Page 17 - MetalForming-Nov-2018-issue

precision terminal pins for fast con- nects and disconnects in various appli- cations found in automobiles, light trucks and all-terrain vehicles, as well as hybrid and electric vehicles.
The volume and speed with which these tiny parts must be made is mind boggling. On average, says Cafarelli, the company stamps ter- minal pins at rates of 150 to 350/min., or about 15,000/hr. Annual volume runs about 14 million. What’s more, the precision tooling is fragile and the materials used must remain oil- free during production.
“The carbide tools used for cutting are prone to shattering when encoun- tering static vibration,” explains Cafarelli. “And the materials—bronze, copper, stainless and aluminum—used in making the parts must be oil-free, so they can be sticky. This requires the stamping press to provide a means to prevent the parts from sticking and adhering to the tooling.
Ideal Press for High-Tolerance Work
To manufacture the pins, a servo- feed delivers the strip into a high-speed press, where it travels through a 10- to 20-station progressive die.
Cafarelli says that all production challenges related to the terminal pins are met by a customized Stamtec HSD- 80 high-speed straightside press. Orig- inally designed to run motor lamina- tions, the 80-metric-ton press has many features not standard in a typical straightside machine, allowing it to reach KSR’s required high-volume-pro- duction rates while addressing material concerns and other challenges, says Michael Wisnoski, integrated systems engineer for Manchester, TN-based Stamtec.
“For example, the frame and slide, made of cast steel as opposed to plate steel, has greater vibration and noise- dampening characteristics, critical to ensuring a low-vibration, high-speed press,” explains Wisnoski. “Moreover, the rigid, low-deflection frame, bed and slide enable to the HSD to exhort only 0.0010-in. deflection for high accu-
racy and repeatability, a necessity when running high-speed, tight-tolerance dies.”
Also serving to lessen deflection is the eccentric-shaft design, with “more bearing surface, and better torsion and deflection characteristics than a typical crankshaft machine,” continues Wis- noski, explaining that the shaft is machined from one solid-steel piece. “Because of the eccentric design, the
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shaft is supported along its length, and with the support bearings placed closer to driving points, shaft deflection is reduced.
“In addition,” he adds, “our plunger guiding system allows for accurate guiding assistance to the roller guides, and we are able to seal the upper por- tion of the machine and lubricate the gearing and internal components of the drive system.”
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