In-Die Fastening Pays Off at PWO Canada

This stamper employs in-die technology to attach fasteners to an automotive bracket at high speeds, heading off assembly concerns and improving productivity and part quality.

PWO Canada stamps a horseshoe-shaped mounting bracket with a total footprint of 13 by 14 in. (depicted above) that supports a cross-car beam and also mounts an optional heads-up display unit in a luxury automobile. A new in-die fastening system such as that shown here installs—from the bottom—three flush-mounted nuts on the bracket in a 600-ton progressive-die application at high speed. Flush mounting allows for a simplified part without extra forming and embossing needed to place a non-flush-mount nut.

PWO Canada, a Tier One and Two stamping supplier to the automotive marketplace, operates with 125 employees out of a 145,000-sq.-ft. plant in Kitchener, Ontario. Core competencies include complex metalforming and deep-draw applications, courtesy of presses in capacities to 600 tons for progressive-die work and deep-draw transfer presses to 1200 mtons. In addition, PWO Canada specializes in rollforming and joining technologies such as gas-metal-arc and resistance welding, friction welding, laser welding and in-die secondary processes.New equipment and techniques for one in-die process, fastener insertion, has helped the company avoid assembly problems and gain valuable production speed.

Flexible System Added

Already experienced in using in-die-fastening technology, PWO Canada recently opted for the Pemserter in-die fastener feeding system and fasteners from PennEngineering, Danboro, PA, for a set of German OEM parts. The Pemserter in-die system, consisting of die tooling, fastener-feeding-system module and dispensing module, can be configured to feed nuts, studs or standoffs for multiple or single insertions, usually at the same speed as the stamping press.

As is typical with all in-die processes, employing fastener insertion within the press brings numerous advantages including elimination of costly and time-consuming secondary operations, improved quality, increased productivity, reduced work in process and reduced floor-space requirements.

One part PWO Canada supplies to the OEM, a horseshoe-shaped mounting bracket with a total footprint of 13 by 14 in., supports a cross-car beam and also mounts additional equipment to the dashboard carrier.

Flush-Mount Fasteners Ease Assembly Headaches

Each lefthand and righthand part, known as a HUD supporting frame, uses three nuts.

“The negative effects of other fastener designs was the embossing and forming required on the steel surfaces to allow clearance for the fastener,” explains Lew Carlton, sales and project manager at PWO Canada, who was responsible for sourcing a new in-die-fastening system and facilitating its design and launch. “This recess then would cause mounting problems with the method designed for installation.”