Page 25 - MetalForming-Apr-2018-issue

of concerns during design- for-manufacturability reviews. The cross-section- al profile around the hole was quite thin relative to sheet thickness. Resulting cut- and break-edge con- ditions likely would be unsuitable for press-fit assembly, and customer design constraints did not allow for larger profiles, which would have resolved these concerns. As a result, laser welding would be required, driving up capital and per-piece costs.
Limited by these con- straints, Penn United staff
developed an unconven- Fig. 2—Positive simulation results for a new part design convinced designers and the customer that tional solution: forming a development and testing could move forward.
round stud directly from
the flat base stock. With no precedence for such a design, the solution present- ed several concerns. Type 301 stainless steelhasafairlyhighwork-hardening
rate, so large deformation may lead to cracking. Starting with quarter-hard material, to meet customer strength requirements,onlyincreasesthisrisk.
Also of concern: how round, uniform and filled the stud would be at various heights.
Needing a way to evaluate the
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