Page 40 - MetalForming May 2013

Tooling Technology
sizes; the tool holder is a Mate Ultra- form thick turret B-station. Testing the tool on prototype display models, McDonald found it to be “a very suc- cessful replacement for the original welding method.”
Cost Savings Compounded
Since the firm powder-coat paints all of its displays, the previous design using welded fasteners required mask- ing plugs to keep threads free of paint. In some cases, operators had to man- ually clean the painted nuts so screws would fit freely into them. In contrast, the threaded helix made with the new threadform tool requires no cleaning after painting. Screws fit and turn eas- ily using simple hand tools.
“The Mate Hybrid Threadform tool provides just enough thread depth and engagement to tightly secure shelf com- ponents,” reports McDonald. “When we submitted the prototype models to our customer, its engineers liked what they saw based on rigidity, appearance
and quality. But most importantly, they were really pleased with the time and cost savings realized using the new threadform process.”
McDonald quantified the cost sav- ings using the new threadform tool several ways. He calculated a direct- savings benefit of one cent for each of 24 threadforms per display, compared to 15 cents each for the same number of welded nuts per display. The direct savings from eliminating welding was significant due to the elimination of secondary operations. Also eliminated was the need to move each display panel to the welding station, as well as setup and welding time for each nut.
Indirect savings also prove signifi- cant, beginning with the elimination of labor input—once the threadform tool is loaded into the press turret. Also, the tool operates at 200 hits/min., much like a standard piercing tool, so actual production time for threadforming is much lower than for welding. Energy savings has proved to be substantial as
well, and there’s no need to inspect the painted holes or clean the threads.
“As Good As New,” After 240,000 Cycles
McDonald calculates that to fulfill the firm’s initial order for 10,000 dis- plays, its new threadform tool com- pleted more than 240,000 cycles, each cycle requiring 24 thread helixes. What amazed him was that “the Mate tool was still operating as good as new and ready for its next assignment.”
Anticipating future similar projects benefiting from the threadforming process, McDonald ordered six addi- tional Mate Hybrid Threadform tools to handle 14-, 16-, 18- and 20-gauge material.
“We want to introduce the new threadform feature with customer pro- totypes even when they don’t ask for it,” says McDonald. “As soon as they see it they’re sold on its many benefits. It helps sell the entire project.” MF
Article provided by Mate Precision Tooling: 763/421-0230; www.mate.com.
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