Page 33 - MetalForming July 2011

Ask the Expert
Arc Welding
Deanna Postlethwaite,
marketing manager, Lincoln Electric Automation
Q:How does the owner of a metalforming business performing welding and/or finish- ing operations learn if the EPA’s National Emissions Standard for Hazardous Air Pol-
lutants regulation applies to them? What procedures should they follow to meet the requirements?
A:Compare your company’s NAICS/SIC codes to applicable codes in the regulation, then check the MSDS of your welding consumables to determine if the threshold for cadmium,
chromium, lead, nickel or manganese is met. If so, the operation can potentially emit a metal fabrication hazardous air pollutant (MFHAP), and the regulation applies. To comply, develop a welding management plan to minimize emissions and, if more than 2000 lb. of welding consum- ables is used annually, perform visible emissions monitoring. www.lincolnelectric.com
MetalForming magazine proudly pres- ents: Ask the Expert. These brief infor- mational tidbits allow readers to learn from those who have the answers. If you’d like to see your technical question addressed here, please e-mail the editor: bkuvin@pma.org.
If your company provides technology- based solutions to the metalforming industry, please contact Andrew Flando at aflando@pma.org to learn more about this program.
Tool Steels
Patricia Miller, senior technical manager, Bohler Uddeholm Corp.
Q:I’m stamping DP780 and experi- encing chipping on my trim sec-
tions. How can I improve this and improve die performance?
A:Avoid the use of grades like D2, S7 and A2, not stable under high-pres-
sure conditions and which do not permit the use of coatings, should the need arise. Also, their properties will vary with grain direction. As the process window narrows, the uniformity of the tool steel must improve. Select grades that are either remelted or powder metallurgically pro- duced. www.bucorp.com
In-Die Tapping
L. Ray Osborne, mechanical engineer, business development manager, Anchor Danly Co.
Q:During in-die tapping (IDT), how long will taps typically last in production?
A:Many factors influence tap life—prehole diameter (65 percent of theoretical full thread is ideal), material type and coating, depth to tap, type and amount of tapping lubricant,
tapping and press stroke and press speed. For M6 x 1.0-in mild steel, life can range from 5000 to 50,000 cycles, with 25,000 cycles about the norm. The best approach: Optimize and main- tain parameters according to the IDT manufacturer’s recommendations, then closely monitor thread quality during early runs to establish a reliable benchmark. www.anchordanly.com
Laser Cutting
Jason Hillenbrand, laser product manager, Amada America, Inc.
Q:Since so many machine-tool OEMs now offer fiber lasers, why are
CO2 gas lasers still so prevalent in today’s market?
A:Fiber lasers have gained momentum during the last 5 years or so for cut- ting sheetmetal generally 10 gauge or thin-
ner. However, while fiber lasers can be used to cut thicker plate, the speed and edge quality is not on par with that of CO2, essentially making CO2 lasers more cost effective in thick plate and more flexible for shops wanting to cut a full range of materi- al thicknesses. www.amada.com
Laser Cutting
Bob Lewinski, vice president, marketing and sales, Wayne Trail Technologies, Inc.
Q:Can I laser weld and laser cut in the same workcell and still have quick-change capability?
A:With the right choice of laser and a little planning, fabricators can effectively change between laser welding and cutting. Fiber and disk lasers produce the beam quality need-
ed to perform either task. Specify the laser to feature a two-position beam switch, and supply two separate, pre-wired cable-management systems within the workcell. Connect and locate each laser head on a stand within the enclosure, and use quick-change robotic couplers.
www.waynetrail.com
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