people depend on daily. In this article, we explore the fundamentals of metal stamping, including different metal stamping techniques and the metal stamping process.
Sheet metal stamping involves using dies and presses to transform flat metal sheets into desired shapes and forms. The process starts with designing custom dies, typically made from hardened steel or carbide, with a negative impression of the desired part shape. These dies are then mounted onto a stamping press.
The metal sheet, often fed from a coil, is placed between the die and the press. The press applies immense pressure to force the metal to conform to the shape of the die. The amount of pressure applied depends on factors such as the thickness and type of metal and the complexity of the part design.
The metal stamping process involves various techniques to create parts with different levels of complexity, precision and size. The technique choice depends on the specific requirements of the part being produced, such as its intended use, desired features and production volume.
Metal stamping is compatible with various materials, including steel, aluminum, copper, brass and titanium. The selection of material depends on the specific requirements of the part, such as strength, weight and corrosion resistance. For example, steel is often chosen for its high strength and durability, while aluminum is preferred when lightweight components are required.
The metal stamping process also creates parts with various finishes and coatings, which can enhance the appearance, durability and functionality of the final product. These finishes and coatings can include painting, plating, anodizing and powder coating.
The metal stamping industry uses diverse techniques to achieve different results depending on the complexity and specifications of the part needed. Four of the most common metal stamping techniques include:
This technique uses multiple dies, each performing a specific operation on the metal sheet as it progresses through the stamping process. Progressive die stamping is ideal for producing complex parts with high precision and consistency, making it well-suited for automotive, electronics and medical device manufacturing. It also has high production rates and reduced material waste.
In transfer die stamping, the metal sheet is transferred between multiple dies, each responsible for a specific forming operation. This process is beneficial for larger parts that require numerous forming steps and is commonly used in the automotive and aerospace industries.
Four-slide stamping is a technique that uses four sliding tools, which move independently to form the metal sheet from four different directions. It produces smaller, intricate parts with complex bends and shapes, making it valuable for electronics and consumer goods.
Deep draw stamping involves using a punch and die to create deep, cup-like shapes from flat metal sheets. It creates parts with high depth-to-diameter ratios, which are difficult to achieve with other stamping methods. Deep draw stamping is commonly used in producing household appliances, automotive components and packaging materials.
The sheet metal stamping process typically involves several key steps, each contributing to creating a high-quality metal component.
The sheet metal stamping process begins with designing the desired part using computer-aided design software. Once the design is finalized, a custom die is created to match the part’s specifications. The die is made from hardened tool steel or carbide and is precision-machined to ensure accurate and consistent part production.
The appropriate metal sheet is selected based on the part’s requirements, such as strength, durability and corrosion resistance. Other factors considered are the part’s intended use, operating environment and cost constraints. Choosing the right material is essential for achieving the desired performance and the longevity of the stamped part.
Blanking is the process of cutting the metal sheet into the desired shape, removing excess material and creating a flat blank. It is performed using a blanking die, which consists of a punch and a die. The metal sheet is placed between the punch and die, and the punch is lowered to shear the metal along the desired outline.
Forming involves using dies and presses to apply pressure and deform the metal into the required geometry. Various forming techniques are used depending on the part’s complexity and the end product’s requirements. Standard forming operations include bending, drawing and stretching.
Bending involves using a die to fold the metal along a straight line. Drawing uses a punch and die to create a three-dimensional shape by stretching the metal over the die. Stretching applies tension to elongate the metal and make shallow, curved shapes.
Trimming uses a trimming die to remove the excess material around the perimeter of the part, creating a clean and accurate edge, while piercing makes holes, slots or other openings in the part.
The final step in the sheet metal stamping process is finishing, which enhances the stamped part’s appearance, durability and functionality. Standard finishing operations include deburring, cleaning, polishing and coating.
Metal stamping finds extensive applications in precision manufacturing processes across various industries:
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