Page 25 - MetalForming April 2020

One of several parts Engel moved from its conventional mechanical press to the new servo: a running-board bracket
formed from 8-gauge HSLA (Grade 50) steel. Run rate for the bracket has climbed from 488 parts/hr. on the old press to
1000 parts/hr. on the servo.
tools and is running them on the servo, averaging about two such tools/month. Here, again, is where the unique capa- bilities of the servo press shine.
“Most if not all takeover tools bring with them a distinct set of challenges,” says Handzel. “Of course, having our own staff of toolmakers inhouse cer- tainly helps us diagnose and cure those challenges quickly. But also beneficial is the ability to use the hand-wheel and step mode on the servo press to inch the ram down, under full load, and see exactly what is happening with the material at every die station. I’d estimate that using the servo press reduces the time to debug takeover tools by at least 30 percent.”
“And,” adds Rubin, “once we do get the tool running effectively, it gives us a competitive advantage, helping prevent
the tool from ever leaving our shop.”
Rubin, quick to point
out the numerous benefits already realized with this new press investment in just a matter of months, sees a lot more to come as the Engel team becomes more familiar with the ins and outs of operating a servo press. On its list of expected benefits yet to come:
• Design and development of new tools specifically to take advantage of the servo press’ capabilities. This means designs that use fewer and more-com- plex die stations, “which we will have to simulate running in the press in order to prove out and optimize the concepts. For this process, we’ll rely on our newly purchased Logopress3
die design software,” Rubin says. “In addition, we can use the in-stroke restrike capabilities of the press to reduce the number of restrike stations and reduce tool size
and cost.”
• Performing more work under the
ram, to eliminate secondary processes such as annealing between draw oper- ations or reaming to clean up blanked edges.
• Reduced energy consumption.
• Reduced press maintenance. “Based on the advantages we’ve
already experienced,” Rubin summa- rizes, “we estimated, very conserva- tively, a 5-yr. payback on the line. We’ll come in way under that.” MF
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