Photo A: UMX straightside progressive die press from AIDA-Dayton Technologies Corp. (Dayton, OH) features the company's hydraulic overload protection system (HOLP), as well as a ball joint designed to provide greater spherical area. This feature enables the transmission of higher forces with less wear. The machine also has a long guiding system with six flat faces, providing greater resistance for off-center loads—whether they are front to back or right to left.

Photo B: DEFORM software from Scientific Forming Technologies Corp. (Columbus, OH) gives engineers a preview of how a designed metalforming application will actually perform. The process simulator uses finite element analysis methods to model material behavior during and after a process is performed. Graphical output modules include deformed mesh, nodal velocities (to quantify local material flow during the process), and field variables. Animation capabilities let users take analysis to the next level, demonstrating material flow and changes in field variables in real time. Modules for both cold and hot processes are available.

Photo C: Programmed for designing stamping dies, Optris 6.0 CAD software from Altair Engineering, Inc. (Troy, MI), uses macros to simplify the setup of an application simulation. Using newly included element formulation equations, the simulation provides improved stress and springback results. Other features include alerts to possible problems (like wrinkling or tearing), and automatic filleting.

Photo D: Custom die sets for stamping from Producto Machine Co. (Bridgeport, CT) feature guide pins with high concentricity and surface finish for smoother die movement. Ball cages are engineered with more points of contact for good support and guidance. To streamline the time it takes to quote, make, and ship die sets, the company can electronically accept AutoCAD, CADKEY, DXF, and IGES files. Custom bolsters and press frames can also be provided upon request.

Photo E: HC series pneumatic die cushions from Dayton Die Cushions (Eden Prairie, MN) help control the force of the downstroke of the press, preventing cracks and wrinkles in applications with high or extended force. The cushions operate on 200 psi pressure, and are designed to let the user adjust the holding force on the blank with a supplied regulator unit. Used for stamping, blanking, piercing, and drawing applications, the cushions are supplied with everything you need to install and use them. Available options include a hydraulically controlled hold-down function, and special raised pin pads for presses with small bed openings.

Photo F: Unlike traditional tooling fingers, these articulated units from Atlas Technologies, Inc. (Fenton, MI) can be reconfigured for use in more than one application or adjusted on the fly. Also unique to the tooling is the ability to adjust one axis at a time without losing orientation on the other axes. Three basic sizes and a full line of shovel-type fingers, pneumatic grippers, part sensors, actuators and quick connect devices provide plenty of choices for users. And rounding out the options is a setup fixture that records finger dimensions to make it easier to return to original settings.

Photo G: Quick die change (QDC) systems from Wardcraft (Spring Arbor, MI) are available in two models. The Tee-Lift handles dies to 20 tons, while the Di-Glide can manage dies to 80 tons. The QDC systems have crowned rollers mounted on rails installed in the press bolster. Air bags that sit under the rails are inflated and deflated to raise and lower the rails, aligning them with the die handling system. This lets users insert and remove dies quickly. Both versions of the QDC system work on 60 to 100 psi.

Photo H: Designed for the removal and storage of finished stampings, Peak Industries' (Dearborn, MI) press unload conveyor systems are custom engineered to user specifications. As an example of this system, the company cites its recent installation at the Ford Dearborn stamping plant. Two self-contained conveyors are mounted on electric motor-driven wheels running on rails in the floor. By setting up the 18-ft. conveyors this way, Ford can reconfigure them as needed. Integrated into the 24-in. wide conveyor is a smaller, cleated conveyor belt that diverts parts off the main conveyor to be picked up or dropped into bins for storage.

Photo I: TUFFserv servo driven press feed systems from Dallas Industries, Inc. (Troy, MI) are engineered to feed coil stock to smaller presses. All models have cluster gears, crodon finish rolls, hardened and ground entry guides, a remote jog pendant, and dual pneumatic cylinders for roll release. The series of systems is divided into model packages, each of which provides certain performance or range characteristics. One package has stock capacities ranging from 0.135 in. × 12 in. to 0.070 in. × 24 in. Another package has five capacity sizes from 0.170 in. × 12 in. to 0.070 in. × 36 in. The third package, based on performance, includes a "smart" system with full programmability.

Photo J: Fineblanking, according to the people at Feintool Cincinnati, Inc. (Cincinnati, OH), can result in better parts because certain components of the process are highly controlled. For example, the part being formed is supported against the ram stroke. This reduces deformation and die break. Also, instead of pulling blanks from the material outright, they are cold extruded. This kinder, gentler way of removing the blank is also kinder to the part, often reducing post process operations to merely deburring. Effective for both ferrous and nonferrous parts, fineblanking can be used for parts up to 0.75 in. thick. Accuracy to ±0.001 in. and flatness to 0.001 in./in. can be maintained.

Photo K: Rapid prototyping services at 3-Dimensional Services (Rochester Hills, MI) has been expanded to include hydroformed parts. The company can prototype using both high and low pressure hydroforming, as well as both stationary and axial feed (deep draw) forming. To round out prototyping services, 3-Dimensional will also perform design verification and analysis, prototype-to-production tool design, and pre-hydroforming tube bending operations. To cut prototype lead-time from the usual 12 to 14 weeks to as little as two or three, a 7,000-ton press with working pressures up to 60,000 psi is coupled with tooling made from softer metals such as aluminum.