Page 25 - MetalForming April 2017

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clinched into the stock strip. Inserting and clinching in this sequence assures the micropin is installed within the required tolerances.”
Reliability and Repeatability
...always are concerns with any stamping operation, but perhaps more so with this setup. Mahnic explains.
“When we first launched the tool, we dialed it down to about 25 strokes/ min. In a month or so we ramped up to 35 strokes/min., fine-tuning air-flow regulation and the layout of the feed tube. The feed tube is fixed to the press ram, and runs underneath the light cur- tain and loops back up to the stripper plate. We shortened the tube (to about 15 ft.) and positioned it to, as much as possible, get gravity on our side.”
Slug management also played a crit- ical role in the project’s success. The bottom die half includes a specially designed slug-management system that uses a continuous vacuum to suck slugs out of the tool. “The ‘slug sucker,’ says Mahnic, “is tied to press actuation with its own channel on the Wintriss press control—the press won’t cycle unless that airline is hooked up and running.”
The final quality-control step in the process: periodic push-out tests to ensure the strength of each pin-to- stamping connection.
“We have to meet a 200-N strength requirement,” Mahnic says. “Initially, the specified diameter of the pre- pierced hole was too large to meet this requirement. We reengineered the hole and gained approval from the cus- tomer. Since then it’s been smooth sailing.
“If we were to run this process with the pin insertion as a secondary process, we could probably run the press at 60 strokes/min., Mahnic adds. “However, the customer under- stands well that the payoff for the extra cost of the in-die insertion equipment, and for running the press more slowly, comes quickly when accounting for improved quality con- trol and efficiency of eliminating the secondary operation.” MF
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