Stampingjournal20130102 DL

Die spring
fundamentals
Feeding sensitive
material
Expertise to help you transform metal into gold
Choosing the right

blank for the job
www.stampingjournal.com
JANUARY/FEBRUARY 2013
A PUBLICATION OF THE FABRICATORS &

MANUFACTURERS ASSOCIATION, INTERNATIONAL
AA PUBLICATION
PUBLICATION OF
OF THE
THE FABRICATORS
FABRICATORS &
&
MANUFACTURERS
MANUFACTURERS ASSOCIATION,
ASSOCIATION, INTERNATIONAL
INTERNATIONAL
A PUBLICATION OF THE FABRICATORS &

MANUFACTURERS ASSOCIATION, INTERNATIONAL
An Official Publication of the

Fabricators & Manufacturers Association, International
Vol. 25 No. 1 JANUARY/FEBRUARY 2013
>> COVERSTORY
14 Not your fathers fineblanking
Fineblankng now can produce not only flat parts, but
also those with 3-D features, often to size and position tolerances of less than 0.025 mm. It also offers
extremely high part-to-part repeatability; the first part
and the millionth part are identical. A confluence of
technologies has made such parts a reality.
On the cover: Cover images courtesy of Precision Resource Inc., Shelton, Conn.
>> Features
18 Die springs put on the pressure
Without something to manage and absorb pressure, a

die set would cease to function properly. This is why
die spring selectionwhich considers spring size,
travel, number, and placement within the toolis so
critical.
22 Feed with care
Although many of the traditional coil-handling rules

apply, processing coated coil material requires additional considerations. Stampers need to check for
equipment clearances and alignment at every point
where the finished material surface may contact
another surface.
27 Forming & Fabricating 2013

Lubricant Buyers Guide
14
>> departments
4 Meet the Press
In this economy, the one thing that is relevant is jobs. This
jungle of federal regulations isnt one where U.S. citizens can
be physically injured, but it may kill their ability to create jobs
or find work.
5 News &Notes
8 Product Innovations
Springback simulation advancements added to stamping
software; fluids impart corrosion resistance in metalworking
applications
9 Stamping Solutions
LMC Industries, a metal stamping and molding company, was
looking for a furnace to process tool steels in its facility.
10 Die Science
Columnist Art Hedrick explains that selecting the proper
blank size and profile can be critical to achieving a successful
stamping process. Attempting to form a part geometry with the
incorrect blank size or shape can result in splitting or excessive
thinning. The blank shape also affects the consistency of the
trim line tolerance.
12 R&D Update
Researchers hope to establish a practical and robust process
that increases the formability of aluminum sheet for forming
more complex parts with difficult geometries, such as tight die
corners, tight fillet radii, and deep draws.
26 Product News
33 Advertisers Index
33 Classified Advertising
34 Ask the Expert
22
an fma publication STAMPINGJOURNAL
Tom Vacca answers the question, What are the best practices
for progressive-die maintenance?
WWW.STAMPINGJOURNAL.COM january/february 2013
MEET THE PRESS
Its a jungle out there
Dan Davis
Editor-in-Chief
[email protected]
This jungle
of federal
regulations
isnt one where
U.S. citizens
can be
physically
injured, but it
may kill their
ability to
create jobs or
find work.
hat makes a jungle a scary place? Its probably fear of

what might happennot so much of what has happened. Uncertainty feeds paranoia, and paranoia forces
one to lose focus. Without focus, a person is more likely to find
himself in a dangerous spot.
Upton Sinclair observed those dangers firsthand when he went
undercover for several weeks in 1904 in the Chicago stockyards.
The journalist observed the dangers that unskilled workers had
to cope with every day, the sickness that was rampant among the
workforce, and the abuse that was heaped upon the workers by
greedy company management. Back then the workplace could be a
deadly place for someone that didnt have his wits about him.
Sinclairs book The Jungle, published in 1906, brought these conditions to the attention of most Americans and eventually led to
legislation that set federal standards for meat and food inspection.
Sinclair actually wanted the book to generate more interest about
worker safety and well-beingwhich didnt really happen until
several years later.
Today workers in the food processing industry and consumers
arent consumed with the dangers associated with delivering food
to the dinner table. People go about their lives without too much
thought of whether or not someone died getting that pot roast to
the table.
Nearly 100 years since The Jungle was published, manufacturing
company owners and managers find themselves in an environment
where they dont know whats ahead and they are handicapped in
their decision-making. They are having to deal with more and more
federal regulations, and thats causing them to focus more time on
that than on their own businesses.
Macroeconomic Impacts of Federal Regulation of the Manufacturing Sector, a report prepared by NERA Economic Consulting,
found that federal agencies under the Obama administration are
issuing an average of 72 major rules annually targeting the manufacturing community. Under the Bush-led White House, the agencies approved an average of 45 such rules.
And thats on top of manufacturing regulations already in effect.
The same study, commissioned by the Manufacturers Alliance for
Productivity and Innovation (MAPI), revealed that the federal government has drawn up almost 2,200 manufacturing regulations
since 1981. Stephen Gold, president/CEO of MAPI, called this type
of regulatory environment death by a thousand cuts.
In this economy, the one thing that is relevant is jobs. This jungle
of federal regulations isnt one where U.S. citizens can be physically
injured, but it may kill their ability to create jobs or find work.
These laws meant to protect individuals are slowly killing the manufacturing industry in this country.S
january/february 2013 WWW.STAMPINGJOURNAL.COM
www.stampingjournal.com
stamping journal staff
President & CEO, FMA
Edward Youdell
Group Publisher
Dave Brambert
Editor-in-Chief
Dan Davis
Senior Editor
Tim Heston
TPJ Editor
Eric Lundin
Senior Copy Editor
Teresa Chartos
Associate Editor
Amanda Carlson
Contributing Editor
Amy Nickel
Graphic Designers
Margaret Clark, Janell Drolsum,

Mary Mincemoyer, Jennifer Paulson
Publishing Coordinator
Kelly Palmer
Director of Circulation
Kim Clothier
Web Content Manager
Vicki Bell
Multimedia Specialist
Sherry Young
Senior Web Developer
Jason Bartholme
Web Developer
Johanna Albee
stamping journal editorial

advisory board
Tom Bell, Bohler Uddeholm Corp.
Bruce Braker, Tooling & Mfg.
Association (TMA)
Jerry Busse, Rockford Toolcraft Inc.
Michael Chester, Buhrke Industries Inc.
Mark Fansler, Thomas Built Buses, Inc.
(Ret.)
Steven E. Gruver, Orchid International
Art Hedrick, Dieology

Brad Rine, Honda of America
Mary E. Schacht, E.C.
Styberg Engineering Co., Inc.
Jim Schwartz
Eagle Wings Industries, Inc.
Zeev Zimerman,
Bethlehem Steel
Advertising Sales
Associate Publisher

Senior Account Representatives
Michigan/Northeast

Jim Gorzek 815-227-8269

[email protected]

Sean Smith 815-227-8265
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Ohio/Southeast/
International
Mike Lacny 815-227-8264

[email protected]
Louisiana/Mississippi/West Tony Arnone 815-227-8263

[email protected]
Minnesota/Iowa/Indiana/ Amy Hudson 815-227-8237
Missouri/Wisconsin/Canada [email protected]
Alabama/Florida/
Illinois/Tennessee
Michael Scott 815-227-8271

[email protected]
Classified Advertising

Patty DAmico 815-227-8278

[email protected]
Director of Accounting
Bob Young
Accounts Receivable/
Credit Coordinator
Mary Simons

How to Contact Us
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Web site www.stampingjournal.com
Statement of Policy
The STAMPING Journals objective is to disseminate new and
complete information relating to the metal stamping industry. The
main editorial text consists of articles and news releases designed to
assist owners, managers, manufacturing engineers, supervisors and
foremen in the evaluation of new methods and techniques. It is an
official publication of the Fabricators & Manufacturers Association,
International. The policy of the publisher and this journal is to be
nonpartisan, favoring no one product or company. The representations of facts and opinions expressed in the articles are those of the
author and are not necessarily endorsed by the publisher and this
journal. By including information on new products, new literature,
news of the industry, articles, etc., this impartiality is strived for and
extends to the mention of trade names. Unless product identification
makes reference unavoidable, the generic name is used. We acknowledge that on occasion there may be oversights or errors; the editors
regret such oversights and re-emphasize their policy to be impartial
at all times. The Publisher reserves the right to refuse advertising
it deems inappropriate for publication in STAMPING Journal,
including ads for classes of products and services not considered of
significant interest to the readership. (ISSN 1091-2460) STAMPING
Journal is a trademark of FMA Communications Inc. All rights
reserved. Publications of FMA Communications Inc., maintain a
policy of keeping editorial and advertising separate to ensure editorial integrity that most benefits our readership. Editorial content,
including feature articles and press releases, is determined solely
by the publisher. Editorial content cannot be purchased, nor can it
be used as a benefit of advertising dollars spent. Editorial is freeof-charge, subject to space availability, and open to all interested
parties that submit items meeting our editorial style and format as
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card for full rates and data.
Note: Some photographs printed in this publication may be taken
with safety equipment removed for photographic purposes. However,
in actual operation, it is recommended that correct safety procedures
and equipment be utilized.
STAMPINGJOURNAL an fma publication
NEWS & NOTES
Dayton Progress,
Anchor Lamina to be
acquired by Misumi Group
Misumi Group Inc. of Japan has
signed a definitive agreement to
acquire Dayton Progress Corp. and
its subsidiary, PCS Co., from Connell
Ltd. Partnership, pending certain
regulatory approvals. The acquisition also will include the Anchor
Lamina Die Components business of
Connell, known for its Danly, IEM,
Lempco, and Lamina brands.
The Die Set and Fabrication divisions of Anchor Danly, not included
in this acquisition, will continue to
remain subsidiaries of Connell Ltd.
Partnership and will continue as a
strategic partner of the Components
Div. of Misumi.
Dayton Progress and Anchor

Lamina manufacture tooling and die
components for stamping and forming. Dayton Progress has 10 factories in North America, Europe, and
Asia employing 1,000 people and
shipping to 13,000 customers in 51
countries. Anchor Lamina employs
more than 400 people at two U.S.
and two China factories.
Kenmode Precision
Metal Stamping
receives two safety awards
Kenmode Precision Metal Stamping,
Algonquin, Ill., has received two
awards from the Tooling & Manufacturing Association (TMA) in recognition of its commitment to safety
in the workplace.
Kenmode received the 2011 Safety Award for having achieved an outstanding safety record that exceeds
the industry average for occupational injuries or illnesses during 2011.
This was the second year in a row
Kenmode applied for and received
this award. Out of more than 700
members, Kenmode was one of
80 employers that applied for and
received this award.
Kenmode also received the 24/7
First Aid Award, which is an award
given to member companies that
have a first-aid team certified in first
aid and CPR/AED. Kenmode was
one of two recipients of the award.
TMA is a manufacturing association serving more than 1,200 member companies in the greater Chicago area.
NEWS & NOTES
Dickten Masch Plastics

acquires Nyloncraft Inc.
Dickten Masch Plastics (DMP), a
thermoplastics and thermoset manufacturer with metal stamping and
assembly capabilities in Nashotah,
Wis., has acquired technical plastics

manufacturer Nyloncraft Inc., Mishawaka, Ind.
The two companies offer Nyloncrafts patented vacuum boost aspirator and injection compression
technology, complemented by DMPs
thermoplastic and thermoset processes, fluid level indicators, and

materials analysis lab services.
Nyloncraft operates as a wholly
owned subsidiary of DMP, retaining
the same name, organization, and
team at its Mishawaka and Jonesville,
Mich., facilities. DMP operates facilities in Nashotah; Ankeny, Iowa; and
Monterrey, Mexico.
Plant news
Rolled Alloys has opened a new
facility in Windsor, Conn. The
40,000-sq.-ft. service center replaces
the previous location. Rolled Alloys
supplies stainless steels, nickel,
cobalt, and titanium alloys.
Canada-based Thunder Tool
& Mfg. Ltd. has purchased a
30,000-sq.-ft. metal stamping facility in Richmond, Ky. The company
plans to create 45 new, full-time
jobs and invest $2.2 million in the
project.
NEWS & NOTES
Equipment news
FerrouSouth has announced the

installation of what the company
says is the most powerful stretcher
leveler in the country. The Butech
Bliss machinedubbed The Eliminator for its ability to eliminate steel
memoryis in operation at FerrouSouths Iuka, Miss., facility.
The machine can produce more
than 4 million lbs. of stretching
force to remove internal stress from
steel sheets measuring 0.125 to 0.5
in. by 96 in. The resulting material,

including ultrahigh-strength steel, is
laser flat with no memory, the company states. The stretcher leveler is
installed inline with a Herr-Voss 0.5by 96-in., 11-roll precision leveler.
FerrouSouth, an operating division of Ferragon Corp., provides toll
processing services for hot-rolled
steel products.
Herr-Voss Stamco, Callery, Pa.,
is providing a new cut-to-length line
for Ken Mac Metals Div. of ThyssenKrupp Materials North America Inc. The line will process ferrous
and nonferrous material from 0.075
to 0.312 in. thick by 72 in. wide in
coils up to 60,000 lbs.
The line features a Precision Leveler, as well as a roll feed and shearing system. A dual stacking system
completes the line.
PRODUCT INNOVATIONS
Springback simulation advancements added to stamping software
Forming Technologies Inc. has

released FormingSuite v10.0 and
FTI CATIA V5-based software,
aimed at sheet metal forming and
costing engineers, designers, and
estimators in the automotive, aerospace, consumer product, and electrical/electronic industries.
The software features several
advancements in springback simu-
lation, including new forming constraints to simulate clamping for

positioning in jig and fixture tooling,
a new springback alignment feature
to position the results relative to the
original part, and improved NAS
and STL file export for CAD springback compensation.
New measuring tools eliminate
the need for users going to CAD
dimensional information. Optional
direct 3-D CAD data translators read
NX, CATIA V5, SolidWorks, JT,
and Pro/ENGINEER.
In addition, a dFIT solver has
been added to Fastform MultiStage
to complement the existing iFIT
solver. The user can import any
blank geometry and use the dFIT
solver to evaluate the process start-
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ing from the known blank size and

location and progressing through
the stamping stages. The simulation
identifies the extent of first-form
deviation from design, as well as
any formability concerns resulting
from the change of the blank from
net shape. The dFIT solver also can
optimize the location of in-process
trims to help ensure the final part is
to print.
Forming Technologies Inc., 3370
South Service Road, Burlington,
ON L7N 3M6, Canada, 905-3403370, www.forming.com
Fluids impart corrosion

resistance in metalworking
applications
Houghton Intl. offers Drawsol
850 X4 straight oil lubricant for
heavy-duty drawing and stamping
and Rust Veto AS corrosion inhibitor.
The lubricant is formulated primarily for drawing, stamping,
forming, and extruding. Suitable
for difficult steel and stainless steel
operations, it is a compounded
blend of EP agents, fatty lubricants,
petroleum oil, and other inhibitors. A corrosion-inhibition package
allows steel parts to remain free of
corrosion during storage.
The corrosion inhibitor is
designed for long-term protection of
drill pipe and capped casing threads,
especially in offshore tubular products. It protects metal against corrosion for up to 12 months during
outdoor storage in extreme climate
conditions. Indoors, it provides protection for two years or more.
Houghton Intl. Inc., Madison &
Van Buren Aves., P.O. Box 930, Valley Forge, PA 19482-0930, www.
houghtonintl.com
STAMPING SOLUTIONS
Dual-chamber furnace lets stamping

company heat-treat tool steels in-house
firebrick and mineral wool block
insulation for energy efficiency and
low outside shell temperature, the
9- by 12- by 24-in. upper chamber
heats to 2,300 degrees F. Heating
elements are mounted on side walls
and the door in removable panels
with V grooves open to coils for
maximum radiation and quick heat
response. The vertical-lift, counterweighted door is operated with a
hand crank.
A lower tempering chamber of the
same dimensions, built with 4.5 in.
of insulating firebrick and mineral
wool block, heats to 1,200 degrees
F. A 16-ga. stainless steel liner forms
the work chamber. A 16-HP-motor,
recirculating alloy fan directs the

heated air in a horizontal flow pattern while isolating heating elements
from the work load. The lower
chamber features a horizontal swing
door with 5 in. of insulation, a cam
lock, and safety microswitch.
Both chambers are controlled by
Honeywell UDC 2500 microprocessor-based, digital, time-proportioning temperature controllers with a
separate high limit controller on the
upper chamber.
Lucifer Furnaces Inc., 2048 Bunnell
Road, Warrington, PA 18976, 800378-0095,
www.luciferfurnaces.
com
Situation
LMC Industries is a metal stamping
and molding company in Arnold,
Mo. The company was looking for
a furnace to process tool steels in
its TS 16949- and ISO 9001-certified facility, which supports both the
stamping and molding divisions.
The goal of adding the furnace was
to move heat-treating operations inhouse and to improve heat-treating
turnaround time in emergency situations and on weekends.
Resolution
After searching the web and talking
to several companies, LMC chose
the model HL82-H24 dual-chamber
furnace from Lucifer Furnaces Inc.
According to Max Vogl, toolroom
manager, the furnace gives us the
versatility of heat-treating a wide
variety of tool steels, which includes
powder metals such as CPM.
Built with 5 in. of multilayered
DIE SCIENCE
Choosing the right

blank type for your
stamping application
By Art Hedrick
electing the proper blank size

and profile often is critical to
achieving a successful stamping process. Attempting to form a
parts geometry with the incorrect
blank size or shape can result in
splitting or excessive thinning. The
blank shape also affects the consis-
es, and frictional values, using a fully

developed blank often results in
mild to severe variation and inconsistency in the edge dimensions
(trim lines) of the part. When severe
drawing and stretching are used to
form the part, something as simple
as mixing and applying the forming
Attempting to form a parts

geometry with the incorrect
Fully Developed Blank
blank size or shape can result in

splitting or excessive thinning.
tency of the trim line tolerance. You
must carefully consider the parts tolerance, the amount of material being
used, and how the blank size affects
the drawing ratio and the amount of
springback that will occur.
Although blanks come in many
configurations, only three fundamental types are used in sheet
metal stamping: fully developed,
partially or semideveloped, and
undeveloped.
Fully Developed Blanks

A fully developed blank (see Figure
1) is shaped so that after it is formed,
it will not require any additional
trimming operations. The net shape
of the part is already established.
Because of normal sheet metal
variables, such as small differences
in mechanical properties, thickness10
lubricant can result in significant

trim line inconsistency.
A fully developed blank typically
is susceptible to high springback
because theres no additional metal
in the blank to constrain. To reduce
springback in a part, you must permanently deform the metal using
stretching, drawing, or compressing, but these operations can be
performed only when additional
metal is available outside the actual
product.
One advantage of a fully developed blank is that it can reduce
material consumption and tooling
cost. Because the blank does not
require any extra material to make
the part, it can be smaller to begin
with, and trimming dies can be
eliminated. Fully developed blanks
lend themselves to simple geometry,
Formed Part
Figure 1
A fully developed blank is shaped so that
after it is formed, it will not require any
additional trimming operations.
so they can be formed with mostly simple bending, flanging, and

embossing processes.
Semideveloped Blanks
A partially or semideveloped blank
(see Figure 2) is shaped so that just
enough material is used, allowing
for minimal material trimming later.
This type of blank is used for parts
with small trim tolerances. A semideveloped blank requires slightly
DIE SCIENCE
inward, resulting in excessive material stretching and possible splitting.

Although somewhat conservative
for some materials and excessive for
others, a good rule of thumb is to use
a blank no larger than two times the
punch diameter. The same guideline
applies to the corners of a square or
rectangular drawn shell.
Undeveloped Blanks
Drawn Cup
Semideveloped Blank
Figure 2
A partially or semideveloped blank is shaped so that just enough material is used.
more material to produce a part than

a fully developed blank, and secondary trimming is required.
When a part must be drawn,
the blank must be shaped with the
blank edge close enough to the
forming punch to allow metal to
flow inward toward the punch. This
relationship between the punch and
the blank edge is known as the limiting drawing ratio. Consider how an
axial symmetrical cup is drawn. For
the larger-diameter round blank to

become the smaller-diameter cup,
the metal must flow inward toward
the centerline of the cup at the same
time it compresses. If the compression is controlled between the die
face and a pressure or drawing pad,
the result is a part with a flat flange.
Metal in compression has a great
resistance to flow. If there is too
much surface area outside of the
punch, the metal will resist flowing
Undeveloped Blank
An undeveloped blank (see Figure

3) starts off as a basic shape such
as a square, rectangle, trapezoid, or
any other shape that can be created
using straight-line cuts. You can use
a simple shearing die to cut a special
shape from an undeveloped blank
there is no need to purchase a special blanking die.
An undeveloped blank often is too
large or too far from the punch to
allow metal flow to occur, and this
can result in splitting. Like semideveloped blanks, undeveloped
blanks require secondary trimming.
Combination Blanks
Blanks also can be fully developed
in certain areas and partially developed in other areas. This allows the
process engineer to hold tight tolerances in areas of the part that require
them and save material and the cost
of additional cutting operations in
areas that have greater tolerance.
Dont underestimate the impact
of the blank size and shape. All too
often, the need for materials savings
overrides the ability to make a good
part. Avoid sacrificing part quality
and creating scrap to save a few pennies in material cost. Use just what
you needno more and no less.
Until next time Best of luck!S
Formed Part
Figure 3
An undeveloped blank starts off as a basic shape such as a square, rectangle, trapezoid, or any other shape that can be created using straight-line cuts.
Art Hedrick is president and senior consultant of

Dieology, 8730 10 Mile Road S.E., Rockford, MI
49341, 616-894-6855, [email protected].
com, www.dieology.com.
11
R&D UPDATE
Aluminum sheet forming

for automotive applications,
Part I
Material properties and design guidelines
By Tingting Mao and Taylan Altan
ever, 5xxx alloys are prone to the

formation of Lders bands during
forming, so they are used mostly for
inner-panel applications. 5182 and
5754 are the principal 5xxx series
alloys used in autobody panels. 5754
also is recommended for elevatedtemperature applications.
The 6xxx series alloys are heattreatable to reach ultimate tensile
strength of 125 to 400 MPa. The
alloys, especially 6022 and 6111,
often are used for outer panels since
they are precipitation-hardened and
free of Lders bands.
Editors Note: This is Part I of a two-part series that

discusses the forming of aluminum sheet for automotive products. Part II, to appear in the March/
April 2013 issue of STAMPING Journal, will
discuss the lubricants used in aluminum forming.
luminum is used extensively

for such automotive parts as
hoods, trunk lids, and doors
because of its light weight, workability, and recyclability. and its market
share continues to increase.
Commonly Used Alloys

The 5xxx and 6xxx aluminum alloys
are used most commonly for automotive applications. Their mechanical properties for automotive body
sheets are listed in Figure 1, and
their specific properties and main differences are shown in Figure 2.
The 5xxx alloys have ultimate tensile strength of 125 to 350 MPa and
cannot be heat-treated. They have
relatively good formability and are
highly resistant to corrosion. How-
Design Guidelines and

Requirements
The key requirements for automotive
closures are panel bending stiffness
and dent resistance. The elastic modulus of aluminum (70 GPa) is about
one-third that of steel (210 GPa). As
a result, parts previously designed for
steel need to be redesigned to achieve
the same stiffness.
Mechanical Properties
Alloy
AA5022
Ultimate Tensile
Strength (MPa)
275
Yield Strength
(MPa)
135
Elongation
(%)
30
n-value r-value
0.3
0.67
AA5023
5000
AA5182
Series
AA5052
285
135
33
265
125
28
0.33
0.8
190
90
26
0.26
0.66
AA5754
212
90
22
0.34
AA6022
275
155
31
0.25
0.6
235
130
28
0.23
0.7
290
160
28
0.26
0.6
6000
AA6016
Series
AA6111
Figure 1
The mechanical properties of several aluminum sheet alloys for automotive applications are shown here. Source: T. Sakurai, The latest trends in aluminum alloy sheets
for automotive body panels, Kobelco Technology Review, No. 28 (Oct. 2008).
12
One way to improve stiffness in

aluminum is to increase the ribbing
used in the product or increase the
part thickness. For closures and
body-structure sheets, the thickness
should be increased by a factor of
about 1.45:1
3
taluminum
Esteel
= E
= 1.44
tsteel
aluminum
where: t = thickness

E = Youngs modulus
The resulting weight saving is
about 50%:
massaluminum
= 1.44
masssteel
densityalu
1.44
densitysteel =
2.7
7.8
= 0.5
Another important design criterion

for aluminum alloys is dent resistance
for static and dynamic conditions. To
reach a static dent resistance comparable to steels, aluminum sheet
should meet the following thickness
requirement:
taluminum tsteel
YSsteel
YSaluminum
Where: t = thickness

YS = yield strength
Figure 3 shows the aluminum
sheet properties compared to those
of steel, based on dynamic dent resistance studies.
Figure 4 shows the weights
of three different hoods made of
mild steel, high-strength steel, and
Al6016, respectively. For mild steel,
the reduction in weight is limited by
the dent resistance; for high-strength
steel, it is limited by local stiffness.
When the hood is made of Al6016,
its weight can be reduced by 50 percent.
Critical Material
Parameters
Some critical parameters are different
for aluminum than steel, and they
affect formability:
AA6016
AA6111
AA5182
AA5754
Jo
in
W
eld
ab
ili
ing
ty
De
nt
Re
sis
ep lity
De a b i
aw
Dr
tan
ce
Stretchability
on
si ce
rro tan
Co sis
Re
Life Cycle
Process Chain
min
Quality
Surface Appearance
220
180
140
100
200 250 300 350 400
Reference Steel Panel YS (MPa)
Figure 3
Figure 2
Properties and forming characteristics vary among the 5xxx and 6xxx alloys used for
manufacturing car body components. Source: I.J. Hirsch, Automotive trends in aluminum The European Perspective, Aluminum Alloys: Their Physical and Mechanical Properties: proceedings of the 9th International Conference on Aluminum Alloys
(ICAA9), eds. B. Muddle, A. Morton, and J. Nie (Institute of Materials Engineering
Australasia, 2004).
Elastic ModulusWith an elastic modulus one-third that of steel,

aluminum parts experience more
springback. This can be reduced by
increasing the blank holder force,
the amount of stretching, and sheet
thickness. The forming operation
must be optimized to ensure at least
2 percent stretch throughout the part
(see Figure 5).
FrictionFriction between the
tool and the aluminum sheet is
expected to be higher compared to
steel sheet because aluminum has a
surface roughness (Ra) from 0.25 to
0.38 micron. In comparison, the Ra
of steel sheet is about 0.63 to 0.88
micron. The smoother texture of alu-
260
Automobile
Hood
For
Properties
Aluminum Panel YS for 50%

Weight Saving (MPa)
R&D UPDATE
minum requires dry, waxlike lubricants.

FormabilityFor the stamping
of autobody parts, the lower formability of aluminum compared to steel
can be offset to some extent by using
technology such as advanced addendum design, local blank holder force
control with multiple-point hydraulic cushions, or warm forming. Warm
forming using heated dies and heated
blanks has been investigated extensively, and recent studies have shown
that the use of heated dies complicates the process and increases costs.
Present R&D efforts are focused on
heating the sheet to warm forming
temperature while keeping the dies
This graph compares yield strength of

aluminum and steel based on dynamic
dent resistance studies. Source: Design
with Aluminum (European Aluminum
Association, 2011).
at room temperature.
Researchers hope to establish a
practical and robust process that
increases the formability of aluminum sheet for forming more complex
parts with difficult geometries.S
Tingting Mao is a graduate research associate and
Taylan Altan is professor and director of the Center for Precision Forming (CPF) at The Ohio State
University, 339 Baker Systems, 1971 Neil Ave.,
Columbus, OH 43210, 614-292-5063, www.
cpforming.org and www.ercnsm.org.
Notes:
1. The Aluminum Automotive Manual, version
2011, European Aluminum Association.
Mild Steel
Design Criteria Specification (YS = 200 MPa)
t 0.8
Dent Resistance YS t2 Cte
Local Stiffness
E t2 Cte
t 0.7
Weight (kg)
14
* After Deformation and Paint Baking
High-strength Steel
(YS = 300 MPa)
t 0.65
t 0.7
12.4
AI 6016
(YS = 150 MPa)*
t 0.92
t1
6.1
Figure 4
Automobile hood weight decreases substantially when Al6010 is used rather than
steel. Source: Design with Aluminum (European Aluminum Association, 2011).
Figure 5
Strains of at least 2 percent are necessary when stamping aluminum to
reduce springback. Source: W. Thomas
and T. Altan, Saving weight with aluminum stampings Part II, STAMPING
Journal, July/August 1999, p. 84.
13
Not your
fathers
fineblanking
A confluence of advancements has made

extremely complex forms possible
By Kaveh Vafaei
or decades fineblanking has

been known to produce parts
with smooth, extremely precise
edges. But the processs current capabilities are quite different from when
it was originally patented in 1923
and commercialized in the 1960s.
Cut edges can have as much as
a 100 percent sheared surface, if
required; while some taper remains,
Figure 2
Cut edges can have as much as a 100
percent sheared surface, if required.
14
JANUARY/FEBRUARY 2013 WWW.STAMPINGJOURNAL.COM
it is typically only half a degree. Its

precision and repeatability make it
perfect for manufacturing critical
parts in moving mechanisms, producing near-net-shape, finished components right out of the press.
Fineblankng now can produce
not only flat parts, but also those
with 3-D features, often to size
and position tolerances of less than
0.025 mm. It also offers extremely
high part-to-part repeatability; the
first part and the millionth part are
identical.
A confluence of technologies has
made such parts a reality (see Figures 1 and 2). Without
advances in presses,
tooling, software,
and
lubrication,
many of todays
advanced
fineblanking applications
simply wouldnt be possible.
Fineblanking Fundamentals
Fineblanking combines the concepts
of metal stamping and cold-metal
extrusion. It requires specialized
Figure 1
Incremental advancements in various
areas, from tooling to press operation,
have allowed engineers to fineblank
complex parts, including those with 3-D
features like bends and offsets.
presses, unique tooling, as well as

workpiece materials that lend themselves to forming without inclusions
and impurities.
To blank and pierce in conventional stamping, the punch contacting the
workpiece induces highly compressive stresses and plastic deformation.
The desired behavior of the material
is to reach its rupture point abruptly,
essentially breaking the material into
the required shape.
While perfectly acceptable in conventional stamping, this isnt accurate enough for precision parts. Many
such components may require additional machining. Fineblanking can
eliminate that requirement, and it
also can produce parts that may have
been made previously by costlier
processes, like powder metallurgy or
metal injection molding.
STAMPING JOURNAL AN FMA PUBLICATION
Unlike conventional blanking

which forces the metal to its ultimate
tensile strength quicklyfineblanking does the opposite, promoting
material flow like in an extrusion.
A compound tool, with a blanking
punch on one side and a counterpunch on the other, supports the
workpiece throughout much of the
stroke.
This tool allows the process to produce small holes and thin web sections relative to the material thickness. And with punches held in place
by the counterpunch, they are always
in the same position relative to other
features blanked in the same station.
During the stroke an impingement
ring, or V ring, presses into the material to prevent lateral material movement during piercing or blanking.
The ring also ensures enough material is in the die cavity to create a fully
sheared, straight edge.
Figure 3 shows a simple slidingpunch fineblanking tool making a
round washer with a hole at its center
(1). In this setup, the tool closes and
pressure embeds the impingement
ring into the stock (2). The blanking punch advances until the part is
fully sheared and resting in the upper
die opening (3). In the same action,
the pierce punch produces a hole in
the workpiece. Simultaneously, the
counterpunch pressure holds the part
firmly against the face of the advancing blanking punch. This maintains
flatness and produces a clean, precise
edge. After this, the press relaxes all
forces, the tool starts to open, and the
ram descends by gravity.
Next, blanking pressure reverses,
the punch pulls back, and an ejector pin pushes out the slug. At the
same time, raw material advances to
the next cycle (4). Finally, pressure
from the counterpunch is reapplied,
pushing the part out of the die opening (5), and air blasts or mechanical
sweeps remove the part and slug from
AN FMA PUBLICATION STAMPING JOURNAL
the die area (6). The system then is

ready to start the next cycle (7).
Extruding a Blank
The forming is a controlled extrusion
of the workpiece material into the die
cavity. The tooling clamps the workpiece in place to control its elastic
flow. To that end, the die cavity has
radiused cutting edges that allow
the material to flow instead of being
cut. In effect, the part is extruded out
of the strip.
In fact, the material does not rup-
ture until the punch moves all the

way through the material thickness.
Only in this controlled state, with the
part edge pinched between punch
and die components, does fineblanking allow the metal to rupture.
This fundamental difference makes
the press itself quite different from
conventional machines. Fineblanking presses must be especially rigid
to minimize stretching and deflection during operation. This enables
the use of tools with very tight fits
and clearances, without concern
Metal Stock
1.
5.
Piercing Punch
Counterpunch
Die Plate
Stinger
Plate
Blanking
Punch
Impingement Ring
Ejector Pin
6.
2.
3.
7.
Figure 3
This simple fineblanking setup produces a washer with a round hole in
the center.
4.
WWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2013
15
for damage. Clearance between the

punch and die is typically 0.5 percent
of the material thickness.
Also known as triple-action presses,
fineblanking presses perform three
motions. First is the stinger pressure,
which brings the two halves of the
tool together and clamps the material with the stinger, or impingement ring. The second motion is the
blanking pressure, which pushes the
part into the die cavity. The third is
the counterpressure, which applies
the counterforce against the part
throughout the blanking cycle.
Suitable Materials
Because the fineblanking press
extrudes the metal, workpiece elongation characteristics are important.
Many different carbon steels, alloy
steels, stainless steels, and nonferrous metals can be fineblanked. Generally speaking, the lower the yield
point of the material, the greater its
elongation, which makes it more
suitable for fineblanking.
The grain size and the level of
spherical cementite structure also
influence the process. The smaller
the grain size and the higher percentage of spheroidization, the better the material will flow; this means
the part will exhibit a better surface
finish in the areas of the cut.
part. Advances in tool steels and tool

surface coatings, as well as extremetemperature, oil-based lubrication
and methods of application, have
allowed the tools to keep up with the
increased blanking speed.
Presses can be mechanical (for
lower-tonnage applications), hydraulic, and, most recently, servo-driven
machines. Modern hydraulic fineblanking presses can stroke much
faster than their older cousins. For
instance, the weight of the press bed,
or table, traditionally has pushed the
oil down on the return stroke. Now
the return stroke may be driven by
separate hydraulics.
Unlike conventional
blankingwhich forces
the metal to its ultimate
tensile strength quickly
fineblanking does the
opposite, promoting
material flow like
in an extrusion.
Advances in Press Technology

Fineblanking has evolved rapidly in
recent years, mostly through various
incremental improvements, and one
of the most significant advances has
been in the press itself. For many
years fineblanking was labeled as
a slow process requiring cumbersome hydraulic presses. Now new
hydraulic presses can run at more
than 50 strokes per minute (SPM),
in many cases matching the speeds
of conventional stamping of similarthickness materials, all without jeopardizing the precision of the blanked
16
Servo-driven fineblanking presses are just beginning to make an

appearance in the field, and their
fully programmable stroke is showing its advantages, especially when
performing multiple forms. During
the development process, a technician usually inches down the ram to
determine the right shut height and
other parameters for the application.
With a servo-driven press, the technician can dial in the ram position,
adjusting it in increments down to
a fraction of a millimeter. The table
remains at a constant pressure, and

the technician can perform the operation in slow motion and in a controlled manner, to discover how the
metal really is forming. This greatly
reduces the time required for development work.
A fully controllable ram also allows
technicians to vary the speed, moving
slower during a portion of the form,
then faster during the second portion
of forming. Say an application calls
for a 5-mm-thick workpiece material.
The operation may require a 2-mm
coin, then an extrusion to blank the
part. The press ram can move slower
for the coining operation, then speed
up to perform the extrusion.
Advances in Tooling
and Toolmaking
Many of todays fineblanked components use progressive tooling, a
departure from the single-station,
compound-tooling concept the process is known for. Although many
concepts of cold forging and progressive stamping have been converted for use in fineblanking tools,
the processs advantage remains the
rigidity of the press-tooling combination. These rigidity requirements
mean that the tooling and press can
be only so large, which limits the die
space and the number of stations.
In these situations, additional
innovations have helped make fineblanking work. In many cases, several forming processes may need to
take place in the same die station to
keep relative feature positions intact.
New concepts of punch holding as
well as in-die fastening help overcome these challenges.
Additional hydraulic cylinders
also may be integrated within the
tooling. These can control the timing of certain operations, like the
ejection of a part or slug or the
application of an opposing pressure
when forming a certain element, to
maintain a controlled material flow.

When it comes to speed, the constraint quite often isnt the press;
its the toolmore specifically, the
mechanisms used to eject a slug. So
in many cases, slugs arent ejected
but instead are dropped through the
bottom of the die. A misplaced slug
can cause a crash, so such setups
often require sensors to ensure slugs
evacuate at the right place and time.
Trends in machining also have
pushed toolmaking forward. Modern wire electrical discharge machining (EDM) centers cut tooling components within a few microns. The
components coming off the wire
EDM require almost no secondary
finishing; the traditional white layer
on the tool component surface has
been all but eliminated. High-speed
machining operations can cut complex forms in tools, often in the
hardened condition.
Adopting concepts from highspeed stamping and cold forging,
fineblanking now makes extensive
use of carbide tooling materials.
These, along with the polishing of
tool components and hard machining of die forms, have allowed fineblanking to create intricate 3-D
forms.
To take advantage of new machine
tool capabilities, 3-D modeling software and forming simulation have
allowed tool designers to build and
perform initial tool tryouts virtually.
This has reduced optimization time
and helped designers troubleshoot
certain problems before any real tool
is built, reducing tool-build costs
substantially.
press technology, and lubrication

have had a compounding effect.
Costs continue to go down due to
better output; the complexity of fineblanked components continues to
grow; and the process continues to
help eliminate secondary operations
and improve product reliability. All

in all, thats a good combination.S
Kaveh Vafaei is division manager, Precision
Resource Technical Center, 10 Cherry Blossom
Road, Cambridge, ON N3H 4R7, Canada, 519653-7777, www.precisionresource.com.
Same Fundamentals,
Better Fineblanking
Although the basics remain the
same, fineblanking advances in all
aspects of the processincluding
tool machining, software, tool steels,
tool surface coating, tooling design,
17
Die springs put

on the pressure
18
Springs must apply the right pressure

at the right time and place
ie springs, an essential
stamping die component,
create the optimal pressure for restraining the sheet material in a fixed position while it is
being pierced, formed, flanged, or
trimmed. The springs also provide
controlled return pressure for the die
stripper to permit the punches and
other die-mounted tools to evacuate
the material during the presss return
stroke.
Die springs are most commonly
used to actuate strippers, but they
can also be found behind form pressure pads and binder rings in draw
dies. The goal is to provide adequate
die spring pressure within the limited remaining space of the die (see
Figure 1).
To select a die spring, you first
should gather information about
three different aspects of the die
design: how much pressure is needed; what spring size and how many
are needed to produce that pressure;
and how far these springs must collapse or travel.
Pressure
Requirements
To determine spring pressure for a
spring used in a stripper, first calculate the perforating pressure for
the entire die. To do this, you need
to know the thickness and shear
strength of the part material as well
as the length of shear or cutting distance. These elements multiplied
together will give you the perforating pressure. The formula reads:
Perforating pressure = S T L
Where:
S = Shear strength of the part
material
T = Part material thickness
L = Total length of shear or cutting
distance
A pressure equal to 10 to 15 percent of the total perforating pressure
typically is used to actuate the stripper (the range accommodates the
Figure 1
This flow chart shows the information needed to select the proper die spring.
potential differences among spring

manufacturers). This allows for the
downward ram speed to align safely
and engage the die shoe components
into their guided, mated components before material contact (see
Figure 2).
The formula for stripping pressure
is:
Stripping pressure = Perforating
pressure 0.10 to 0.15
Although the formula for determining pad pressure in a form die
is different from that of a stripper,
it must still contain the same three
elements of (1) pressure, (2) quantity and size of springs, and (3) the
travel. The pad pressure in a forming operation should be at least 1.5
times greater than the force required
for bending the part (see Figure 3).
Bending pressure = (S 0.166
T2 ) / ( T + R1/2 + R2/2 ) L
Where:
S = Tensile strength
T = Material thickness
R1 = Radius on form punch
R2 = Radius on form die
L = Length of form
The pressure pad formula is:
Pad pressure = Bending pressure
1.5
A forming operation requires
more pad pressure than a bending
operation because of the need to
control sheet material movement
over the forms and maintain its new
shape. The pad pressure also helps
to prevent material from scoring or
tearing as it is being formed.
Pressure requirements for binder
rings in draw dies tend to be less
scientific, determined by trial and
error. It is not uncommon to find
a note on a draw die design stating
the spring requirement as springs
to suit.
As the binder ring holds the
material in its locating position, the
spring pressure required tends to be
adjusted to eliminate the tearing and
Figure 2
As the ram moves down, the stripper makes contact with the part material and stops.
The spring continues to compress, or travel, until the ram reaches the bottom of its
stroke.
shearing that may occur while the

material is being drawn or stretched.
A too-high spring pressure will
inhibit the drawing of the material,
while too little pressure will draw
material up the form and fail to provide a uniform wall thickness.
Spring Size and

Quantity
The amount of available space in
the die will help determine how
many springs to use and what sizes
to choose. Whenever possible,
try using numerous low-pressure
springs rather than a few high-pressure springs. This will reduce stress
on the springs.
As long as the tool layout permits
the necessary space, more springs of
lower pressure allow for more evenly
distributed pressure and a more balanced stripper pad. This enhances
sheet material control throughout
the complete press stroke. Also, if
just one die spring becomes fatigued,
the die pad will continue to operate
with the other springs.
Die spring placement, when
applicable, should be nearest the

area being pierced, formed, flanged,
or trimmed. This enhances the ability to locate the most pressure on the
area being worked upon while maintaining sheet material control. The
use of spring cams, retainer bolts,
or spring pockets serve to guard
the springs from debris and protect
the tool die details in the event of a
fatigued or broken die spring.
Travel Requirements
When springs are installed in a die,
they are compressed approximately
0.125 in. Called preload, this compression is necessary to keep the
springs from working their way out
of the die. As a side benefit, the preload reduces the shock associated
with rapid loading and unloading of
the die and increases the spring life.
The bottom of the stripper draws
up just short of being flush with the
end of the punch. This ensures that
the part material strips completely
off the end of the punch. When the
press cycle starts, the ram begins
to move downward. The stripper
19
Figure 3
This form die shows spring position and travel.
makes contact with the part material and stops. As the ram continues
descending, the springs compress,
allowing the punches to extend
through the part material and into
the die button until the ram reaches
the bottom of its stroke. This compression is called stripper travel.
The travel of a spring is determined by the spring preload, thickness of the material, entry of the
punch into the die button, and the
distance the stripper hangs below
the bottom of the punch. Put simply, preload plus the stripper travel
equals the total spring travel.
The same is true in form and draw
dies. Pressure pads or binder rings
will also travel and compress the
springs. Preload plus travel of the
stripper or comparable component
will give you the total travel of the
spring.
To reduce stress and allow for
20
maximum spring life, you should

keep preload and travel to a minimum. The more rapidly a spring
works in compressing and decompressing, the greater the fatigue
factor. Slower-spring applications
permit longer spring travels, longer
spring life, and the ability to operate near maximum spring deflection
levels. The faster a die spring cycles,
the shorter the spring life expectancy. In such fast cycling applications,
you should lower the spring deflection.
Spring Selection
Now that you know the pressure,
approximate size, and travel, you
can begin the actual spring selection
process. This starts by combining
the three aspects of the die design.
First, divide the total stripping force
required by the number of springs to
be used.
The selected spring must deliver

the desired pressure at preload. To
determine the pressure of the spring
at a given preload, multiply the
amount of preload by the amount of
pressure the spring develops over 1
inch. Most spring catalogs give pressure ratings over 1 in. as well as various other amounts of compression
or travel.
Keep in mind that the spring must
offer sufficient travel within its normal operating range. For example,
the maximum operating range of a
medium-pressure spring is approximately 50 percent of the free, or
static, length. The efficient operating range of this spring is between
10 and 35 percent of the free length.
Higher-pressure springs will have a
shorter range of travel.
Although springs will compress
beyond the maximum operating
range, you should avoid this at all
cost. Compressing beyond maximum range will severely hinder
spring life and could damage the
die. It is also a good idea to choose
a spring with extra travel to prevent
overtraveling the spring after a tool
has been resharpened.
Small but Critical

Improperly selecting die springs can
lead to coil setting or springs breaking, resulting in costly repairs that
put production behind schedule.
In a just-in-time world, this can be
truly devastating.
Without something to manage
and absorb pressure, a die set would
cease to function properly. This is
why die spring selectionincluding the size, travel, number, and
placement within the toolis so
critical.S
Information and figures provided by Dayton
Progress Corp., 500 Progress Road, Dayton, OH
45449, 937-859-5111, www.daytonprogress.com.
Untitled-1 21
1/3/13 9:16 AM
D
E
FE
WITH CARE
Designing a press
feed for specialty
material
By Jim Ward
ts been nearly a century since

engineers developed methods to
unroll aluminum and steel coil
to apply finishing coats or primers,
and then recoil the material and ship
it out to fabricators and stampers.
Today sophisticated press feeding
lines process specialty and surfacesensitive materials, such as metals
that have been anodized, polished,
precoated, or otherwise finished for
the end product.
Forming parts from prepainted
metals eliminates the high costs of
an on-site paint shop and the environmental concerns that go with it.
From a cosmetic standpoint, prepainted metal can be formed and
shaped with a finish that can be
better than surfaces painted or coated after forming and fabrication
surfaces that often carry dirt and
residue.
Coated coil materials allow appliance manufacturers to introduce
new products with specialty finishes
that are fingerprint- and bacteriaresistant. In the automotive industry, coil coating provides extended
22
Figure 1
This system includes a coil feed mandrel with full-radius pads, a coil car with a urethane V deck and riser, and a hold-down with a urethane-coated end wheel.
warranty protection against corrosion. In construction, coil coating is

the most popular method of finishing metal to look like wood, copper,
clay, or other materials.
Processing these materials without degrading the surface requires
forethought. Although many of the
traditional coil handling rules apply,
processing coated coil material
requires additional considerations.

Be sure to consider the gauge,
because the coating itself can change
material thickness significantly. You
also need to factor in the setup and
cleaning of a coil processing line.
In general, carefully evaluate the
design of the coil processing equipment (see Figure 1). Materials can
be particularly prone to problems
during operations such as slitting,

recoiling, and cutting to length. You
need to check for equipment clearances and alignment at every point
where the finished material surface
may contact another surface.
Considerations for
the Feed
Rolls for these applications typically
have either a matte chrome coating or a urethane coating that has
some give. How the various rolls are
balanced and the acceleration and
deceleration rates play parts in maintaining the material surface integrity.
Gripper feeds can index surface-
applications. Feed rolls coated with

a No. 5 matte chrome finish with a
130-150 RMS (root mean square)
can provide necessary traction on
the coil strip while still protecting
specialty material finishes.
Counterbalance of the upper
feed roll. The upper feed roll can
be counterbalanced mechanically
or pneumatically. Mechanically, air
cylinders that lift the upper feed roll
can have a built-in spring that counterbalances the weight of the upper
roll and pivoting yoke assembly.
Pneumatically, an air counterbalance system can offset the weight of
the roll and pivoting yoke assembly.
Either way allows you to select the
often have urethane-coated rollers

or individual low-inertia rolls (see
Figure 2). The soft urethane coating protects the material and allows
the catenary section to transition the
stock effectively from the slack loop
into the servo feed.
Considerations for
the Control
Servo roll feeds can handle materials
of various widths, thicknesses, and
surface finishes, and sophisticated
computer controls help monitor and
fine-tune feed parameters.
Servo feed optimization. Most
modern servo feed controls come
with a feed adviser or feed optimiza-
You need to check

for equipment
clearances and
alignment at every
point where the
finished material
surface may
contact another
surface.
Figure 2
sensitive materials effectively, but
the area where the gripper contacts
the coil is often lost as scrap. This is
why many use roll feeds for surfacesensitive applications.
In general, the feed design should
incorporate the following features:
Full-width matte chrome-coated feed rolls. The major diameter
of the feed roll body should be equal
to the maximum stock width plus 1
inch. This is a must when running
light-gauge material or nonmarking
These catenary rollers have a urethane coating for handling surface-sensitive materials. The threading table also has a urethane surface.
optimum amount of force on the coil

strip to avoid marking or inducing
an edge wave on light-gauge and
prepainted materials.
Urethane coating of catenary
rollers. Conventional catenary rollers are made with steel rollers. Catenary sections for prepainted and
nonmarking applications, however,
tion feature. This helps fine-tune the

feed-move profile based on the feed
index length and amount of time
allowed to perform the index. The
minimum, optimized rates of acceleration and deceleration, as well as
the feed velocity, are used to achieve
the feed index. This minimizes wear
on the servo feeds mechanical sysWWW.STAMPINGJOURNAL.COM JANUARY/FEBRUARY 2013
23
tem and reduces the chance of material marking.

S-curve move profile. Servo feed
controllers with trapezoid move
profiles can have sharp transitions
between accel/decel and full velocity of the feed rolls, which can leave
witness marks on surface-sensitive
materials. A servo feed controller
with an S-curve move profile, however, provides smooth transitions
between the accel/decel and full
velocity, allowing optimum traction
without marking the material as the
roll feed accelerates to high speeds.
Considerations for
the Threading Table
Folding door-type thread tables
come in both single- and doublesided construction based on the line
width. Pivoting knee-type thread
tables also are used in many coil
processing lines. Either type can be
provided with the necessary features
to process surface-sensitive materials (see Figure 3).
Nylon can be bolted to the top
surface of the threading table to prevent material marking during initial
threading operations. Some tables
also have roller surfaces, where rollers along the length of the table support the material to prevent marking
when threading the leading edge.
24
Figure 3
This threading table has a urethane surface for handling sensitive materials.
Considerations for
the Straightener
The following considerations are
critical for straightener design for
nonmarking and surface-sensitive
applications.
High-polish chrome rolls. The
straightening rolls should be coated
with a high-polish chrome finish (see
Figure 4). This provides a smooth
working finish and is the least likely to pick up debris that can mark
surface-sensitive material as it passes
through the straightener.
Matte chrome-coated pinch
rolls. Straightener pinch rolls should
have a No. 5 matte chrome finish
with a 130-150 RMS to provide the

necessary traction, so they can pull
off heavy coils without damaging
the material (see Figure 5). In conventional coil lines, the straightener
or pinch roll stand must be able to
pull off coils weighing up to 50,000
pounds and accelerate the strip up to
maximum line speed. In applications
with surface-sensitive materials, any
slipping between the pinch rolls and
coil strip may damage the material.
Air counterbalance of upper
pinch rolls. The upper pinch rolls
also should have an air counterbalance system to offset the weight of
the upper roll. This allows you to
select the optimum amount of air
Figure 4
Figure 5
These straightener rolls are coated with a high-polish chrome

finish.
These pinch rolls have a No. 5 matte chrome finish, providing

the necessary traction to pull off heavy coils without damaging
the material.
pressure and downward force on the

coil strip to avoid material marking
and edge wave.
Urethane coating of catenary
rolls and peeler table. To process
prepainted materials effectively, the
peeler table and catenary rolls should
be urethane-coated. This helps transition the material from the coil reel
into the straightener and from the
straightener into the slack loop area.
Considerations for
the Coil Reel
Coil reels can be configured to work
in a pull-off application with power
straighteners and roll forming equipment, or they can be provided as payoff reels with the drive mechanism
built into the machine to unwind the
coil.
Full-radius mandrel pads. Special mandrel pads provide maximum
surface contact between the pads and
the coils inside diametersometimes up to 300 degrees of the coil ID
(see Figure 1).
Automatic drag brake compensation. This decreases the amount
of drag brake tension as the coil size
and weight change. An ultrasonic
sensor or laser monitors the coil outside diameter and provides a variable,
low-voltage signal to a proportional
valve system. You set the initial brake
pressure, and the automatic system
then modulates the pressure to maintain constant tension on the strip as
the coil diminishes. This prevents
excessive brake pressure and slipping
between the coil reel and pinch rolls.
Threading drive assembly with
air clutch. Many stampers specify
this along with the automatic drag
brake compensation to minimize the
potential for slippage. The hydraulic threading drive has an integral
air clutch to disengage the threading drive during pull-off operations.
Engaging the clutch bypasses all back
tension from the hydraulic system,
and the drag brake sets back tension

to further reduce the chance of slipping.
Urethane-coated coil car V deck.
This helps transport prepainted coil
without damaging the outer wraps
(see Figure 1).
Urethane-coated end wheels. In
many coil lines, the reel has a holddown arm with either a powered
or nonpowered end wheel. These
devices help the threading process
and prevent the coil from clockspringing. A urethane-coated end
wheel that contacts the coil OD helps
prevent surface marking of the coils
outer wraps (see Figure 1).
A Growing Market
industry. More than 4.5 million tons

of coated coil steel and aluminum are
processed in North America alone.
And the demand for specialty metals
is only going to increase.
With proper planning and forethought, you can handle these materials with the right coil feed design.
Advanced controls combined with
specific threading tables and coated
feed rolls work together to handle
sensitive material with care, presenting blemish- and scratch-free
metal to the forming and fabricating
machinery downstream.S
Jim Ward is general sales manager at COE Press
Equipment Corp., 40549 Brentwood Drive, Sterling Heights, MI 48310, 586-979-4400, www.cpec.
com. Images courtesy of COE Press Equipment.
Today steel and aluminum sectors

combined make up a $100 billion
25
PRODUCT NEWS
Destacking system
Bilsing Automation offers a flexible
destacking system that can separate
and feed both steel and aluminum
blanks in various sizes and configurations. The system comprises
2.5-in.-dia. aluminum round-body

tooling and other components manufactured by the company.
During a cycle, the automation
lowers so that the peeler suction
cups are all level, with the front cups
spring-loaded and programmed to
fire just before the other cups. Air
knives then fire to help peel back
the top sheet, breaking the vacuum
to help separate the blanks.
Bilsing Automation North America 586-463-0686 www.bilsingautomation.com
Fixturing system
The new Carr Lock system from
Carr Lane Mfg. Co. allows locating and clamping at the same time,
with the twist of a hex wrench or
the operators hand, for mounting
quick-change tooling on a subplate.
The system comprises a clamp,
a liner bushing, and a receiver
bushing. All components are interchangeable with the manufacturers
Ball Lock mounting system.
Carr Lane Mfg. Co. 314-6476200 www.carrlane.com
Mobile sheet, coil
calculating app
United Performance Metals has
unveiled a mobile app for stainless
steel sheet and coil buyers called
UPM Toolbox. The app allows steel
buyers to calculate the weight of
sheet and coil through their mobile
devices.
iPhone and iPad mobile applications are available for free download at the iTunes App Store. An
Android version is available at
Google Play. The app also can be
accessed at www.upmet.com.
United Performance Metals 888282-3292 www.upmet.com
26
FORMING & FABRICATING 2013 STAMPING LUBRICANT BUYERS GUIDE
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Personal Protection
Reactivity
Flammability
Health Hazard
Solvent
Aqueous
3 3
Chemtool Inc., Crystal Lake, IL

ReNu 920
ReNu 900 WS
NuSol Lubriform Penultimate
Nusol Lubriform Superior
CT 499
Lubridraw 3305 WX
Lubridraw 3320
Lubridraw 3476
Lubridraw 3488
CT 3302
CT 3303
CT 3304
Lubriform 3900
Lubriform 3905
Lubriform 3935
Lubriform 4200
Lubriform 500 CF
Lubriroll 4240
CT 3340
CT 3388 CU
Galvanized/Galvannealed
Steel
Stainless Steel
Brass/Copper
Aluminized
Aluminum
Metal
Airless Spray
Flood
Drip
Manual/Hand
Roller Coating
Precoat Wet Film
Precoat Dry Flim
Solvent
Application Method
Synthetic
Semisynthetic
Straight Oil
Water-soluble Oil
Dry Film
Series/Formula Name
Anchor Danly, Farmington Hills, MI
Chemistry
Severe Stamping/Drawing
Heavy Stamping/Drawing
Light/Medium Stamping/Drawing
Deep Drawing
Operation
Hazardous
Materials
Cleaning Identification
Method Systems (HMIS)
Enter code 437060 at www.ffid.net

3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3 3
3 3 3 3 3
3 3 3
3 3
3 3 3
3 3
3 3 3 3 3
3 3
3
3 3 3
3
3 3 3
3
3 3 3
3 3 3 3 3
3
3 3
3
3 3 3
3 3
3
3 3 3
3
3 3
3 3
3 3 3 3 3
3 3 3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
3
1
1
1
1
2
2
0
1
0
0
0
0
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
0
1
1
1
1
1
0
0
0
1
1
0
0
0
0
0
0
0
0
0
0
0
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Cimcool Fluid Technology, Cincinnati, OH

Oak Draw 505
Oak Draw 519
Milform 1920M
Milform 610
Milform 6265
Milform 6276
Milform 635
Milform 636
Milform 640
Milform 645
Milform 64SST
Milform 6670
Milform 8050 TM
Milform 8060
Milform 65
CIMFREE VG-MF5350
3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3
3
3
3
3
The information presented was provided by the manufacturers. For additional

information, use the corresponding advertising code at www.ffid.net or the
links in this online buyers guide at www.thefabricator.com. Copyright 2013
by FMACommunications Inc. Reproduction in full or in part without written
permission of the publisher is prohibited. Buyers guides are a part of the
Forming & Fabricating Industry Directory. Go to www.thefabricator.com/
directory to add your free company listing.
3
3
3
3
3
3 3 3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3
3 3 3 3
3 3 3 3
3
3
3 3
3
3 3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3 3 3
3
3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3 3
3 3 3 3 3 3
3 3 3 3 3 3
HMIS Personal Protection Index

A
27
3 3 3 3
3
3
3
3
3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3
3
3 3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3
3 3
3
3
3 3
3 3
3
3 3
3 3
3 3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
I.C. 1599
I.C. 2502
28
3
3
3
3
Personal Protection
Reactivity
Flammability
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3 3 3
3
3 3 3
3 3 3
3 3 3
3
3
3 3 3
3
3 3 3
3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 1 1 0 C
3 3 1 1 0 C
3 3 1 0 0 C
3 3 1 3 0 C
3 3 1 1 0 C
1 1 0 C
3
1 1 0 C
3
1 1 0 C
3
1 1 0 C
3
1 1 0 C
3
1 1 0 C
3
1 1 0 C
3
1 1 0 C
3
1 1 0 C
3
1 0 0 C
3
1 0 0 C
3
1 0 0 C
3
1 0 0 C
3 3
1 0 0 C
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3 3
3 3
3
3
3
3
3
3
3 3
3
3 3
3 3
3 3 3
3 3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1 0 0 A
3
1 0 0 A
3
1 0 0 A
3 3
1 0 0 A
3
1 0 0 A
3
3 3 3 1 0 0 B
3 3 3 1 0 0 B
3 3 1 1 0 B
1 1 0 B
3 3
3 3 3 1 1 0 B
1 1 0 B
3 3
1 1 0 B
3 3
3 3 1 1 0 B
1 1 0 B
3
1 0 0 B
3
1 1 0 B
3
1 1 0 B
3 3
3
3
Health Hazard
1 0 0
1 0 0
1 0 0
1 1 0
3
3
International Chemical Co., Philadelphia, PA
Solvent
3
3
3
3
Fuchs Lubricants Co., Harvey, IL

Eco Draw HVE-1
Eco Draw HVRG-8
Eco Draw HVE-2
Eco Draw 7905
Renoform OS 7910
Montgomery DB 4265 C
Montgomery DB 4265 BW
Tuf Draw 2806 M-100
Tuf Draw HPAL
Anticorit PL 3802-39 LV8 US
Anticorit PL 3802-39S
Anticorit 4107-S
Renoform FB 2000
Renoform FB 43 Light
Renoform EXT 319 IS
Renoform EXT 519
Anticorit PL 39 SX
Aqueous
3 3
3 3 3 3
3 3 3 3 3
3
3 3 3 3 3
3 3
3
Etna Products Inc., Chagrin Falls, OH

Masterdraw 6050B
Masterdraw 727
Masterdraw 7002HVRP
Masterdraw VOL G
Daphne AF8AU
Masterdraw SOL G
Masterdraw SOL H 3850
Masterdraw SOL S 3950
Masterdraw SSY G
Avantin SSY H
Masterdraw SSY S
Masterdraw SYN G
Masterdraw SYN H
Masterdraw SYN S
Masterdraw SYN S 5100
Masterdraw 434
Masterdraw 417
Steel
Stainless Steel
Brass/Copper
Aluminized
Aluminum
Metal
Airless Spray
Flood
Drip
Manual/Hand
Roller Coating
Precoat Wet Film
Precoat Dry Flim
Solvent
Application Method
Synthetic
Semisynthetic
Straight Oil
Water-soluble Oil
Dry Film
Chemistry
Series/Formula Name
Oak Draw 750-10
Oak Draw 786
Oak Draw 785
Oak Draw FB 941A
Deep Drawing
Operation
Hazardous
Materials
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3 3 3 3 3 3 3 3
3 3 3 3 3 3 3 3 3 3 3
3
3
1
1
0
0
0
0
D
D
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3
3 3
3 3
3 3
3 3
3
3 3
3 3
3 3
3 3
3 3
3
3
3
3
3
3
3
3
Solvent
Aqueous
Steel
Stainless Steel
Brass/Copper
3
3
3
3
3
3
3
3
3
3
3
3
3
Personal Protection
3 3 3 3
3 3 3 3 3
3
3
3
3 3 3 3 3
3
3
3 3 3 3 3
3
3
3 3 3 3 3
3
3 3 3
3
3
3
3
3 3
3
3
3 3
3 3 3 3 3 3
3
3
3 3 3 3
3
3
3
3
3
Reactivity
3
3
3 3
3 3
3
3
3
3
Aluminized
Aluminum
Airless Spray
Flood
Drip
Manual/Hand
Roller Coating
Metal
Flammability
3
3
3
Precoat Wet Film
Precoat Dry Flim
Solvent
Synthetic
Semisynthetic
Straight Oil
Water-soluble Oil
Dry Film
3
3
3 3 3
3
3 3 3
3
3
3
3
3
3 3 3
3 3
Application Method
Health Hazard
Chemistry
Series/Formula Name
I.C. 2504
I.C. 1598
I.C. 1576
I.C. 2801 Series
I.C. 920-R
I.C. 1211 Series
I.C. 848 Series
I.C. 345
I.C. 126-B
I.C. 152
Rolleze 2500
Pre-Lube 2801-DL
Deep Drawing
Operation
Hazardous
Materials
1
1
1
1
2
1
2
0
2
2
1
1
0
0
0
1
1
1
2
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
D
D
D
C
C
B
D
B
E
D
E
D
1
1
1
1
0
1
1
0
0
1
1
0
0
0
0
0
0
0
0
0
0
A
A
A
A
A
A
A
John Neale Ltd., Halesowen, United Kingdom

Superdraw FS
Superdraw ST2000
Coating Lubricant CR
Vanishing Oil JN60
Superdraw SG
Tube Lubricant JN7+
Tube Bending Resin WS8
3 3 3 3
3 3 3 3
3
3 3
3
3 3 3
3
3 3
3
3
3
3 3 3 3
3 3
3
3
3
3
3
3
3 3 3 3
3
3 3 3
3 3 3 3
3 3 3 3 3 3 3 3 3
3 3 3 3
3
3
3 3 3 3
3
3 3
3 3
3 3
3
3 3
3
3
3
3
3
3
3
Lamson Oil Co., Rockford, IL

HeavyDraw 1100 Series
HeavyDraw 1200 Series
FormAll 2200 Series
FormAll 2300 Series
LamSyn 3000 Series
LamSyn 4200 Series
Vanish 6800 Series
Vanish 6900 Series
3
3
3
3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3
3 3 3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Metalloid Corporation, Sturgis, MI

Addvance 5140
Addvance 5270
Addvance 6090
Addvance 6110
Addvance 6110 HV
Addvance 6120 HV
Addvance 6120
Addvance 6170
Addvance 6370
Addvance 6380
Addvance 6323
Addvance 6325
Metdraw 5110
Metdraw 9050
Metdraw 9060
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3 3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3 3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3 3
3
3
3
3
3 3 3
3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
29
MPT Industrial Lubricant
3 3
3
3
3
3 3
3
3 3
3
3 3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3
3 3 3 3
3 3 3 3
3
3 3 3 3
3 3 3 3
3 3
3 3 3 3
3
3 3
3 3 3 3
3
3 3
3 3
3 3
3 3 3 3
3 3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
1
1
2
2
2
1
0
0
0
0
0
0
0
0
0
0
0
0
0
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3
3 3 3 3
3
3
PPX Inc., Hutchinson, KS

Metalpro Alpha 52199
Metalpro Beta 52204
Metalform 2000 52190
Metalform 2000-P 52194
Metalform 2000-HD 57140
Synthetic Drawing & Stamping
Compound 55661
Heavy-Duty Synthetic Drawing
& Stamping Compound 55666
Industrial Super Lube 12845
Light-Duty Straight Oil 55760
Med-Duty Straight Oil 55762
H-D Straight Oil 55782
Extra H-D Straight Oil 58590
General-Purpose Soluble Oil
55764
H-D G-P Soluble Oil 55766
H-D G-P Soluble Oil w/
Chlorine 55835
Semi-Synthetic G-P Soluble
Oil Med.-Heavy-Duty
Enviro Extra H-D G-P Lubricant
55732
Enviro Mist Lubricant 55745
Synthetic G-P Machining
Fluid 55768
H-D Synthetic G-P Machining
Fluid 55786
30
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3
3 3 3 3 3 3 3 3 3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
3 3 3 3
3 3 3 3
3
3
3 3 3 3 3 3 3 3 3 3 3
3 3 3 3 3 3 3 3 3 3 3
1
1
1
1
0
0
3 3 3 3
3 3
3 3 3 3 3 3 3 3 3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3 3
3 3 3 3 3 3 3 3 3 3 3
3 3 3 3
3 3 3 3
3
3
3 3 3 3 3 3 3 3 3 3 3
3 3 3 3 3 3 3 3 3 3 3
1
1
1
1
0
0
3 3 3 3 3 3 3 3 3 3 3
3 3 3 3
Personal Protection
Reactivity
Flammability
Health Hazard
Solvent
Aqueous
Steel
Stainless Steel
Brass/Copper
Aluminized
1 1 0 A
3 3 3 3 3 3
3 3 3
Pico Chemical Corp., Chicago Heights, IL

Picodraw 4067
Picodraw 4066
Picodraw 4030
Picodraw 4042
Picodraw 4030 Gel
Picodraw 4036
Picodraw 4015
Picosol 5381
Picocut 6012
Picoform 4700
Picoform 4730
Picoform 4792
Picomist 4098
Aluminum
Metal
Airless Spray
Flood
Drip
Manual/Hand
Roller Coating
Precoat Wet Film
Precoat Dry Flim
Solvent
Application Method
Synthetic
Semisynthetic
Straight Oil
Water-soluble Oil
Dry Film
Chemistry
Series/Formula Name
MPT Industries, Dover, NJ
Deep Drawing
Operation
Hazardous
Materials
Personal Protection
Health Hazard
Steel
3
3
3
3
3
3
Stainless Steel
Precoat Wet Film
Precoat Dry Flim
Water-soluble Oil
Brass/Copper
3
3
3
3 3
Reactivity
3 3 3 3 3 3 3 3 3 3 3
Flammability
Solvent
3 3
Aqueous
Aluminized
Aluminum
Airless Spray
Flood
Drip
3 3 3 3 3 3 3 3 3 3 3
Solvent
Synthetic
3 3
Semisynthetic
3
3
Straight Oil
3 3
3
3
3
3
3 3
3
3
3
3
3
3 3
3
3 3
3
3
3
3 3
3 3
3
3
3
3
3 3
3 3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3
3 3 3 3
3 3 3 3
3 3 3 3
3 3
3 3 3 3 3
3
3
3 3
3 3
3
3
3
3
3
3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
0
1
1
1
1
0
1
0
0
0
0
0
0
B
B
B
B
B
B
1 3 0 B
3 3 3 3 3 3
1 3 0 B
3
3
1 3 0 B
3
1 3 0 B
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3
3
3
3 3
3 3
3 3 3 3 3
3
3 3
3 3 3
3
3 3 3 3 3
3
3
3
3
3 3
3 3
3 3 3
3
3 3 3
3
3 3 3
3
3
3 3
3
3 3
3 3 3
3
3 3 3
3
3 3 3 3
3 3 3 3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3 3 3
3 3
3 3 3 3 3
3
3 3
3 3 3 3 3
3 3
3 3 3 3 3
Tower Oil & Technology Co., Chicago, IL

TowerSol G-966
TowerSol G-9196
TowerSol A-1325
TowerPro 7725-E
TowerPro 7800-E
TowerDraw A-818
Tower 6514-CF
Tower 6523-CF
Tower CF-1301
TowerDraw 9560-TD
Tower A-108
TowerCool 455
Klenedraw 3242
KleneDraw 3421
KleneDraw W-4177
KleneDraw W-4801
TowerDraw E-310
TowerDraw AA-604
Tower Draw A-617
Saf-T-Vanish Green 25
3
3
3
3
3
3
3
3
3
3
3
3

3
3
3
3
Metal
Manual/Hand
3 3 3
3
3
3
3
3
3 3 3
3
3
Application Method
Roller Coating
Pro-Draw 722 Tapping Gel

Pro-Form 850 Emulsifiable
Pro-Form 855
Pro-Form 858
Pro-Form 865
Pro-Form 870 (Botanical
Based)
Pro-Form 870-15 (Botanical
Based)
Pro-Form 875 (Botanical
Based)
Pro-Form 805
Pro-Form 807
Pro-Form 809
Pro-Form 811
Dry Film
Series/Formula Name
Pro-Chem-Co Inc., Lake Station, IN
Chemistry
Deep Drawing
Operation
Hazardous
Materials
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
2
2
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
A
1
1
1
1
2
2
1
2
0
0
1
1
1
1
0
0
0
0
0
0
0
B
B
B
B
B
B
B
Wallover Oil Co. , Strongsville, OH

Vanishing Oil 3
Prodraw 365
FB Fineblanking Oil
Wocodraw 19
Wocodraw 30
Wocodraw 34
Prodraw 200
3
3 3
3
3
3
3 3
3
3 3
3
3 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
31
32
Reactivity
Personal Protection
3
3
3
3
3
3
3
3
3
3
3
Flammability
3
3
3
3
3
3
3
3
3
3
Health Hazard
3
3 3 3 3
3
3
3 3 3 3
3 3 3 3
3
3
3 3 3
3 3 3
3
Solvent
3
3
3
3
3
3
3
3
3
3
3
Aqueous
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Steel
Stainless Steel
3
3
3
3
3
3
3
3
3
3
3
Brass/Copper
3
3
3
3
3
3
3
3
3
3
3
Aluminized
Precoat Wet Film
Aluminum
Airless Spray
3
3
3
Flood
3
3
3
3
3
3
Drip
3
3
Metal
Manual/Hand
3
3 3
3
3
3
3
3
3
Precoat Dry Flim
Solvent
Synthetic
Application Method
Roller Coating
3
3
3
3
3
3
3
3
Semisynthetic
Straight Oil
Water-soluble Oil
Chemistry
Dry Film
Series/Formula Name
Prodraw 210
Prodraw 220
Posidraw 300
Posidraw 309
SDC/SDC-H
Woco CHL-20
Prodraw 175
Prodraw 177
Prodraw 100
Prodraw 125
Prodraw 150
Deep Drawing
Operation
Hazardous
Materials
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
B
B
B
C
B
B
B
B
B
B
B
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Ask the Expert

(from page 34)
3. Continuous improvement
Once youve achieved consistent,
measurable results, you can begin
the final leg of the best-in-practice
maintenance policy. What can be
improved upon? What can you do
to improve the robustness of the
tool? How can you address areas of
the tool that are yielding the greatest variation and improve tooling
life? What can you do to increase
stamping speed and throughput?
Perhaps a new steel or carbide
would improve hits per service. A
new coating might reduce wear.
Continuous improvement is an
absolute requirement in which
SMART (specific, measurable, attainable, relevant, time-bound) goals
should be documented and tracked.
Remember, if you are not improving,
you are, in effect, losing ground as
a result of your competition moving
forward (see Tooling Law 10).
A best-in-class maintenance procedure will result in a very predictable process. You can predict what
needs to be done and when you
need to do it. Your quality data will
be consistent, and youll minimize
unplanned downtime as you predict and plan for service intervals.
You will be able to better meet production schedules and achieve perfect execution (see Tooling Law 5).
Good luck and happy stamping!S
Has a shop floor stamping or tool and die
question stumped you? If so, send your
questions to [email protected] to
be answered by Thomas Vacca, director of tooling and design engineering at
Micro Stamping Corp.
STAMPING Journal (ISSN 1091-2460) is published bimonthly by FMA Communications Inc., 833
Featherstone Rd., Rockford, IL 61107-6302. STAMPING Journal is circulated free upon request to those
who qualify and who are involved in metal stamping. Subscription to all others is $65.00 per year. Foreign
subscription is $95.00 per year. Periodical postage paid at Rockford, IL and additional mailing offices.
Postmaster: Send address changes to: STAMPING Journal, 833 Featherstone Rd., Rockford, IL 611076302.
Copyright 2013 by FMA Communications Inc. Reproduction in whole or in part without written permission of the publisher is prohibited.
33
12/12/12 8:01 AM
ASK THE EXPERT
What are the best practices

for progressive-die
maintenance?
By Tom Vacca
Q: I manage a toolroom of 15 toolmakers. We supply the automotive

connector industry primarily. I am
looking for best practices on progressive-die maintenance. Do you
recommend any die maintenance
procedures?
A: I am literally inundated with
questions on the proper way to maintain progressive dies. Here is the standard response:
Review all the cutting sections for
wear and sharpen as needed.
here is not to overlook any areas of

degradation. Two oversights are very
common: We fail to capture every
item that will degrade over time, and
we make judgments on items that
will not affect part quality. As a result,
areas of degradation are overlooked
because we assume that they have no
effect, which ultimately yields inconsistent hits per service and part quality off the tool (see sidebar, Tooling
Laws 4 and 9).
2. DocumentationWhat is the
If you are not improving, you are

losing ground as a result of your
competition moving forward.
Check all the pilots and replace if
worn.
Review all the form punches and
dies and replace if there is any measurable wear.
Check the lifters and springs and
replace as needed.
Check the timing on all the
inserts.
This is what many tooling managers would expect to hear, and in fact
these items are required. But is this
what we are looking for when we talk
about maintenance best practices?
When maintaining any process,
it is best to first understand the end
goal, then fill in the tasks (similar to
the ones I just listed).When maintaining a progressive die, the three
primary end goals are:
1. ConsistencyIdentify, measure, and assess every area of the tool
that will degrade over time. The key
34
procedure for servicing the areas

of degradation? For example, how
much do you grind off the punch and
die when sharpening? What polishing
tool and media do you use to polish
the forming inserts? Which tooling
dimensions need to be checked, and
to what tolerances? With this huge
area of variation, you need a guide to
ensure each service tech does things
the same way to get the same results
(see Tooling Laws 2 and 8). You cannot adjust or improve on an inconsistent process.
Continuous improvement does not
start until you have captured all the
wear items and have a documented,
consistent way to maintain them.
The results must be measurable and
consistent. You should be able to take
part measurements off the stamping
die with minimal accepted variation
defined and controlled using statis-
Tom Vaccas 10
Tooling Laws
1. Have no other goal except
your personal best. Your work is
a reflection of you.
2.
Quality workmanship is
defined as consistency.
3. Always strive to be consistent in every minute detail. Even
if you think it does not make a difference, do it the same every time.
4. For better or worse, if nothing changes, then nothing will
change.
5. Achieve perfect execution. It
is either perfect or its not.
6. Never make changes without
evidence. There must always be a
reason that something changes.
7. Do not bear false witness
to bad results. Success is based
on understanding. If something is
done twice, it was not done right
the first time.
8. If it needs to be done, it
needs to be on the print. If it is
on the print, it needs to be done
every detail.
9. Nothing is the only thing that
is insignificant. By nature if you
can identify something, it is subject
to change (see Tooling Law 4).
10. Grow and improve in steps.
Take steps closer to perfection one
at a time. Taking more than one
at a time may lead you down an
unknown path. Take no steps and
you go nowhere.
Editors Note: Want to learn more
about Toms 10 Tooling Laws? See his
next article in the March/April issue of
STAMPING Journal.
tical process control (SPC). In addition, your hits per service should
be consistent from run to run, and
component replacement should
have no effect on the part quality.
(continued on page 33)

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What are the three primary end goals of progressive die maintenance?

What are the three primary end goals of progressive die maintenance?

What are some common oversights when maintaining a progressive die?

What are some common oversights when maintaining a progressive die?

Die spring

Expertise to help you transform metal into gold

Choosing the right

A PUBLICATION OF THE FABRICATORS &

A PUBLICATION OF THE FABRICATORS &

An Official Publication of the

Vol. 25 No. 1 JANUARY/FEBRUARY 2013

Without something to manage and absorb pressure, a

22 Feed with care

Although many of the traditional coil-handling rules

27 Forming & Fabricating 2013

MEET THE PRESS

Its a jungle out there

hat makes a jungle a scary place? Its probably fear of

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Art Hedrick, Dieology

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Michael Scott 815-227-8271

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NEWS & NOTES

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Attempting to form a parts

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