Let me explain. My current job responsibilities involve advance product engineering with a primary focus on developing niche automotive components. When a new product program begins, the customer provides each supplier competing for the new business with a set of engineering performance requirements. These requirements may include specifications similar to the following: The new product must fit in the allocated vehicle space (referred to as packaging). When force X is applied at angle W the resulting deflection must not exceed Y. The normal force required to make the movable portion of the product slide must be less than Z. When the product is subjected to temperatures of 100 C, the force required to make the movable portion slide shall be less than two-times Z at room temperature. When subjected to lifecycle testing, the product must not fail below one million cycles. The new product must use standard bearings from the ABC Company.
Goto Aomate to know more.
This represents the birthing process for an engineered product.
It would not be unusual to receive 10, 20, 30 or more requirements, depending on the product's complexity. Each supplier uses the requirements to create concepts for its own unique design in preparation to bid on the project. Each supplier evaluates the grade of materials to use based on the applied loads, temperatures and the number of stress cycles. Lubricants are selected based on sliding efforts, temperature conditions and material compatibility. Design trade-offs are evaluated in order to meet the performance requirement (e.g. a larger-sized product functions better, but if it does not fit the space allocation it's unacceptable). The most competitive bid that meets all of the design requirements wins the business.
Now let's look at how we buy dies. 'Here's a part print and my die design standards. Quote the die out of D2 tool steel (yes, it's on page 4 in our standards). Heattreat the die sections to the specifications on page 10. Make sure all of the forming blocks have keys and heel blocks, just like it says on page 25. All of the strippers must have removable windows so that the punches can be removed in the press (page 36, I think). The die must fit press number 100 and you must use AAA brand die lubricant. You'll find the lube in our standard because it's the only kind we have in the shop. And don't forget, if you want my business you have to be the lowest bidder and guarantee me that the die will produce the part to print. Oh, and one last thing, do you think I could get a quote back by tomorrow?'
Similarities and differences between these two scenarios are remarkable.
First, the similarities. Both the automotive component and the die are manufactured products; both have well-written and explicit requirements; both are being competitively bid; both are unique one-of-a-kind designs, even though a similar design may exist for each; each is subjected to stresses and deflections; both have sliding mechanisms; both require high-temperature performance; both require lubricants; both must fit into pre-allocated spaces (vehicle packaging and press bed); and both require the use of standardized products.
But the real story is in the differences. The automotive product is purchased based on meeting a set of performance requirements. The die is purchased based on meeting a set of design standards, totally independent of performance.
You may be thinking that performance requirements like these are unnecessary. You're confident that your company's tooling standards, if followed properly, ensure that the required performance is met for any die that is built. Well if that's true, then the majority of the tools you purchase are over-engineered (and over-priced) because your standards were written to accommodate extreme, worst-case conditions. Does your application really require D2, or would less expensive, more easily welded tool steel suffice? Are you sure that you want to accept the finished die based on making a part to print? Dimensional compliance does not ensure that the manufacturing process is stable. Excessive thinning can be occuring even as the part checks dimensionally correct. When the part splits open in service, will your customer be satisfied that the die produced a part to print?
The problem with most die standards is that they are function-based. That is, the design requirements are based on the function (operation) of the die. There are procedures, materials and heattreatment specifications for draw operations, another set of requirements and specifications for piercing and blanking, and still other requirements for forming, coining and flanging operations.
I often make reference in my columns and seminars that we must replace our traditional die-designing practices with die-engineering practices in order to remain competitive. Engineering is based on science, and mathematics and is driven by data and analysis. The following example illustrates this difference:
An engineered die would have performance requirements similar to the engineered automotive product. Again, there could be 20, 30, 40 or more requirements for any given tool. Here is a small sampling: Tipping moments must be calculated for all tools; the tipping moments shall not exceed X in.-tons. Snapthrough forces (negative tonnage) shall be calculated and compensated for in each tool; the snapthrough forces shall not exceed negative-Y percent. Expended flywheel energy shall not exceed 8 percent per hit on progressive dies and 20 percent per hit with single-hit deep-draw tooling. Tool-steel selection shall be based on achieving the following minimum requirements under the agreed-to operating conditions: 50,000 hits between die sharpening and 150,000 hits between radius polishing on form steels. Pierce-punching pressures must be calculated for each tool; when punch-head pressures exceed 20,000 psi, hardened backing plates must be used. Under no circumstances shall punch-head pressures exceed 40,000 psi. Pierce punch-point pressures must not exceed 60 percent of the punch body's compressive strength. The final stamping must have a minimum of 2-percent biaxial stretch throughout the panel. Thinning strains must not exceed 20 percent in the critical zone identified on the part drawing.
I refer to theses as 'Performance-Based Die Standards.' These requirements truly fit the definition given earlier for the term 'standard': An acknowledged measure of comparison for quantitative or qualitative value. Each requirement can be measured, compared and evaluated. These requirements not only ensure the integrity of the tooling but also the press equipment by addressing tipping moments, snapthrough forces and flywheel energy requirements.
It may not be long before die-performance requirements like these begin emerging. If you want to get a head start, check to see how your current die standards stack up against performance-based die standards. Oh by the , there's a trash can in the corner. MF
Technologies: Tooling
Precision metal stamping is an industrial design process that involves turning metal sheets into the needed sizes and shapes. It ensures a cost-effective and fast production of precision metal parts for vehicles, electronics, industrial engineering, airplanes, and more. Metal stamping dies are precision tools that aid in shaping and cutting sheet metal parts.
These tools are developed through computer-aided design software to prove high accuracy and the best designs. The resulting designs are transferable to the stamping dies by skilled personnel known as diemakers. However, designing precision metal stamping dies involves some crucial factors you must adhere to.
What Is Precision Metal Stamping?
It's a manufacturing or industrial process that uses high-end machinery fitted with dies to transform flat metal sheets into a coil or blank. These then form different custom shapes used in several industrial manufacturing processes. This process is mostly applicable in producing large numbers and various products. It's applicable in two main stages:
A single-stage operation ' in this stage, each stroke of the pressing produces a desired shape or design on the metal sheet.
A series of stages is where the metal press can produce several shapes on the metal sheet to meet the custom shape.
Contact Us To Learn More About Our Precision Metal Stamping Services
Things To Consider When Designing Precision Metal Stamping Dies
When designing precision metal stamping dies, you need to ensure the production of precision metal parts. However, to ensure you get the best result, you can dwell on the following factors:
1. Tensile Strength
The company is the world’s best stamping die technologies supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
This is the amount of force any material can withstand without breaking. Metals come in different strengths; some are pretty much stronger than others. This usually depends on the components of the materials in the metal alloy. The metal you choose to work with should have the strongest tensile strength. This is so that it can withstand any amount of force you apply while in use.
2. The Work Hardening Rate
The temper changes through metal stamping, making the metal more brittle or harder. The rate at which this process occurs is what's known as work hardening. Depending on how much work you need to be done on the metal and in any operation, the metal may require annealing. This is the process of resetting the metal's properties so that it doesn't break or crack and prevents other material imperfections.
3. High Level of Quality And Quantity
The manufacturing industry faces increasing competition daily. As a result, this has pushed the precision metal stamping industries to focus more on quality and quantity. Therefore, meeting the accuracy specifications is an added advantage. Moreover, applying this to designing precision metal stamping gives room for achieving a high volume of exact specifications. This also makes precision metal stamping one of the most popular and preferred processes over others.
4. The Types Of Materials Used In Stamping
The materials used in precision metal stamping play a significant role. This is because it helps decide the amount of force necessary for cutting to achieve a desired shape or outcome. Some of the common materials you could use include:
Ferrous metals
Precious metals
Specialty metals,
Non-ferrous metals
5. Productivity And Run Times
Precision metal stamping has an amazing production rate and chances for incorporating any additional services in operation. In addition, the precision metal stamping process is automated; this can, in turn, produce hundreds of parts per hour. Therefore, productivity and run times play a huge role in ensuring efficiency in the long run.
6. Ductility And Formability
Forming and cutting are types of die-stamping operations. Forming usually occurs between the tensile strength of the material and the yield strength. If the yield strength is low, forming doesn't occur. However, exceeding the tensile strength results in a material fracture. There is usually a small window between the tensile and yield when using high-strength materials.
The grain size of a material determines its formability. A consistent grain size gives high desirability for the forming operations. On the other hand, the grain size is controllable by a re rolling mill within a close range. This is done by monitoring the annealing furnace temperature and the strip's speed as it passes through the line.
7. Machinability
This is the ease by which a material can easily be shaped or cut. The machinability of the material you choose to work with should come after choosing other requirements that will satisfy your part. This is because the properties responsible for improving the material's performance can easily reduce its machinability. For instance, a machinable material is easy to cut and gives a beautiful finish, reducing costs. However, you must choose a material that will meet all the requirements for your desired part rather than focusing on the machinable aspect of the material.
Precision metal stamping capabilities are common and preferred over other industrial processes. With your requirements in mind, you can create a personalized precision metal stamping effect that's cost-effective, efficient, and effective to aid in driving your business to the next level.
Ujjwal handles crucial roles like AGM Marketing, researcher, and is an author for KDDL ' Eigen. He currently works with Eigen for implementing proven techniques and strategies for marketing plans on online and offline platforms. An expert in efficiently executing SEO, SEM, marketing, social media marketing, PR marketing, Print campaigns, etc. Ujjwal has coordinated an efficient marketing team on various creative campaigns and programmatic buying to support various digital cross-promotion efforts. Implement efficient search optimization strategies with the help of collateral material and metrics.
In his former years, Ujjwal has years of experience in a managerial role for several reputed companies. His years of experience combined with the flair of writing help him come up with result oriented strategies for Eigen.
If you are looking for more details, kindly visit 300 ton stamping hydraulic press.