2-DAY COURSES
PRODUCT DESIGN FOR SHEET METAL STAMPING - 16 HOURS
This advanced practical course is a tool-maker and stamper's perspective of product design. The goal of this course is to highlight the "true cost" of part features and part tolerances. Designers will be shown just what can and can't be made using the metal stamping process as well as the process steps needed to make the feature. Alternate design features will also be explored.
COURSE TOPICS:
EFFECTS OF MATERIAL SELECTION
R And N Values
Grain
Anisotropy
Strain Distribution
Commercial Names
Yield Strength
Plain Carbon Steels
High Strength Steel
Bake-Hardenable Steel
A.H.S.S. - Dual Trip, Complex Phase
Stainless Steel
Aluminum
Anisotrophy / Grain
DRAWING OR STRETCHING
Understanding The Difference
Depth Of Forms
Blank Development
Solid Forming
UNDERSTANDING DRAWING RATIOS
Defining Draw Ratios
Calculating Blank Size
Calculating Draw Reductions
Risking Compression / Ductility Fractures
DESIGNING FORMS FOR FORMABILITY
Punch Shape Versus Strain Distribution
Radii Size For Formability
Open Wall Angles
Achievable Depth
Class "A" Surfaces
METAL CUTTING
What Can Be Expected With A Die Cut Edge
Hole Size Tolerance
Hole Location Tolerance
Hole Shapes
Shaving
Developed Holes
Cutting On Angled Walls
The True Cost Of Cams
PART FLATNESS
The Effects Of Cutting On Flatness
Pressure Blanking
Fine Blanking
Gripflow®
Stippling
BENDING, FLANGING, & EXTRUDING
Designing To Reduce Splitting And Wrinkling
Drawing In Features
Realistic Bending Tolerancing
Ironing In Extruding
Part Straightness
Click here to see a sample of forming simulation
ENGINEERING & DESIGNING PROGRESSIVE DIES - 16 HOURS
This practical course focuses on understanding the key principles needed to design, build, and troubleshoot progressive dies. It is intended for individuals with moderate sheet metal stamping experience.
COURSE TOPICS:
UNDERSTANDING MATERIAL
Yield / Tensile Strength
N And R Values
The Effect Of Thickness
Strain Distribution
Commercial Names
COIL DEFECTS
Camber
Crown / Rust
STRIP CARRIER DESIGNS
Solid Carriers
Stretch Carriers
STRIP STARTING & PILOTING
Pitch Stop
First Hit Line
Smooth Feeding Techniques
Stand-Offs
Bar Lifters / Round Lifters
METAL CUTTING
Cutting Clearance Selection
Scrap Removal
By-Pass Burrs
Pinch Trimming
HOLDING PART FLATNESS
Pressure Blanking
Stippling
FLANGING, BENDING, CURLING, & EXTRUDING
Stretch Flanges / Compression Flanges
Holding Bend Tolerances
Hole Flanging Techniques
PRESSURE & STRIPPER PADS
Design Guidelines
DRAWING IN PROGRESSIVE DIES
Draw Ratios
Radii
Timing
WEB CARRIER DEVELOPMENT
Wax Method
PROCESSING TOOLS
Rubber Skins
Wax Development
PRESS SELECTION
Tonnage
Ram Speed
Deflection Rate
Counter Balance
DEVELOPING A TROUBLE-SHOOTING PROCESS
Data-Based Approach
COST ESTIMATING
Methods & Factors
UNDERSTANDING, PROCESSING, & TROUBLESHOOTING DRAWING & STRETCHING OPERATIONS - 16 HOURS
This advanced, practical course focuses on understanding the key principles needed to process and design deep-drawing and stretching dies. It is intended for experienced sheet metal process engineers, tool designers and die makers.
COURSE TOPICS:
Understanding material
R And N Values
Grain
Anisotropy
Strain Distribution
Commercial Names
Yield Strength
Plain Carbon Steels
High Strength Steel
Bake Hardenable Steel
A.H.S.S. - Dual Trip, Complex Phase
Stainless Steel
Aluminum
Anisotropy / Grain
DRAWING GUIDELINES
Blank Holder Functions
Getting Consistency
Pressure Or No Pressure?
UNDERSTANDING DRAWING RATIOS
Defining Draw Ratios
Calculating Blank Size
Calculating Draw Reductions
Compression / Ductility Fractures
DRAW DIE DEVELOPMENT
Binder Shape / Wrap
Length Of Line Analysis
Addendum Development
CONTROLLING METAL FLOW
Binder Pressure
Draw Beads
Draw Bars
Stand-Offs
Binder Shape
Die Entry Radius
Punch Radius
Material Forming Speed
Air Pads
Hydraulic Cushions
Nitrogen Systems
PRESS SELECTION FOR DRAWING
Tonnage Considerations
Ram Velocity
Off-Loading
Hydraulic Presses
FRICTION CONTROL
Lubricant Types
Lubricant Additives
Lubricant Application
Tool Steel Coatings
Alternate Die Materials
Thin Film Barrier Lubricants
DRAW DIE TROUBLESHOOTING PROCESS
Seven Critical Steps
PRODUCT DESIGN FOR FORMABILITY - 16 HOURS
This practical course focuses on product design features from a die engineer's perspective. All too often stamped products are designed with features that are very costly or extremely difficult to make. Although these features and tolerances are sometimes necessary, often the part design can be changed and result in lower tooling and part costs. This course is designed for those with good product design skills.
COURSE TOPICS:
THE EFFECTS OF MATERIAL (COIL)
R And N Values
Grain
Anisotropy
Strain Distribution
Commercial Names
Yield Strength
Plain Carbon Steels
High Strength Steel
Bake Hardenable Steel
A.H.S.S. - Dual Trip, Complex Phase
Stainless Steel
Aluminum
Anisotropy / Grain
DRAW RATIO VERSUS PRODUCT DEISGN
Drawing Versus Stretching
Stretch Distribution
Calculating Reductions For Costing
The Effects Of Cold-Working The Metal
FORMING PUNCH GEOMETRY
Radii Size
Wall Angles
Blank Types
Stretch Distribution
Spring-Back Problems
METAL CUTTING
Edge Control
Burrs
Hole Location Guidelines
Diameter Tolerancing
BEND ANGLES, FLANGES, AND EXTRUSIONS
Bending Tolerances
Flange Heights Cost
Extrusion Or Reduction?
Bending Tolerances
Flange Heights Cost
Extrusion Or Reduction?
Bending Tolerances
Flange Heights Cost
Extrusion Or Reduction?
STAMPING DIE MAINTENANCE & TROUBLESHOOTING - 16 HOURS
This hands-on course focuses on identifying and correcting the root cause problems associated with stamping dies. Attendees will learn the physics behind all "tool rool magic".
COURSE TOPICS:
UNDERSTANDING / VERIFYING MATERIAL
R And N Values
Grain
Anisotropy
Strain Distribution
Commercial Names
SELECTING CUTTING CLEARANCE-REDUCING BURRS
Piercing
Blanking
Shearing
Cut And Carry
Trimming
Effects Of Improper Cutting Clearance
Slug Pulling
Retaining Part Flatness
BENDING, FLANGING, & EXTRUDING
Controlling Wrinkles
Avoiding Fractures
Maximizing Extrusion Height
Flanging Sequence
Obtaining Accurate Bend Angles
Die Coatings
CONTROLLING METAL FLOW IN DRAWING OPERATIONS
Understanding Draw Ratios
Selecting The Proper Radius
Avoiding Wrinkling And Fracturing
Draw Beads And Bars
Selecting Binder Pressure
Using Equalizers
Controlling Metal Flow
UNDERSTANDING THE ROLE OF THE PRESS
Press Types
Deflection
Counterbalance
Tonnage
Ram Velocity
TOOL ROOM PSYCHOLOGY
Dealing With Associates