Page 36 - MetalForming May 2009

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MetalForming 2007 Feature Articles
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Metal Stamping by Design
By Larry Crainich
These articles focus on tooling issues that metal stampers, tool- maintenance personnel, and tool designers and builders wrestle with every day.
The Science of Forming, Vol. 1
By Stuart Keeler, ScD, President, Keeler Technologies, LLC
Articles help stamping-plant engineers and managers overcome problems related to springback, tool design and other formability issues. Also included are articles on advanced high-strength steels.
The Science of Forming, Vol. 2
By Stuart Keeler, ScD, President, Keeler Technologies, LLC
This CD-ROM includes dozens of MetalForming magazine columns on springback, tool design and material formability. Multimedia presentations bring forming issues to life; and presentations cover forming of higher-strength steels, statistical deformation control and virtual sheetmetal forming.
Metalforming Electronics
Sensors & Controls
By George Keremedjiev
Columns as well as papers and exclusive new presentations cover all aspects of die protection and part-quality inspection, starting and maintaining sensor programs, the role of controls in in-die sensing, and the benefits of a sound sensor program.
Tooling by Design
By Tim Stephens, President,
Competitive Action Technologies
Articles explore foolproofing of dies, prevailing theories, incorrect practices, die-set essentials and the Laws of Die Mechanics.
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34 METALFORMING / MAY 2009
www.metalformingmagazine.com
Technology
not provide 100 percent accuracy, but it is much more accurate than the tradi- tional method,” Veach says.
The engineers then went back to the second operation, setting up the die to trim to the line determined by inverse simulation of the third operation. No simulation was required for piercing in the fourth operation.
No More Guesswork
“For this application,” says Veach, “we determined the process, developed the initial blank, controlled the flow of material during the first draw form and monitored thinning percentages before we even started building the die. The result was that the die worked perfect- ly the first time we hit it. There’s no way to know for sure exactly how much money and time we saved by not having to recut and retest the die—it all depends on how quickly we would have been able to find a solution using the cut-and-hope method. But I am confi- dent that we have captured projects because the savings through simula- tion has made us more competitive. We have seen savings of the same magni- tude on many other complex parts that presented similar challenges.”
This application demonstrates how computer simulation has helped Wright Industries offer competitive prices and quicken delivery time.
“Instead of building and testing the die to see if it works, we simulate a number of different potential designs and pick the one that best meets our customer’s requirements,” concludes Veach. “We frequently can improve the efficiency of the forming operation by reducing the number of stations and determining die size. We also can reduce material costs by simulating the stamp- ing operation with several different types of materials. In many cases, a less- er grade of material than the one orig- inally selected by the customer will work. Optimizing the size of the blank also can reduce material consumption.”
MF
Tooling