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Article

May 10, 2011
Attempting to defy the laws of physics, Part II
Editor's Note: This is Part II of a two-part article on part tolerancing. Part I, which appeared in the March/April 2011 issue, discussed the effects of variations in the incoming metal and the importance of consistent strain levels. It is... Read more...

Article

March 11, 2011
Attempting to defy the laws of physics, Part I
Trying to form a very small part or locate a pierced hole to a precise tolerance can be difficult. Achieving consistency in these tasks is even more daunting. In my career as a consultant, I have been exposed to part tolerances so small that a... Read more...

Article

December 13, 2010
DIEVESTIGATION: Deep-drawing and stretching variables – Part II
Part I of this two-part series explained how every material used in stamping has a given tolerance and discussed stress and strain, two variables that affect metal drawing and stretching. This article examines the variables that affect the amount... Read more...

Article

October 21, 2010
Deep-drawing and stretching variables – Part I
As a consultant for the sheet metal stamping and die building industries, I often am asked questions like these: How come only one out of every 500 or so parts splits? Why can’t I make this part shape consistently? Why is it that when... Read more...

Article

August 9, 2010
DIEVESTIGATION: Diemaking, from concept to reality
Many steps are involved in making dies: quoting the job, determining the materials and process to be used, building the die, trying it out, and signing off on the project. Die Quoting Before you receive a contract to design and build a... Read more...

Article

June 16, 2010
DIEVESTIGATION: Important considerations when designing deep-drawn parts
The previous DIEVESTIGATION column discussed design considerations for stamped parts made primarily by stretching the metal rather than drawing. This article discusses design considerations for deep drawing. What Is Deep Drawing? The... Read more...

Article

April 13, 2010
DIEVESTIGATION: Draw or stretch? That is the question
The first DIEVESTIGATION article, " Designing stamped parts : How material selection affects downstream operations and costs," discussed factors you should consider when specifying a metal during part design for operational efficiency and cost... Read more...

Article

March 9, 2010
Preventing oil canning problems
I have spent a great deal of time on die building and stamping jobs, dealing with everything from soup to nuts. What I find most frustrating are die shops and stampers that waste a great deal of money trying to correct oil canning problems... Read more...

Article

February 9, 2010
DIEVESTIGATION: Designing stamped parts
When you design a part, do you consider how the design affects manufacturing costs? All too often stamped parts are designed to have certain features and tolerances with little consideration given to the effect these features have on the... Read more...

Article

December 15, 2009
Sheet Metal Stamping 101, Part V
Editor's Note: This series presents an overview of metal stamping. Part I of this series focused on the various careers in the metal stamping industry. Part II discussed stamping materials and equipment; Part III focused on dies and... Read more...

Article

December 15, 2009
Sheet Metal Stamping 101
The author of the "Die Science" column in STAMPING Journal®, Art also has written several other series that appear at www.thefabricator.com, including: Solving Punch Breakage Problems Die Basics 101 Cutting Tooling Costs Read more...

Article

October 27, 2009
Sheet Metal Stamping 101, Part IV
Editor's Note: This series presents an overview of metal stamping. Part I of this series focused on the various careers in the metal stamping industry. Part II discussed stamping materials and equipment; Part III focused on dies and... Read more...

Article

August 25, 2009
Sheet Metal Stamping 101, Part III
Editor's Note: This series presents an overview of metal stamping. Part I of this series focused on the various careers in the metal stamping industry. Part II discussed stamping materials and equipment; Part III focuses on dies and... Read more...

Article

August 1, 2009
'Bad' steel — the ultimate scapegoat
What the heck is "bad" steel? It seems like every time there is a problem making a good part, the steel is blamed. Cracking problems? It's bad steel. Wrinkling problems? It's bad steel. Springback problems? It's bad steel. Cold and rainy outside?... Read more...

Article

June 9, 2009
Sheet Metal Stamping 101, Part II
Editor's Note: In this series, tool-and-die expert Art Hedrick presents an overview of metal stamping. Part I focused on the various careers in the metal stamping industry. Part II discusses stamping materials and equipment; Part III focuses... Read more...

Article

April 14, 2009
Sheet Metal Stamping 101, Part I
Editor's Note: This series presents an overview of metal stamping. Part I focuses on the various careers in the metal stamping industry. Part II discusses stamping materials and equipment; Part III focuses on dies and cutting and Part IV... Read more...

Article

February 10, 2009
Survival—Are factors other than the economy dragging down your operation?
I'm not going to sugar-coat it; our economy stinks. As optimistic as I'd like to think I am, I am also a realist. Maybe it's because I live in Michigan, the heart of the U.S. automotive industry. Need I say more? Like many of you, I also... Read more...

Article

December 14, 2008
Revealing the Magic — Using data and conducting experiments to solve metal forming problems
If you've ever attended one of my die troubleshooting clinics or seminars, chances are you heard me vent my frustration about how the United States views the tool and die industry. All too often, the process of designing, building, and... Read more...

Article

October 28, 2008
Buying time—by welding
Nothing lasts forever, especially those things that are used and abused excessively. Stamping dies are no exception to this fundamental rule. It also must be clearly understood that despite your best efforts to maintain these dies properly, they... Read more...

Article

August 12, 2008
3 deadly tool design sins
Throughout the last 28 years of my tool and die career, I have seen a plethora of dies ranging in size from a 20-station progressive die that you can hold in your hand to single-station dies that are 30 feet long. I have seen tools running as... Read more...

Article

June 17, 2008
Measuring forming severity
It's a simple fact that many factors contribute to a metal cutting and forming operation's success. To produce a robust stamping process, you must be able to measure the forming severity of a part. Purchasing a die for drawing or stretching... Read more...

Article

June 2, 2008
Reading progressive die strip — Part II
Editor's Note: This is the second part of a two-part article about reading progressive-die strips. Part I , which appeared in the May issue, covered the causes of pilot hole distortion and mismatched cuts. Hard marks, otherwise known as coin... Read more...

Article

June 1, 2008
Reading progressive die strips — Part II
Editor's Note: This is the second part of a two-part article about reading progressive-die strips. Part I covers the causes of pilot hole distortion and mismatched cuts. Hard marks, otherwise known as coin marks, occur when metal is... Read more...

Article

May 1, 2008
Reading progressive die strips — Part I
Editor's Note: This is Part I of a two-part series discussing causes of distorted pilot holes and mismatched cuts. Part II, which discusses hard marks, poor die design, and coil-related problems, will appear in the June issue. A reader... Read more...

Article

April 29, 2008
Getting the most from your cutting punches: Part II
Many factors influence tool steel selection. Part I of this article focused on selecting the right cutting clearance. Part II discusses properties to look for in tool steel and the importance of heat treating, preparation for production,... Read more...

Article

March 15, 2008
Successful Extruding: Part I
Editor's Note: This is Part I of a two-part series discussing critical variables controlling the success of an extruding operation. Part II discusses the effects of the die design and the use of ironing and preforms. Extruding a hole... Read more...

Article

February 12, 2008
Getting the most from your cutting punches: Part I
It seems as though stamping challenges run in cycles or groups. A few weeks ago, I spent a great deal of time helping solve formability problems. You know… splits, wrinkles, springback—typical issues. More recently I have been... Read more...

Article

January 15, 2008
Stamping 101: Die basics
Processing, designing, and building a stamping die can be very complicated. This broad overview of stamping dies—what they are, types, how they are made, and the components that comprise them—is intended to provide a foundation for... Read more...

Article

December 11, 2007
Why is it Dieology, not Dieologism?
Note: Before I begin with the technical portion of Die Science, I would like to thank all of my loyal readersand wishyou a happy holiday season. I am looking forward tocontinuing this column in 2008. If you have anytopics that you would like to... Read more...

Article

December 11, 2007
Die Basics 101: Part XVII
Part XVI of this series wrapped up the discussion of bending in stamping operations. This article focuses on drawing. What Is Drawing? Drawing is a metal forming process in which a product is made by controlling sheet metal flow into a... Read more...

Article

November 6, 2007
Piercing, cutting aluminum sans slivers
I have had a few consulting jobs in which the primary focus was on cutting aluminum. Slivers and burrs were the main problems. To address metal stamping problems such as slivers and burrs, the process engineer, tooling designer, or... Read more...

Article

October 9, 2007
Die Basics 101: Part XVI
Part XV of this series described several bending methods—wipe, coin, relief, pivot, and V. It also discussed springback and how to compensate for it when using these methods. This article focuses on other bending processes. Keep in mind that... Read more...

Article

October 9, 2007
Finding, addressing the root cause of die galling failures
As a consultant, I spend a great deal of time answering questions about die galling failures: What's the best tool steel I can use to prevent this galling problem? How can I prevent these punches from breaking down? What's the best tool... Read more...

Article

September 11, 2007
Stamping aluminum
I remember distinctly my very first experience with building a die that was supposed to draw a sheet of aluminum into a deep, contoured shape. Not knowing much about aluminum, I assumed that it must be extremely formable—after all, they... Read more...

Article

August 8, 2007
Die Basics 101: Part XV
Part II of this series presented a basic overview of metal forming operations, such as bending, flanging, drawing, ironing, coining, curling, hemming, and embossing. This and future installments discuss these operations in more detail. We will... Read more...

Article

August 1, 2007
Cutting tooling costs: Part II
Editor's Note: This article is Part II of a two-part series that discusses how to cut tooling costs without sacrificing die quality. Part I defined cost versus quality and fit and function. You might laugh to think of a die completely made... Read more...

Article

July 10, 2007
Cutting tooling costs: Part I
Editor's Note: This is Part I of a two-part series that discusses how to cut tooling costs without sacrificing die quality. Part II, which will appear in the August issue, will examine tool steels and using special die engineering software to... Read more...

Article

June 12, 2007
Developing forming dies Part III
Editor's Note: This is third installment of a three-part series that discusses die development for producing nonuniform, contoured parts by breaking the process down into eight steps. Part I covers the part material, its form, and its function.... Read more...

Article

June 12, 2007
Die Basics 101: Part XIV
Although fineblanking and GRIPflow® often are categorized as metal cutting operations, they more closely resemble a cold metal extrusion process that creates what appears to be a blanked part. The processes can be defined simply as methods in... Read more...

Article

June 12, 2007
Developing forming dies
Editor's Note: "Developing Forming Dies" is a three-part series. See Part I , Part II , and Part III . Read more...

Article

May 8, 2007
Developing forming dies Part II
Editor's Note: This is first installment of a three-part series that discusses die development for producing nonuniform, contoured parts by breaking the process down into eight steps. Part I covers the part material, its form, and its function.... Read more...

Article

April 10, 2007
Developing forming dies Part I
Editor's Note: This is first installment of a three-part series that discusses die development for producing nonuniform, contoured parts by breaking the process down into eight steps. Part I covers the part material, its form, and its function.... Read more...

Article

April 10, 2007
Die Basics 101: Part XIII
Figure 1 Pinch trimming die design Various specialty metal cutting methods are used in stamping operations. Among them are pinch, breakout, and shimmy. Pinch Trimming Pinch trimming is a special method in which... Read more...

Article

March 13, 2007
Tips for grinding and wire machining tool steel
As a consultant, I frequently get asked, "My die sections are cracking—what type of tool steel should I use?" or "My punches chip frequently—how do I prevent this?" Tool steel selection is a crucial part of the die design process;... Read more...

Article

February 13, 2007
Die Basics 101: Part XII
Slug pulling, which occurs when scrap metal—the slug—sticks to the punch face upon withdrawal and comes out of the button, or lower matrix, is a serious problem that can damage parts and dies. Various methods can help reduce the occurrence of... Read more...

Article

February 13, 2007
Solving punch breakage problems - Part III
Editor’s Note: This is one article in a three-part series. Part I discusses typical causes of premature failure. Part II covers the roles of cutting shear and retainers. Part III discusses how tool steel selection, press deflection, and... Read more...

Article

January 9, 2007
Solving punch breakage problems - Part II
Editor's Note: This is Part II of a three-part series that discusses the numerous factors that contribute to punch breakage and solutions to each problem. Part I, which appeared in the December issue of STAMPING Journal, discussed the typical... Read more...

Article

December 12, 2006
Solving punch breakage problems - Part I
Editor's Note: This is one article in a three-part series. Part I discusses typical causes of premature failure. Part II covers the roles of cutting shear and retainers. Part III discusses how tool steel selection, press deflection, and heat... Read more...

Article

December 12, 2006
Die Basics 101: Part XI
Slug pulling is a serious problem in a stamping operation. Addressing the issue requires first understanding why the slugs are pulling. What Is Slug Pulling? When a pierce punch creates a hole, it also produces scrap, usually referred to as... Read more...

Article

December 12, 2006
Solving punch breakage problems
Editor’s Note: Part I discusses typical causes of premature failure. Part II covers the roles of cutting shear and retainers. Part III discusses how tool steel selection, press deflection, and heat from processes such as EDM and grinding... Read more...

Article

November 7, 2006
Designing dies 2-D or 3-D?
A while ago a loyal reader of STAMPING Journal® and the Die Science column e-mailed me and asked if I would discuss the topic of die design. Specifically, he wanted me to address 2-D versus 3-D design methods. I don't know for sure, but my... Read more...

Article

October 10, 2006
Setting up progressive dies - Part II
Editor's Note: This is the second part of a two-part series that discusses proper die setup procedures for progressive dies. Part I discussed press and die cleanness, die alignment, clamping procedures, and preliminary shut height calibration.... Read more...

Article

October 10, 2006
Die Basics 101: Part X
Cutting is the most severe metalworking process that takes place in a die and shouldn't be taken lightly. Cutting Basics Cutting metal requires great force. For example, it takes approximately 78,000 lbs. of pressure to cut a... Read more...

Article

October 10, 2006
Die Basics 101
Part I provides an introduction to stamping. Part II covers various forming operations. Part III discusses several production methods used to make stamped parts. Part IV and Part V cover common stamping die components. Part VI... Read more...

Article

October 3, 2006
Setting up progressive dies - Part I
Editor's Note: "Setting Up Progressive Dies" is a two-part article. Part I discusses press and die cleanness, die alignment, clamping procedures, and preliminary shut height calibration. Part II discusses the process for getting metal into the... Read more...

Article

August 8, 2006
Unique forming short cuts
Figure 1 The use of a 1-to-1 rocker ratio mounted beneath the forming section allows the metal to be formed both up and down, thereby twisting it. Die designers and process engineers often are faced with the challenge of making a part... Read more...

Article

August 8, 2006
Die basics 101 starts with eight basic components
Editor's Note: This article is edited from Part IV and Part V of an article series on thefabricator.com covering stamping die fundamentals and focusing on the components used in manufacturing stamping dies. A stamping die is a special,... Read more...

Article

August 8, 2006
Die Basics 101: Part IX
Part VIII of this series discussed some of the specific mechanical properties of metals—ductility, elongation percentage, tensile and yield strength, and hardness—and how to derive these properties. This article describes other important... Read more...

Article

July 11, 2006
The process of fineblanking
Figure 1 When a punch makes contact with the sheet, the metal begins to deform and bulge around the point of the punch. Image courtesy of Dayton Progress. Fineblanking is a specialty type of metal stamping that can achieve part... Read more...

Article

June 13, 2006
Die building
It is amazing how many dies stampers build completely with little or no understanding of what is truly required of the dies. Stampers process parts and build dies without even knowing the metal type or thickness, never mind the part tolerances.... Read more...

Article

June 13, 2006
Die Basics 101: Part VIII
Figure 1 Part VII of this series introduced two basic types of metals used to manufacture stamped parts—ferrous, metals that contain iron, and nonferrous, metals that do not contain iron. This article discusses the... Read more...

Article

May 9, 2006
Defining material specifications
Author's Note: It has been almost six years since my first article appeared in STAMPING Journal. I would like to take a moment to thank the editors, designers, and loyal readers of SJ and the Die Science column. (Five stars to Associate Editor... Read more...

Article

April 11, 2006
Guidelines for forming high-strength material
More and more stampers and die builders, both automotive and nonautomotive, are increasing their use of higher-strength materials. Grades of steel such as dual- or triple-phase; high-strength, low-alloy; and bake-hardenable are not uncommon in... Read more...

Article

April 11, 2006
Die Basics 101: Part VII
Previous articles in this series focused on stamping dies and production methods. This article discusses stamping materials—both ferrous and nonferrous. To process, design, and build a successful stamping die, it is necessary to fully... Read more...

Article

February 7, 2006
Die basics 101: Part VI
Previous articles in this series discussed common stamping die components. This article focuses on less common specialty components found only in certain dies, most of which are available from various suppliers. Figure 1 Inidie Tapping... Read more...

Article

December 13, 2005
Die basics 101: Part V
Many specialty components can be used in dies, but the most commonly used are die plates, shoes, die sets, guide pins, bushings, heel blocks, heel plates, screws, dowels, and keys—all of which were explained in Part IV of this series. This... Read more...

Article

November 8, 2005
Die maintenance. Die repair.
Figure 1 When you grind tool steel sections such as D2, M4, and powdered metals, you actually are grinding small carbide pools. Photos courtesy of Bohler Uddeholm. If you find your daily activities include tasks such as fixing... Read more...

Article

October 11, 2005
Die basics 101: Part IV
While many specialty components can be used in manufacturing dies, most dies contain certain common components. Die Plates, Shoes, and Die Sets Figure 1 Various die set types Die plates, shoes, and die sets are steel or aluminum... Read more...

Article

August 9, 2005
Die Basics 101: Part III
Figure 1 Tandem Line Presses Photo courtesy of APT. Among the many factors to consider when choosing a production method are the production speeds necessary to produce the required quantity within a given time frame; the... Read more...

Article

June 14, 2005
Die Basics 101: Part II
Figure 1 Embossing All forming operations deform sheet material by exposing it to tension, compression, or both. Most part defects, such as splits and wrinkles, occur in forming operations. Successful sheet metal forming relies... Read more...

Article

April 11, 2005
Die Basics 101: Part I
Figure 1 When I conduct conferences, it isn't unusual to have one or two attendees who are new to the stamping die and pressworking world. Some are young new hires trying to learn about stamping, and others are individuals who have... Read more...

Article

February 8, 2005
Solving pierce punch breaking and chipping problems
Figure 1 Having a pierce or perforating punch chip, or worse yet break, can cause severe die damage. It also can result in nonconforming parts because of burrs or undersize holes. Broken punch pieces can fall into the die and crush... Read more...

Article

January 11, 2005
Listening to your parts
Figure 1 Even if the scoring is the reason for the split, that doesn't mean that resolving the galling issue will ensure a robust process. I recently had the chance to engage in some very interesting conversation with the head of the... Read more...

Article

December 7, 2004
Cams, cams, and more cams
Figure 1 Cam Basics First let's talk basics. Cams mechanically transfer vertical ram motion and force into horizontal or semihorizontal motion and force. Because cams often are used for cutting when precision alignment is critical,... Read more...

Article

December 7, 2004
Regaining flatness in stamped parts
Of all the geometric tolerances that are difficult to achieve, flatness is one of the hardest. Most stampers probably would much rather try to make a complex-shaped, thin, high-strength steel deep-drawn part than hold a small-tolerance part... Read more...

Article

November 9, 2004
Successful stamping: It's a 'we' thing
As a consultant and educator, I travel to numerous die shops and stamping plants, and almost all of them have the same basic request: "Can you show these tooling guys how to make the dies run better?" I hear comments like "We sure have a lot of... Read more...

Article

October 12, 2004
Using forming assessment tools to make wise die-buying decisions
Establishing a good buying procedure is a critical aspect of the tool purchasing process. All too often tool supplier expectations are not communicated and executed effectively. Miscommunication can cause you to purchase a die that doesn't... Read more...

Article

August 10, 2004
Tackling cutting and piercing problems in stamping operations
Figure 1 Poor cutting section design Cutting problems, such as die sections breaking, slugs jamming and pulling, and burrs, are common stamping challenges. Many of these problems are caused by poor die design. Others are caused by... Read more...

Article

June 8, 2004
Sink-making secrets
Figure 1 Double drawn stainless steel sink Sink photo courtesy of Polarware. Have you ever looked at a deep-drawn double-bowl sink and wondered how it's made? After all, one deep-drawn shell is right next to the other. Where does... Read more...

Article

May 4, 2004
Eliminating slug pulling during piercing operations
Author's Note: Before I get into the meat of this article, I would like to let my readers know how much I appreciate their loyalty to STAMPING Journal® and the Die Science column. STAMPING Journal now is published monthly, and I am... Read more...

Article

April 6, 2004
Pitch notch or not? Factors to consider when designing progressive dies
Figure 1 In today's competitive global market, stampers are looking for ways to reduce tooling and stamping cost by any means possible. Pitch notches, often referred to as French notches, are used commonly to prevent overfeeding and... Read more...

Article

February 12, 2004
Selecting a stamping die pressure system, Part II
Selecting a stamping die's pressure system can be a critical decision. Many questions must be answered to determine what type of pressure system best suits your application. This article is Part II of a two-part series that focuses on the... Read more...

Article

December 11, 2003
Selecting a stamping die pressure system, Part I
Selecting the stamping die's pressure system can be a critical decision. Many questions must be answered to determine what type of pressure system best suits your application. Controlling Factors 1. Pressure requirements Simple conventional... Read more...

Article

October 9, 2003
Controlling bend angles
Spring-back Analysis All metal has a certain amount of spring-back. Spring-back, also known as elastic recovery, is the tendency for the metal to want to return to its original flat blank shape after being bent. To fully understand why metal... Read more...

Article

August 28, 2003
Die geometry for embossing and stretching
Embossing usually refers to the stretching of metal into a shallow depression. Unlike drawing, embossing entails little or no inward metal flow. Some automobile hoods and parts are made using a stretching operation, while others use a combination... Read more...

Article

August 14, 2003
Toolmaker tricks
This article focuses on a few tricks of the tooling trade that have been used for years. It is very important for toolmakers, troubleshooters, and technicians to make rational data based decisions regarding permanent corrective action. These... Read more...

Article

June 12, 2003
Designing high-strength steel stamped parts for formability
The problems associated with forming high-strength steel often are created during the design stage, when products are designed in such a way that they cannot be manufactured using conventional stamping methods. Or the product requires numerous or... Read more...

Article

April 10, 2003
Establishing a die setup recipe for progressive dies
To reduce the number of mistakes, it is important to have a good die setup recipe for each progressive tool. The special setup sheet should contain numerous items in checklist form. Setup Checklist All of the following items are crucial to your... Read more...

Article

April 10, 2003
Drawing on the strength of people
When faced with a financial crunch, many companies react by immediately cutting employees and nixing training programs. While these cutbacks may fix the problems in the short term, they may create even bigger problems in the long term,... Read more...

Article

March 13, 2003
Psychology for the tool room
OK, I admit it—I once was one of those guys. I knew everything there was to know about tool and die, and if you didn't believe it, all you had to do was ask me. Today I'm smart enough to know that I have a lot to learn. In fact, the... Read more...

Article

February 13, 2003
Why use sheet hydroforming dies?
It's a simple fact that the automobile industry constantly strives to reduce vehicle weight, while maintaining or increasing performance and fuel efficiency. Despite major advances in engine and powertrain technology, the need to reduce vehicle... Read more...

Article

November 21, 2002
Reducing Negative Tonnage
Negative tonnage, often referred to as reverse or snap-through tonnage, is the undesirable result of cutting operations. Basically, when a punch breaks through the metal during a cutting or piercing operation, a negative force results that pulls... Read more...

Article

October 24, 2002
Taking advantage of simulation technology
Tremendous advancements have been made in sheet metal stamping during the last decade. Even during my short 22 years of tooling experience, I have seen dies designed with a pencil and a drafting board; with a computer; with solid modeling; and... Read more...

Article

October 10, 2002
Deep drawing aluminum—not as hard as it looks
Aluminum unfortunately often gets a bad rap. For those manufacturing operations that revolve around the deep drawing of steel, the sheer mention of aluminum brings out a grimace. It is universally known for its inability to stretch, its... Read more...

Article

June 26, 2002
Good design, set-up, maintenance can keep dies out of repair shop
A technical society once asked me if I would be willing to write a book on stamping die maintenance. Chuckling, I told the requester that I'd have the book done by Friday. He did a double take. "Friday?" he asked. "You must have already... Read more...

Article

March 14, 2002
Getting the most from your deep-drawn material
Global competition has forced many U.S. stampers to use all means possible to cut costs in their stamping operations. Consumption of costly items, such as lubricants, has been greatly reduced and occasionally eliminated. Special link-drive... Read more...

Article

January 31, 2002
Forming high-strength materials
Fabricators encounter various shape defects in flat-rolled ferrous and nonferrous strip, some simple and some complex. How do these defects originate? What methods and machines can fabricators use to correct them? Simple Shape Defects Simple... Read more...

Article

January 24, 2002
The HOW, WHAT, and WHY of liquid impact forming
Hydroforming has revolutionized sheet metal stamping and tube forming. It can expand, bend, bulge, and change a simple pipe into geometric shapes without a hint of wrinkling. This process has allowed automotive exhaust manufacturers to... Read more...

Article

November 15, 2001
Part nesting and die design tips for reducing and utilizing scrap in stamping operations
In this global and competitive economy, especially now, it is imperative that production sheet metal stampers get the maximum part count by consuming the least possible amount of material. Most production stampers that use plain carbon steel... Read more...

Article

October 11, 2001
Die design for double bending
I'm often asked if double bends can be made easily in a single wipe bending operation. The answer is yes; but keep in mind, the results are slightly different than if the bends are made in a multistage bending operation. When bending in a... Read more...

Article

July 26, 2001
Know your bending basics—Part II
This article is Part II of a two-part article on die design for bending. There are several good ways to design a tool to achieve a 90-degree bend. Whatever method you choose, you must be able to adjust the tool easily in response to... Read more...

Article

May 30, 2001
Key design principles for successful deep drawing
Successful deep drawing depends on many factors. Ignoring even one of them during die design and build can prove disastrous. However, regardless of the many factors involved, the most important element to a successful deep drawing operation is... Read more...

Article

May 15, 2001
Know your bending basics—Part I
Editor's Note: This article is Part I of a two-part series discussing bending. Read Part II . Of all of the operations that typically are done in a stamping die, it seems that achieving and maintaining a 90-degree bend are two of the most... Read more...

Article

February 19, 2001
Die design for flat parts: Achieving perfection in a difficult task
Flatness is one of the most difficult part characteristics to achieve in a conventional stamping die. Some of the factors controlling part flatness are: 1. The severity of the steel cutting deformation. 2. The mechanical properties of the sheet... Read more...

Article

February 19, 2001
Controlling flow and obtaining stretch in deep draw operations
Obtaining a wrinkle-free part and the desired percentage of stretch in a deep drawn part sometimes can be very frustrating and time-consuming. Wrinkles, fractures, loose metal, buckles, and oil canning are everyday problems in the die build and... Read more...