The Future is Forming

Tool & Die Authority - February 2009

2009-07-16T08:52:00.000-04:00

The Tool and Die Authority February 2009 Newsletter contained these articles:

U.S.-Korea Trade Imbalance, Part 2: Joe Brown
Avoiding Punch- Head Breakage: Peter Ulintz
How About a Little ‘Coopetition’ to Ride out the Storm: Bob Quinn
Part Measurement ‘On the Fly’—Part 1: Drew Stevens

and from Danny Schaeffler of Engineering Quality Solutions (EQS)...
What is Steel? Part 2: Medium-Strength and Conventional High-Strength Steels

A good rule of thumb: The transition from mild steel to high-strength steel occurs at a yield strength of about 30 KSI (210 MPa). For yield strengths between 30 and 50 KSI, metalformers typically provide a simple carbon-manganese (C-Mn) steel, unless other restrictions are placed on the order. The composition of these steels approaches that of low-carbon mild steels, except that C-Mn steels contain more carbon and manganese to increase strength to the desired level. No special alloying or thermal treatments are needed at the mill, making these alloys relatively inexpensive. Unfortunately, this approach usually is not practical for yield strengths greater than 50 KSI, due to a drop-off in elongation and weldability. This limits the use of C-Mn steels to those parts without complex requirements for shape, strength or weldability. ...

Visit the Precision Metalforming Association website to learn how to subscribe!

Tool & Die Authority - January 2009

2009-07-13T08:45:00.001-04:00

The Tool and Die Authority January 2009 Newsletter contained these articles:

U.S.-Korea Trade Relationship Points to Reasons for Auto, Tooling Troubles: Joe Brown
Failure Analysis: Punch-Head Breakage: Peter Ulintz
Time-Saving Alternatives for the Toolroom—Part 3: Bob Quinn
The Perils of Reverse Tonnage and Improper Counterbalance Settings: Drew Stevens

and from Danny Schaeffler of Engineering Quality Solutions (EQS)...
What is Steel?…Part 1

I’m sure for some of you, the answer to the question—What is Steel?—is, “really expensive!” That discussion is best left for another column. Here we are going to get back to basics. And most simply, steel is just iron plus no more than about 2.1 percent carbon. (If you have more than 2.1 percent carbon, it’s called cast iron.) For this article, we’ll cover low-carbon steel, where carbon content tops out at around 0.1 to 0.2 percent. ...

Visit the Precision Metalforming Association website to learn how to subscribe!

Tool & Die Authority - December 2008

2009-07-10T08:05:00.002-04:00

The Tool and Die Authority December 2008 Newsletter contained these articles:

Strange Times Call for Strange Bedfellows: Joe Brown
Failure Analysis for Stamping Dies, Part 2: Tool-Steel Heat treatment: Peter Ulintz
Time-Saving Alternatives for the Toolroom—Part 2: Bob Quinn
Error-Proofing Proactively with Proper Setups: Drew Stevens

and from Danny Schaeffler of Engineering Quality Solutions (EQS)
The Case for Thinning Strain Analysis

The past two editions of this series discussed circle grid strain analysis and the potential errors that improper technique can induce in your results. The easiest way to check your measurements is to compare the thickness calculated from your circle-grid surface-strain measurements to thickness measurements made using an ultrasonic thickness (UT) gauge. But, there is so much more information you can get from your part and process with just thickness measurements!
Thinning strain analysis (TSA) is easier to perform than circle grid analysis (CGA), and requires very little operator training. TSA can be performed on any formed part, without special preparation of the blank or tools before stamping, and it requires less stamping-plant involvement and assistance. Production stamping schedules are less likely to be disrupted when a TSA is needed, and TSA can be used when is it not practical to place circle grids on a blank— such as for parts stamped on a progressive die or in the central portion of a very large blank. ...

Visit the Precision Metalforming Association website to learn how to subscribe!

Seawater Composition - The Same Ionic Ratios Around The World

2009-07-09T11:12:00.001-04:00

Salinity is a measure of the total amount of dissolved solids present in water.

The salinity of fresh water is less than 0.05% by weight.
The salinity of ocean water typically ranges from about 3.3% to 3.7% (3.3 to 3.7 parts per hundred) by weight.
Marine geologists normally use units of parts per thousand (abbreviated as ‰), so the salinity of ocean water is about 35‰, compared to less than 0.5‰ for fresh water.
Units of parts per million are sometimes used: the salinity of ocean water is about 35,000 ppm, while the salinity of fresh water is typically less than 500 ppm.

As determined initially by Dittmar in 1884 on samples collected during the Challenger Expedition (1872-1876), the ratios of the various ions in sea water are nearly independent of salinity and location in the ocean.

The Red Sea, for example, with a salinity of close to 40‰, has more ions than “average” seawater. However, here and elsewhere around the world, the relative proportions of all ions are the same. Worldwide, the ratio of chloride ions to sodium ions in seawater is 55.1 / 30.6 = 1.8.
The “Rule of Constant Proportions” applies only to seawater and not fresh water (i.e., river water). Note the magnitude of the ionic concentrations in fresh water – a slight change of a few parts per million either higher or lower will significantly change the ratios.

The ionic concentrations in this table are approximations compiled from numerous literature sources. The specific values in your particular sample may be different from what is shown, but in the case of seawater, the ratios of the ions will be the same.

Tool & Die Authority - November 2008

2009-07-08T08:00:00.004-04:00

The Tool and Die Authority November 2008 Newsletter contained these articles:

Time for Tooling Industry to Step Up and Train: Joe Brown
Failure Analysis for Stamping Dies—General Procedures: Peter Ulintz
Time-Saving Alternative to Six-Sided Grinding—Part 1: Bob Quinn

and from Danny Schaeffler of Engineering Quality Solutions (EQS)
Circle Grid Strain Analysis—Confirm that Ellipse Measurements Make Sense

Last month, we learned that the measurement technique used to determine the dimensions of a deformed ellipse is critical, and that the proper method is to measure from the center-width position of the line that makes up the circumference around the circle.

In this month’s column, I’ll discuss a simple method to confirm that your ellipse measurements make sense. A flat sheetmetal blank has known length, width and thickness dimensions. Since material formability is not exempt from the laws of physics, the total amount of material must maintain a constant volume before, during and after forming, even though the specific values of length, width and thickness will change as a result of forming. This allows for calculation of a thickness strain (et), since the major (eMA), minor (emi), and thickness strains in that volume of material multiplied together must equal 1 ...

Visit the Precision Metalforming Association website to learn how to subscribe!

Tool & Die Authority - October 2008

2009-07-06T14:23:00.005-04:00

The Tool and Die Authority October 2008 Newsletter contained these articles:

We Need Apprenticeship Programs, or Soon the Die May be Cast: Joe Brown
Quick Fixes for Slug Pulling: Peter Ulintz
The Basics of Efficient Die Making: Bob Quinn

and from Danny Schaeffler of Engineering Quality Solutions (EQS)...
Measuring Accurately During Circle Grid Strain Analysis

For several decades, sheetmetal stampers have used strain analysis to make their parts and products more robust to handle the natural and inherent variation in mechanical properties of the sheetmetal they order. But have you ever thought about how much your technique can influence the results?

Visit the Precision Metalforming Association website to learn how to subscribe!

Measuring Accurately During Circle Grid Strain Analysis

2008-10-21T07:32:00.002-04:00

In the inaugural issue of the Tool & Die Authority, Danny Schaeffler of EQS discusses "Measuring Accurately During Circle Grid Strain Analysis".

Read the introductory issue here!

Tool & Die Authority: Exclusive technical information and timely news by industry experts for tool and die professionals

2008-10-20T21:39:00.006-04:00

From Brad Kuvin's Editorial in the September 2008 issue of MetalForming Magazine:

It’s not often that a new publication is launched aimed at the manufacturing community. But when an opportunity is recognized to provide useful, practical knowledge in an area where change occurs so quickly that keeping up becomes challenging, if not impossible, then a new publication is in order. That’s why MetalForming and the Precision Metalforming Association (PMA) are launching Tool & Die Authority, with the tag line: Exclusive technical information and timely news by industry experts for tool and die professionals.

Tool & Die Authority is an electronic-only publication, delivered to the e-mail inbox of paid subscribers each and every month. It will carry no advertising–only page after page, article after article of hard-core tool and die knowledge and insight. In addition, we’ll include an industry-specific job-listing service,where metal formers and tool and die shops can post their job openings.

To launch this new publication, we have lined up an impressive array of industry experts to provide a well rounded editorial package. Note: Subscribers to Tool & Die Authority not only will receive our exclusive technical and practical knowledge and information, but also will have online access to continued dialog on the topics covered in the newsletter.Our authors will provide ongoing discussions of their newsletter columns online, using URLs created exclusively for Tool & Die Authority subscribers.

Meet our lineup of expert columnists:
• Joe Brown, creator of the blog,Will the Tool & Die Industry Ever Recover? Joe’s column in Tool & Die Authority will deliver timely, insightful news of the tool and die industry that you won’t find anywhere else. More importantly, his commentary on the issues of the day will provide a fresh look at the industry with a unique perspective that readers will appreciate.
• Pete Ulintz, a 30-year veteran of the tool and die trade with an impressive background that includes tool and die making, tool engineering, engineering management, advance process planning and product development. Pete has been speaking at PMA seminars, roundtables and METALFORM symposiums since 1996, focusing on topics such as transfer and automation systems, tool and die design, deep-draw technology, metalforming simulation, and problem solving in the press shop. For Tool & Die Authority, Pete will discuss practical, real-life tool room challenges related to all of the above topics, and offer solutions to overcome those challenges.
• Danny Schaeffler, president of Engineering Quality Solutions. Danny brings to Tool & Die Authority expertise in material properties of new sheet steels and other metal alloys.His column also will address the practical application of forming-limit diagrams and circle-grid analysis, and topics such as tooling buyoff and cost-reduction strategies.
• Bob Quinn, president of RCM Inc., a tool and die shop with expertise in progressive and compound dies, fourslide tooling, detail machining, surface grinding and wire-EDM, as well as CAM-system development. Bob’s monthly insights will help tool and die makers tackle the day-to-day production challenges that impact productivity and quality in the tool room, to make sure that the presses–whether they are your presses or those of your customers–keep going down and up, stamping high-quality parts.

The tool and die industry, perhaps more than any other manufacturing discipline, continues to evolve at a breakneck pace, and keeping up with technology is a must. Tool and die designers and makers must learn not only new skills related to operating new manufacturing equipment, but also must become more knowledgeable in material properties–of sheet steels and tool steels.

This is the type of information that our electronic publication, Tool & Die Authority, will feature. To start receiving Tool & Die Authority, log on to www.metalformingmagazine.com/toolanddie.

The first issue is available to everyone by clicking here!

Free Steel Info!

2008-06-27T21:35:00.001-04:00

Have a look at our website - www.EQSgroup.com. You'll see that we changed a few things around and added links for you to get more info about Advanced High Strength Steels (like dual phase, transformation induced plasticity, martensitic, and complex phase steels), as well as basic descriptions of low carbon steel, stainless steel, and aluminum grades. You'll also find the section titles of a "how to do thinning and circle grid strain analysis" article we wrote for the ASM International Metals Handbook on Sheet Metal Formability. All you need to do is contact us, and we can send you more of that article. Let us know some of the things that interest you!

Steel Guru - Website & Newsletter

2008-01-14T09:47:00.000-05:00

For daily news updates about steel and the international steel industry, you may want to look at Steel Guru.

Metallurgists’ Day!

2008-01-14T09:40:00.000-05:00

The 45th Annual "Metallurgists’ Day" was celebrated in India on January 10, as reported by Steel Guru.

Steelmaking and Aluminum Videos - Severcorr, US Steel, and Novelis

2007-12-10T15:14:00.000-05:00

The SeverCorr and US Steel videos highlight two steelmaking approaches: a minimill that uses an electric arc furnace (SeverCorr) and a blast furnace/basic oxygen furnace at an integrated mill (US Steel).
The Novelis video mainly describes the company, and contains some aluminum rolling information.

That is A LOT of Steel - 2007

2007-12-07T20:03:00.000-05:00

As reported by MEPS, the 2007 global steel output is estimated to be 1.350 billion metric tons, an 8% increase over the 1.249 billion metric tons produced in 2006. The 1 billionth metric ton is projected to have been produced on September 27, 2007, the 270th day of the year. This is about 7.5 weeks earlier than in 2005. Furthermore, MEPS projects the worldwide output in 2011 to be 1.6 billion metric tons, with 60% of this increase coming from China. To produce this much steel, it is estimated that China will need to import more than half of its iron ore demand. Wonder what that means for raw materials costs???

POSCO: World’s 2nd largest steelmaker

2007-12-06T16:26:00.000-05:00

With a recently completed blast furnace repair, POSCO now has an annual capacity of 33 million metric tons, making it the world’s second largest steelmaker behind ArcelorMittal (117 million metric tons) and just ahead of Nippon Steel at 32.7 million metric tons. -- from Steel Guru

Hyundai Steel, ThyssenKrupp sign technology deal

2007-12-06T16:20:00.000-05:00

Reuters reports that ThyssenKrupp will provide Hyundai Steel with a range of steel-making technologies from blast furnaces to hot-rolled steel products. Also, Hyundai Steel and Hyundai Motor Group have agreed to buy more steel products from ThyssenKrupp for its U.S. and European auto plants. After their first blast-furnace mill comes on line in 2011, Hyundai Steel will have a capacity of 8 million metric tons.

Is That An American Car?

2007-03-23T14:56:00.000-04:00

USA Today ran a story yesterday that raises the question of what makes a car “American”?

Consider, for example, that according to the article and related table, vehicles made exclusively in Canada are the Chrysler 300 and Pacifica, Ford Edge and Crown Victoria, Chevy Impala and Equinox, Acura MDX, Lexus RX350, and the Honda Ridgeline.

Vehicles made exclusively in Mexico include the Ford Fusion, Chrysler PT Cruiser, Chevy HHR, VW Beetle, and the Nissan Sentra. (All small cars – coincidence?)

And those made only in the USA include the Mazda 6, Subaru Legacy and Outback, Saab 9-7X, Honda Odyssey, Hyundai Santa Fe, Nissan Altima and Titan, Toyota Avalon and Sienna, and the Acura TL. Most of the Accords and Camrys sold in the US are made in the US, with imports from Japan coming in due to product demand and local capacity constraints.

Does it need to be a US based company, like GM or Ford? Or does Chrysler count, even though they are the US division of a German company (at least for now)? What about “Honda of America Mfg., Inc.” or "Toyota Motor Manufacturing Kentucky, Inc.", both US-based divisions of Japanese companies? Does it need to be a company traded on the New York Stock Exchange, like Honda and Toyota? Do the profits from the vehicle need to "stay in this country" for it to count as an American car? Should the wages paid to the US employees in manufacturing, sales, R&D, etc., count? Would this make the Toyota Camry more "American" than the Chevy HHR? What about the Chevy Aveo, which is made in South Korea? Is a company like Volvo "American" because it is owned by Ford? What about Saab, since it is owned by GM, and one of their vehicles is made in Ohio - just like the Accord?

Should we consider the impact of oil usage from national security and environmental perspectives? Does that make it more "American" to drive a Chevy HHR (23 MPG city/30 MPG highway - made in Mexico) or a PT Cruiser (21/26MPG, also made in Mexico) or a Toyota Prius (60/51, made in Japan)? Does your answer change if it was a Toyota Camry Hybrid (40/38, made in Kentucky)?

I'd love to hear your thoughts on these issues - all different shades of grey.

Review: 2007 Great Designs in Steel Seminar

2007-03-19T14:45:00.000-04:00

The 2007 Great Designs in Steel Seminar was held on March 7 in Livonia, MI, with over 1700 people in attendance. This seminar, sponsored by AISI and held annually since 2002, is billed as “the premier forum for the latest trends and applications in automotive steel technologies.”

AISI continues to raise the bar, as this was another excellent day of presentations, exhibits, and informal meetings. In addition to displays on steel fuel tanks, steel wheels, and laser welded blanks, there were teardowns highlighting the high strength steel parts contained on the BMW X5, Chrysler Sebring, and the IMPACT truck.

Over the next few postings, I’m going to give the highlights of some of the presentations. But the theme is clear: Advanced high-strength steels (like dual phase and TRIP steels) are being used now in selected applications, and are being increasingly specified in future vehicles to capitalize on their potential for weight savings, cost savings, and safety.

Updated FMVSS 206 Could Increase Use of Advanced High Strength Steels

2007-02-08T11:09:00.000-05:00

The National Highway Traffic Safety Administration (NHTSA) has just updated Federal Motor Vehicle Safety Standard (FMVSS) No. 206, which addresses Door Locks and Door Retention Components. The new regulations, which go into effect on September 1, 2009, will require among other things, a second latch on minivan sliding doors. The ruling said that automakers expect "major structural modifications" will be needed to B-Pillars and doors in order to comply.

In conjunction to these structural changes, look for increased use of advanced high-strength steels like dual phase (DP), transformation induced plasticity (TRIP), complex phase (CP) and hot-stamped boron steels. Combined processes like the hot forming of tailor rolled blanks for B-pillars may be more widely utilized.

Great Designs in Steel 2007

2007-02-05T15:37:00.000-05:00

Great Designs in Steel is the premier forum for the latest trends and applications in automotive steel technologies. This all-day, four-track program features more than 35 technical presentations on advanced high-strength steels (like dual phase and TRIP steels), automotive safety and manufacturing technologies. It is scheduled for March 7, 2007, in Livonia, MI.

Talks are scheduled to be given by GM, Ford, DaimlerChrysler, Honda, BMW, US Steel, Mittal Steel, Severstal, Noble, TWB, Powerlasers, as well as several Tier 1/2 stampers and tool designers/builders. For the complete program, click here.

Customized Search Engines for the Steel Community

2007-02-01T21:24:00.000-05:00

With the help of Steve from Steel Strip, I've incorporated two search engines into this blog. Both are community-built engines, where the users help refine the search results. In the Swicki, the more popular search terms are listed in a bigger size. To learn more about swickis in general, click here.

Thanks, Steve!

Beverage Cans from Aluminum, Stainless Steel, or Low Carbon Steel?

2007-01-31T16:29:00.000-05:00

Ask a Basher!
http://www.butlersheetmetal.com/tinbasherblog/2006/12/28/ask-a-basher-1/trackback/

Outsourcing Because of Cheap Labor Overseas? Maybe not. Maybe it's not enough skilled workers here

2007-01-31T16:19:00.000-05:00

If the last paragraph in the second article below is really the case, then maybe we should be doing more to encourage higher education for all.

Talent Availability Rather Than Labor Cost Seen Driving Offshoring
Low-cost labor is no longer the most important factor in decisions on moving work offshore; access to qualified workers is, contends a Duke University/Booz Allen Hamilton study released on Oct. 31. Indeed, indicates the study, companies are increasingly moving product design, R&D, and other relatively sophisticated operations to China, India and other places offshore primarily because they can provide the highly skilled engineers and science workers who are in short supply in the U.S. and Europe.
Nearly three-fourths of the 530 US and European companies surveyed that are establishing or expanding product development offshore said "access to qualified personnel" was the most important driver of their offshoring strategies. Almost 70% said site selection was based on the availability of qualified workers.

Skilled worker shortage hurts U.S.
The biggest problem with job growth right now isn't too few new jobs. It's too few skilled workers. Many economists and labor market experts say that job growth and the economy overall would be significantly stronger if employers could find the skilled workers they really need.
"I'm hearing across the board, across industries, companies indicating they can't exploit market opportunity because they can't find people with the right skills," said Jeff Summer, an executive at Deloitte Consulting who leads the firm's management practice. He said that there's virtually no long-term unemployment for skilled workers.
Anthony Chan, chief economist for JPMorgan Private Client Services, said employers are constantly citing the inability to find the workers they need as one of their top problems, if not their biggest worry.
Businesses "feel there's real (unmet) demand out there," he said, adding that "economic growth would be faster" if there wasn't this tight supply of workers.
Economists are forecasting that overall the unemployment rate in December stayed at 4.5 percent. But the rate for college-educated workers was just 1.8 percent in November, near the rate for that group in 1998 and 1999, when the economy was white-hot. The lowest rate for college grads on record was 1.5 percent in three months during 2000.

Advanced High Strength Steel Forming and Joining Guidelines

2006-10-06T16:55:00.000-04:00

The International Iron & Steel Institute just released Version 3 of the AHSS Application Guidelines. This 131 page document covers the formability and joining issues that you might encounter when processing these grades, and ways to address them.

If you need help digesting the plethora of information, that's what we do at Engineering Quality Solutions.

'Low-Cost' Economies Not So Cheap

2006-10-04T14:39:00.000-04:00

This is the title of an article that appears today on IndustryWeek.com.

Once a full account is taken of unit labor costs output per worker across economies, the advantage is narrowed:
Mexico: No competitive advantage if productivity is factored in. Mexico's total wage costs were 11% of the average U.S. level in 2002. But because Mexican workers produce 10 times less than Americans per hour, the unit labor costs came out nearly the same.

Poland: Competitive disadvantage: industrial workers earn about 13% of the average U.S. salary but their unit labor costs come out much higher at 73%.

India and China: Competitive advantage: Total wage cost at less than 3% of the level paid to U.S. workers in manufacturing. Even with lower worker productivity factored in, unit labor costs in India and China are on average 80% lower than those in the United States.

Steel Mills in China

2006-09-28T14:34:00.000-04:00

An article from September 27 states that there are eight 10-million ton iron and steel plants, seventeen 5-million ton plants and more than thirty 3-million-ton plants in China.

As a point of reference, in 1999, the United States had two 10-million ton iron and steel companies and five 5-million ton companies (most having multiple production plants), while Canada had two 3-million ton companies.