Page 23 - MetalForming February 2014

Here are two of the 10 different styles of transmission flexplates stamped on Ultramet’s transfer press. Toler- ances are extremely tight, particu-
larly for runout and offset.
trim, form, pierce and restrike. We saw dimensional specs for one of the part numbers calling for an outside diameter of 281.9 mm (before nitrid- ing), with tolerances of +0.1 mm and - 0.2 mm. Formed skirt length is 4.16 mm ±0.4 mm. A series of 10 punched holes measure 10.5-mm dia. ±0.1 mm. The press runs at 20 strokes/min. Stamped flexplates ship out for nitrid- ing, then head directly to the customer.
The Transfer System
...on the 600-ton Verson comes from Linear Transfer Automation Inc. It’s fully servo controlled and stores as many as 128 recipes. Feed stroke meas- ures 48 in., with an 18-in. clamp stroke per side and 15 in. of lift, all freely pro- grammable. Maximum payload (parts and tooling): 300 lb.
“It’s the only new piece of equip- ment in the entire line,” says Harant of the transfer system, noting that the refurbished press has a new clutch and brake, new plumbing and a freshly remachined bolster and refurbished ram motor. The used servo-controlled coil line he added to the press line han- dles coils to 72-in. dia. to 40,000 lb.
Harant explains that while Linear Transfer initially developed the servo- transfer recipes for two of the 10 flex- plate dies, “our operators were able to quickly and easily develop the remain- ing programs simply by modifying the provided recipes. All it took was one day of training conducted onsite to get our crew up to speed on the new trans- fer system.”
To enable die changes via forklift, Linear Transfer included an auxiliary 80-in. lift axis with the transfer system, which enables the entire system to lift up and out of the way. And, it allows Ultramet to run progressive dies in the press in a pinch.
“Since the transfer press was com- missioned, we’ve called on it several times as a backup to our 600-ton pro- gressive-die press,” says Harant. “That flexibility adds tremendous value to the press. We expect that if and when we acquire an 800-ton transfer press that it will have the same inherent flexibility.”
Ultramet outfitted the dies with sen- sors for die protection and tonnage monitoring; transfer tooling includes part-presence sensors. A Link Systems OmniLink 5100-MPC press control oversees operations.
Runout and Offsets Critical Quality Concerns
The press operator assumes quali- ty-control responsibilities, including piece-part inspection performed every
30 min. In addition to the previously noted dimensional tolerances, Harant adds that runout and offset tolerances are critical.
Also a focal point, early in the process-development stage, was tool development. “Forming clearances required extra attention,” Harant says, “to obtain the specified part diameter within the tolerance specifications. We went through three or four recuts of the form blocks and form rings on the first of the 10 dies, and then applied what we learned to the remaining dies to quicken their development.”
Harant also notes that J2340 steel alloys (340XF and 550XF) are “difficult to stamp. Shear strength is particularly high.”
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