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The Future is Forming Blog

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Talk about materials, stamping, and manufacturing.
Updated: 2 hours 21 min ago

Using Test Data to Derive Product Improvements: Design Tests to Give Pertinent Quantitative Info

Sun, 09/23/2018 - 15:29

NIST and industry partners create new lab test to provide quantitative data on the scratch and damage resistance of automobile polymer clearcoat layers.  Compare this with the 2 common methods currently used that provide only qualitative assessments: one is a rotating wheel of brushes to simulate car wash damage, and the other is a robotic ‘finger” moving back and forth to mimic damage from human contact and abrasive surfaces. Both of these “methods only assess clearcoat performance based on appearance, a qualitative measure where the results vary from test to test, and they don’t provide the quantitative data that scientifically helps us understand what happens to auto finishes in real life.”
https://www.nist.gov/news-events/news/2018/09/improve-auto-coatings-new-tests-do-more-scratch-surface

-Danny Schaeffler,  www.EQSgroup.com and www.Learning4M.com

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Tesla Stamping and Assembly of Model 3

Thu, 09/20/2018 - 07:59

There are only 35 high end Schuler servo stamping presses in auto manufacturing worldwide and the one at Tesla is the first one in the US. The equipment has allowed Tesla to form unique parts, like the Model 3 front fender, which engineers say has greater depth in a single piece of stamped steel than any other fender in production. Tesla chose to build a factory to handle all of its seat production, making it unique in an industry where its competitors all outsource seats.
This is a good article highlighting manufacturing of the Model 3.
https://www.bloomberg.com/news/features/2018-06-08/tesla-model-3-photos-of-elon-musk-s-factory-in-fremont

-Danny Schaeffler, www.EQSgroup.com and www.Learning4M.com

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Schuler and Porsche Form JV for Auto Body Parts

Mon, 09/17/2018 - 08:43

Schuler and Porsche form a 50/50 joint venture to use IoT Industry 4.0 networked equipment capable of machine learning to create the “Smart Press Shop.” The intent is to create “highly flexible production of complex car body parts, with a focus on aluminum body panels.” Schuler technology that enables up to 20 strokes per minute with reduced energy consumption will be deployed. Small batch production will be achieved with a newly developed die-changing approach.
https://www.schulergroup.com/major/us/unternehmen/presse/pressemeldungen/archiv/2018/2018_09_05_porsche/index.html

-Danny Schaeffler, www.EQSgroup.com and www.Learning4M.com

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Increasing Profits by Reducing Complexity and Focusing on Customer

Mon, 09/10/2018 - 10:36

After almost 20 years of losses, GM’s former European division is profitable one year after being sold to the parent company of Peugeot/Citroën. There are obviously many reasons, but some that stood out to me:
– an agreement with labor to trim salary costs by reducing the standard workweek to 35 hours from 40.
– assembly output reduced in Rüsselsheim to 42 vehicles per hour instead of 55 to “focus on cars customers actually want to buy.”
– On the Corsa model which starts at about $14,000, there are 10 possible infotainment systems, down from 57 (!) and there are now 9 windshield / wiper options, down from 16.
https://www.bloomberg.com/news/articles/2018-08-29/the-stunning-one-year-turnaround-of-gm-s-german-castoff

-Danny Schaeffler, https://www.eqsgroup.com/ and http://www.Learning4M.com

Is it cheaper to flood the tools or use an engineered lubricant designed for advanced metals?

Fri, 09/07/2018 - 07:12

Saving pennies or dollars per gallon shouldn’t translate to many thousands of dollars in unnecessary and increased tooling costs or defects and scrap. Learn more about balancing the optimum lube at the optimum concentration vs spraying a cheap lube all over your tools and floor from https://www.irmco.com/products/#newtechnicalbulletins

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Finding Solutions for Wear -Tooling By Design in the September 2018 Issue of MetalForming Magazine

Tue, 09/04/2018 - 07:59
I always read what Pete Ulintz writes. His latest article in Metalforming Magazine (metalformingmagazine.com/magazine/article/?/2018/9/1/Finding_Solutions_for_Wear) is on tooling wear when forming stainless and aluminum. A few additional comments from my experience: A) Your metal supplier may be able to provide you coils with the PE/PVC coating already applied. B) You might need to adjust your forming approach. I’ve worked with parts where the polymer coating was ripped off when going through the draw beads and that balled up dirt restricted metal flow. C) D2 is usually a bad choice for forming stainless steels into parts with even moderate complexity. Chromium in D2 + Chromium in stainless steel = galling. Pete’s also one of the best speakers/teachers that’s out there. You can hear him and others in Nashville on Sept 12/13: https://www.pma.org/home/event.asp?productID=68844416 Advertisements __ATA.cmd.push(function() { __ATA.initSlot('atatags-26942-5b8ef25b0d208', { collapseEmpty: 'before', sectionId: '26942', width: 300, height: 250 }); }); __ATA.cmd.push(function() { __ATA.initSlot('atatags-114160-5b8ef25b0d20b', { collapseEmpty: 'before', sectionId: '114160', width: 300, height: 250 }); });

“Quality is in the eye of the customer for most in the metal fabricating world”

Sat, 09/01/2018 - 10:01

Nice post by @fabricating reminding people that an ISO9001 mindset is great, but not every job needs ISO9001-level documentation. “Quality is in the eye of the customer for most in the metal fabricating world.”

https://www.thefabricator.com/blog/no-single-quality-playbook

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Coil Fed Laser Blanking coming to SET Chicago

Thu, 08/30/2018 - 07:54

SET-Chicago to start laser blanking in 2019: straight line cutting speeds about 2 meters/sec from coil-fed strip continuously fed up to 1 m/sec.
https://www.setenterprises.com/blog/set-enterprises-moves-forward-its-blanking-without-dies-bwd-disruptive-business-model

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Stamping Higher-Strength Steels Seminar – Sept 12/13 in Nashville

Mon, 08/27/2018 - 07:09

Happy to be speaking at PMA’s Stamping Higher-Strength Steels Seminar in Nashville, Sept 12-13.  Learn about high-strength-steels / formability, tool steels & coatings, presses & die design, and effective lubricant strategies.  https://www.pma.org/technical/event.asp?productid=68844416

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FMEA Failure Modes & Effects Analysis in Sheet Metal Forming

Fri, 08/24/2018 - 09:10
Dimensional variability. Random splits. Surface waves. Any of these can cause big production headaches. Scrambling to fix the problems can lead to a host of other issues.  See my article on FMEA Failure Modes & Effects Analysis in the January 2018 issue of @Metalforming from @PMAtalk   http://www.metalformingmagazine.com/magazine/article/?/2018/1/1/See_the_Future_by_Exploring_the_Past

Terms in the Sheet Metal Industry

Wed, 08/22/2018 - 09:40

You might think that you know what you’re asking for, but when talking with your supplier, it’s important that you both use the same language to be sure you’ll get what you need.
See my article on the meanings of terms used in the sheet metals industry in the February 2018 issue of @Metalforming from @PMAtalk   http://www.metalformingmagazine.com/magazine/article/?/2018/2/1/Know_Your_Sheetmetal_Terminology–Part_1

Limitations of Ordering AISI 1008/1010

Mon, 08/20/2018 - 17:27

Not getting what you need from your 1008/1010 #steel? Read about the limitations of ordering AISI 1008/1010, and why you might need to change to something like SAE J2329 for more consistent performance – March 2018 issue of @Metalforming from @PMAtalk
http://www.metalformingmagazine.com/magazine/article/?/2018/3/1/Know_Your_Sheetmetal_Terminology–Part_2

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