A manufacturer of automotive torque converters needed to increase quality and reduce scrap in its metal stamping operations. One of the main parts of the converter is produced on a hydraulic stamping press, which created a series of indentations in a metal ring. In the stamping press, hydraulic cylinders force hardened rectangular punches into the metal blank, displacing the metal into a corresponding die. For the torque converter, the tooling creates 136 indentations in each part.
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The converters are produced on an automated line that turns out one part every 45 seconds. While efficient, automation poses a risk that many defective parts could be made before a visual inspection by the press operator detected that the indentations weren&#;t being properly formed because of a worn punch or one that had failed. To make matters worse, the plant runs multiple punching machines simultaneously, so failures sometimes occurred as often as once per shift. This resulted in a great deal of scrap, since faulty parts cannot be reworked.
To prevent scrap from occurring, plant management needed a highly accurate data acquisition and control device that could continually monitor the punches in real-time for signs of wear and impending breakage. A high-speed, real-time data acquisition system was the answer.
The ADwin-Light-16 is an intelligent, real-time data acquisition and control system with analog and digital I/O, counters and a microprocessor with local memory. Photo courtesy CAS DataLoggers
The manufacturer installed a custom system designed by CAS DataLoggers, incorporating an ADwin-Light-16 real-time data acquisition system to measure the force generated during the stamping operation. A pressure sensor was attached to each hydraulic cylinder used to drive the punches, providing data on the punch&#;s force as the indentation is formed. Data was collected over a period of time to characterize the load signature from a properly operating press. This signal was coded into the ADwin and used as a reference against the real-time signatures collected during production. A start signal from the PLC used to control the press is fed into the ADwin&#;s digital input to trigger the acquisition cycle. The force waveform is sampled at 1,000 times per second over a period of several seconds during which the indentation is formed.
The ADwin immediately computes the maximum and minimum force and compares it to a stored load signature. If the operating curve is outside of the programmed tolerance, the ADwin uses a digital output to send a signal to the PLC to indicate that there is a problem and to stop the machine. This eliminated the production of defective parts that have to be scrapped.
An onboard SHARC digital signal processor with its own local memory handles system management, data acquisition, on-line processing and control of outputs. Processing of each measurement can occur immediately after acquisition. Photo courtesy CAS DataLoggers
This ADwin-Light-16 features eight 16-Bit analog inputs, of which three are used to sample the pressure signal from the three hydraulic cylinders in the press. Two of the six digital I/O are used for the interface to the PLC controlling the press. The system also has a 32-bit SHARC real-time digital signal processor with its own local memory to handle data acquisition, online statistical processing, and control of outputs.
Real-time development was performed using ADbasic software. With ADbasic, engineers can easily create event-driven applications to capture and process data, generate output signals, and provide open- or closed-loop control. ADbasic&#;s functionality allows access to all the ADwin&#;s I/O, as well as implementing calculations, logic and communication with a PC.
The automotive manufacturer benefited significantly following the installation of the custom ADwin system for production monitoring. The system provides real-time monitoring of the stamping operations and allows the plant&#;s broken punches to be detected immediately, greatly reducing scrap costs and wasted time. And, as more data was collected it became possible to identify tooling that had become worn prior to failure, which further reduced scrap and machine downtime. The early-warning system also reduced the once-constant need for operators to inspect each part for defects. The ADwin system provided a near-immediate ROI and greatly increased quality.
For more information, visit www.dataloggerinc.com.
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Precision metal stamping is an industrial design process that involves turning metal sheets into the needed sizes and shapes. It ensures a cost-effective and fast production of precision metal parts for vehicles, electronics, industrial engineering, airplanes, and more. Metal stamping dies are precision tools that aid in shaping and cutting sheet metal parts.
These tools are developed through computer-aided design software to prove high accuracy and the best designs. The resulting designs are transferable to the stamping dies by skilled personnel known as diemakers. However, designing precision metal stamping dies involves some crucial factors you must adhere to.
What Is Precision Metal Stamping?
It&#;s a manufacturing or industrial process that uses high-end machinery fitted with dies to transform flat metal sheets into a coil or blank. These then form different custom shapes used in several industrial manufacturing processes. This process is mostly applicable in producing large numbers and various products. It&#;s applicable in two main stages:
A single-stage operation &#; in this stage, each stroke of the pressing produces a desired shape or design on the metal sheet.
A series of stages is where the metal press can produce several shapes on the metal sheet to meet the custom shape.
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Things To Consider When Designing Precision Metal Stamping Dies
When designing precision metal stamping dies, you need to ensure the production of precision metal parts. However, to ensure you get the best result, you can dwell on the following factors:
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1. Tensile Strength
This is the amount of force any material can withstand without breaking. Metals come in different strengths; some are pretty much stronger than others. This usually depends on the components of the materials in the metal alloy. The metal you choose to work with should have the strongest tensile strength. This is so that it can withstand any amount of force you apply while in use.
2. The Work Hardening Rate
The temper changes through metal stamping, making the metal more brittle or harder. The rate at which this process occurs is what&#;s known as work hardening. Depending on how much work you need to be done on the metal and in any operation, the metal may require annealing. This is the process of resetting the metal&#;s properties so that it doesn&#;t break or crack and prevents other material imperfections.
3. High Level of Quality And Quantity
The manufacturing industry faces increasing competition daily. As a result, this has pushed the precision metal stamping industries to focus more on quality and quantity. Therefore, meeting the accuracy specifications is an added advantage. Moreover, applying this to designing precision metal stamping gives room for achieving a high volume of exact specifications. This also makes precision metal stamping one of the most popular and preferred processes over others.
4. The Types Of Materials Used In Stamping
The materials used in precision metal stamping play a significant role. This is because it helps decide the amount of force necessary for cutting to achieve a desired shape or outcome. Some of the common materials you could use include:
Ferrous metals
Precious metals
Specialty metals,
Non-ferrous metals
5. Productivity And Run Times
Precision metal stamping has an amazing production rate and chances for incorporating any additional services in operation. In addition, the precision metal stamping process is automated; this can, in turn, produce hundreds of parts per hour. Therefore, productivity and run times play a huge role in ensuring efficiency in the long run.
6. Ductility And Formability
Forming and cutting are types of die-stamping operations. Forming usually occurs between the tensile strength of the material and the yield strength. If the yield strength is low, forming doesn&#;t occur. However, exceeding the tensile strength results in a material fracture. There is usually a small window between the tensile and yield when using high-strength materials.
The grain size of a material determines its formability. A consistent grain size gives high desirability for the forming operations. On the other hand, the grain size is controllable by a re rolling mill within a close range. This is done by monitoring the annealing furnace temperature and the strip&#;s speed as it passes through the line.
7. Machinability
This is the ease by which a material can easily be shaped or cut. The machinability of the material you choose to work with should come after choosing other requirements that will satisfy your part. This is because the properties responsible for improving the material&#;s performance can easily reduce its machinability. For instance, a machinable material is easy to cut and gives a beautiful finish, reducing costs. However, you must choose a material that will meet all the requirements for your desired part rather than focusing on the machinable aspect of the material.
Precision metal stamping capabilities are common and preferred over other industrial processes. With your requirements in mind, you can create a personalized precision metal stamping effect that&#;s cost-effective, efficient, and effective to aid in driving your business to the next level.
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