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Forming stainless at Servo press quells In-die forming microscopic level reverse tonnage designs EXPERTISE EXPERTISE TOTO HELPHELP YOUYOU TRANSFORMTRANSFORM METALMETAL INTOINTO GOLDGOLD WWW.STAMPINGJOURNAL.COMWWW.STAMPINGJOURNAL.COM MARCH/APRIL 2021 Making it makable before it’s in the die A PUBLICATION OF THE FABRICATORS & MANUFACTURERS ASSOCIATION, INTERNATIONAL® AA PUBLICAPUBLICATIONTION OFOF THETHE FFABRICAABRICATORSTORS && MANUFACTURERSACTURERS ASSOCIAASSOCIATION,TION, INTERNAINTERNATIONALTIONAL®® Cover_MarchApril21SJ.indd 1 3/8/21 11:25 AM A PUBLICATION OF THE FABRICATORS & MANUFACTURERS ASSOCIATION, INTERNATIONAL® INTRODUCING THE NEXT GENERATION OF DSF-C1-A AIDA80 - 250 Tons | GapSERVO Frame featuring NEWPRESSES Allen-Bradley Controls Standard DSF Press Control Features: DSF-C1-A Step-feed (CNC handwheel) slide motion control Swing-arm mounted 12” color touch screen HMI Display of actual and virtual crank angles Allen-Bradley servo motion controller Optical run buttons to help reduce operator fatigue Allen-Bradley GuardLogix® safety controller 8 PLS cams (expandable to 24) 200 job recipes 8 input die protection with both PNP/NPN signals (expandable to 16) Download/upload job recipes to flash drive NEXT GENERATION POWERFUL & ACCURATE LOCAL EXPERTISE AIDA SERVO MOTOR PRECISION CONTROLS ON-GOING SUPPORT 5-10% Higher Speeds for Increased Throughput CNC Handwheel for Improved Setup Servo Press Training & Optimization Programs Office: (937) 237-2382 Service: (937) 235-3599 [email protected] [email protected] ToC_MarApr2021SJ.indd 2 3/8/21 7:59 AM Exceeding Capacity? Take advantage of all standard production features of the E2G. • Hydraulic Clutch Brake - High Single Stroke Rate for Automation • Hydraulic Slide Lock- Control Die Height in heavy blanking • Center Drive with Splined Connections-Efficient Torque Transfer • Plunger Guided Slide - Unrivaled Slide Accuracy • Single Gear or Double Gear Drive Train • Advanced Electronic Control System • Full Tie Rod Construction • Two (2) year bumper-to-bumper warranty parts and labor. • Stock Delivery with Financing to Suit “you”. Plunger Plunger Guide Locking Nut Hyraulic Pressure No Clearance Slide Standard Hydraulic Slide Lock Komatsu America Industries, LLC 8770 W. Bryn Mawr Ave., Suite 100 ◆ Chicago, IL 60631 Phone: 847-437-3888 ◆ Fax: 847-437-1811 ◆ www.komatsupress.com ToC_MarApr2021SJ.indd 3 3/8/21 7:59 AM An Official Publication of the ® VOL. 33 NO. 2 MARCH/APRIL 2021 Fabricators & Manufacturers Association, International >> COVER STORY 22 Design for manufacturability The process of stamping parts from the initial RFQ, through the tooling design/build process, and finally to the stamping produc- tion can be a long and winding road with a large gap between what is designed and what can be manufactured. A well-designed part with manufacturability in mind will run the smoothest, with the least amount of downtime caused by tooling design-to-pro- duction disconnects. If a tooling house knows a feature’s func- tion during the tool tryout process—or better yet at the time of RFQ—that can be highly beneficial in bridging the gap between p. 22 product design and tooling. >> DEPARTMENTS On the cover: Victory Tool >> FEATURES 6 Meet the Press In “President Biden’s Made in America order will help U.S. stampers,” Editor Kate Bachman cites the improvements to the 28 Servo press puts reverse Buy America Act of 1933 and dwells on the consumer versus tonnage in reverse makers conundrum inherent in protectionism. 1 Stamping manufacturer Clips & Clamps was forming a /8-in.- 8 Readers Respond thick, 78 Rockwell hardness stainless steel part on a 300-ton A reader recounts his lesson in Class A dies. mechanical press and encountered extreme reverse tonnage. 8 News & Notes The press, tooling, and entire system took a beating that even Industrial Magnetics acquires Walker Magnetics; President Joe a hydraulic dampening system couldn’t quell. The company Biden to replace government’s fleet with U.S.-made electric installed a 330-ton servo-mechanical press on which to run the models; Greenheck to acquire Metal Industries; Daimler Trucks NA’s Portland, Ore., truck manufacturing plant achieves car- part and realized a complete reversal of the reverse tonnage and bon-neutral production the problems it created. 14 Stamping Solutions Automotive component-maker future-proofs press line with 34 How do titanium, stainless steel new control system. grain structures affect part forming? 15 Product Innovations A microscopic view into how metal bends, forms, and breaks System tracks stamping press downtime, lubricant use; Vacuum generator designed for automotive press shop automation shows that the selection of stainless steel and aluminum alloys often is centered around strength, ductility, elongation, and 16 Die Science hardness. These properties indicate how a metal’s building Columnist Art Hedrick shares the essential tooling checklist. blocks behave in response to an applied load. Benefits can be 18 Engineering Angle gained by peering one layer deeper into the grain structure that The researchers at Oakland University’s Center of Advanced governs a metal’s mechanical behavior. Manufacturing and Materials dissect ways to control edge split- ting in sheet metal part production. 44 Forming & Fabricating® 2021 40 Product News Stamping Lubricant Buyers’ Guide© 49 Advertisers Index 50 Ask the Expert A reader asks Tom Vacca, “What designs are available for in-die forming?” 4 MARCH/APRIL 2021 WWW.STAMPINGJOURNAL.COM STAMPING JOURNAL • AN FMA PUBLICATION ToC_MarApr2021SJ.indd 4 3/9/21 11:27 AM Made to Handle Metal. The Low-Profile Transporters® magnetically transfers metal blanks, stampings, and parts in automated station-to-station, press-to-press transfer or robotic TPLP50 pick-and-place applications. TPLP30 IN-STOCK TPLP15 READY TO SHIP » Engineered with powerful rare-earth magnets that hold the part during transfer » Available in 1.5”, 3” & 5” sizes Swivel and Spring Compensator Reduces slipping and shifting of parts » mounting fixtures » Pick up stamped, perforated or unusual available for shaped parts in multiple orientations new and » Uses up to 95% less air than custom tooling traditional vacuum cups installation. » Accurate placement in the die » Quick cycle times for increased production » Million-cycle-tested for endurance » Incorporated fail-safe feature that prevents release of parts during power loss » De-stacking, Double Acting and 3/8 BSPP Fitting options available Industrial Magnetics, Inc. 888.582.0823 • 231.582.3100 • www.magnetics.com ToC_MarApr2021SJ.indd 5 3/8/21 7:59 AM MEET THE PRESS President Biden’s Made in America order will help U.S. stampers Closes loopholes, ups content share, provides transparency he Buy American executive order that Pres- ‘American-made’ goods,” according to a Forbes ident Biden signed on Jan. 25 will benefit article, “Biden Signs ‘Buy American’ Executive T U.S. stamping manufacturers and metal Order—Here’s What It Means For Businesses.” fabricators supplying the federal government, Additional good news for stampers and fab despite the requirement that the materials they shops is a provision for small and midsize busi- purchase be produced domestically as well. By nesses for better access to information about con- Kate Bachman strengthening existing Buy American rules, the tracting with the federal government and com- Editor order is positioned to boost U.S. manufacturing petitors’ waivers so they have a better chance of [email protected] because it requires preference to domestic produc- having a seat at the government contracts table. ers and removes much of the price suppression that accompanies global cost competition. Consumers Versus Makers Although the Buy American order applies only The American-made requirement resurfaces the to federal government spending, that pot is siz- age-old arguments about whether or not pro- able—$600 billion—and applies to everything tectionism—required preference for nationally from military contracts and postal and other feder- manufactured products—is good for Americans al vehicles to construction components. and the U.S. economy. Free trade arguments The order, another in a long line of “adjust- enter in. ments” to the 1933 Buy American Act that directs Global competition reduces the price consum- government spending to procure a majority of ers have to pay for goods produced. Low-cost, for- materials and products from U.S. sources, includes eign-produced goods threaten the survival of U.S. significant improvements over previous iterations. manufacturers—which are also employers. It does so by redefining “U.S. content,” pressing to That conundrum has existed for decades, as the The order, increase the content percentage, closing loopholes U.S. trade surplus has eroded since NAFTA. The in the waiver process, and providing oversight and U.S. trade deficit is a stark marker of the result of another in a accountability. manufacturing migration. long line of According to the U.S. Government Account- Charles Fishman’s 2003 Fast Company article ability Office (GAO), “Problems in administering “The Wal-Mart You Don’t Know” revealed in pain- “adjustments” the act involve definitions of ‘substantially all’ of ful detail how U.S. shoppers buying China-manu- the components and definitions of ‘manufactured factured goods at Walmart—then the U.S.’s largest to the 1933 Buy in the United States.’” Additional snags have been importer of products from China—unwittingly in the “public interest” waiver: “The provisions of hastened the demise of their own factory jobs. American Act, the act may be waived if the head of the procur- So, what’s the better trade-off—being able to ing agency determines the act to be inconsistent buy inexpensive products but losing manufactur- includes with the public interest or the cost of acquiring the ing jobs and revenue, or more expensive goods domestic product is unreasonable.” and a healthy U.S. manufacturing industry? significant The executive order creates a new position in Balance Is Key improvements the Office of Management and Budget and impos- es scrutiny of the waiver process that has been I suspect that stamping manufacturers concede over previous abused in the past.