setting yourself up for success, dealing with failures...
TRANSCRIPT
by Scott TachenySpecial Applications EngineerWilson Tool International, Inc.
Punching Division – White Bear Lake, MN USA
Setting Yourself up for Success, Dealing with Failures & Changing Your Future
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Agenda• Setting yourself up for Success
• Understanding the task
• Knowing how success is measured
• Building Partnerships
• Dealing with Failures
• Do it yourself solutions to common problems
• Planning for the Future
• Continuing the success
• Knowing what can be done
• Ask for more……………
Setting Yourself up For Success
Understand the TaskWhat am I being asked to make?
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TASK: make this
But can I really make this?
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How about this?
Much more reasonable,but how big is it?
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Dimensions are the key to defining the task.They can even give a bad image value.
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You cannot achieve this…but this looks more reasonable
The dimensions from the bad image can be used to create a more reasonable form that
could be made in the Punch Press.
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So what defines the task? The answer…………..
the dimensions, not the object.
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Understand the Task Ensure the task is well defined before sending it
downstream. It will only come back!
Knowing How Success is MeasuredHow do I know I made a good part?
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How is success measured? Vernere Calipers CMM
Does it really matter how?
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Its not how. Its what!
And again, its dimensions that define success!
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How success is measured
Neither Modeling software, nor drafting techniques, account for material thinning and thus this image is only a mirage!
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Forms almost always have more volume in them than the sheet did when it was flat!
Volume of Flat Sheet = 1737.5 cubic millimeters
Volume of Formed Sheet = 1927.4 cubic millimeters
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So how do we measure success? The answer…………..
by inspecting to the object to the dimensions.
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Dimensions are the key to both understanding the task andmeasuring ones success!
Building PartnershipsVendors supply……….Partners add Value!
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Create partnerships with those you do business Ask if they offer services
other than the norm LEAN audits Training or Seminars Design advice or training Kaizen support or Kaizen
participation Programming help or
advice Offer up training The better we understand
one another they better we can support one another
Dealing with Failures
Solutions to Common Problems
A list of Do It Yourself solutions
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Pinch Points
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Pinch Points
Rectangle punch in Rectangle die Obround punch in Rectangle die
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Pinch Points
Rectangle punch in Rectangle die Obround punch in Rectangle die
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Pinch Points
Rectangle punch in Rectangle die Obround punch in Rectangle die
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Pinch Points
Rectangle punch in Rectangle die Obround punch in Rectangle die
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Pinch Points
Apply the Rolling Pincher before punching the edge
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Sheet Distortion
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Managing Distortion: Clearances
> clr. %→ > rotation→ > inward draw → > distortionToo little clearance can cause galling!
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Sheet DistortionManaging Distortion via Pad Pressure
• Increased pressure by
reducing the contact
surfaces
• Relieve the Die and/or
Stripper
May increases sheet marking
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Managing Distortion: Programming
Non-linear or
Random Pattern
Programming
This takes a very
talented programmer
or operator
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Managing Distortion: Secondary HitsHole Shaving – Hitting holes twice
• This methodology reduced sheet deformation by 50% when using a 9.8 mm round punch and post punch of 10.0 mm*Published by a leading machine manufacturer
• The same die size
• Two different punch sizes
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Managing Distortion: Secondary Hits
Straddling forms such as extrusions with an empty guide assembly can help
flatten the sheet
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Sheet Shake
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Sheet Shake – Solved via ProgrammingHow to prevent “sheet shake” at the end of your program
Sheet shakes side to side
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Sheet Shake – Solved via ProgrammingHow to prevent “sheet shake” at the end of your program
Sheet is solid side to side
Add these hits vertically as the last operation
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Sheet Shake –Solved via Alternative TabbingHalf Shear toolA forming tool that can create a relatively long tab that breaks off flush to the edge.
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Sheet Shake –Solved via Alternative TabbingHalf Shear toolA forming tool that can create a relatively long tab that breaks off flush to the edge.
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Slug Pulling The adhesion of the slug to the punch
resulting in the slug being pulled back into or thru the sheet
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Cause for Slug Pulling• Lubricants cause a gluing effect• Slug Deformation during piercing creates a vacuum
Area of Vacuum
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Slug Pulling: Avoid the VacuumSlotted Face When Ejector Pins Fail
Pull them out to create a Ported Punch
Cut slots into face allows air
movement
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Slug Pulling: Die Retention
Notches Cut Into Die WallDiamond file or power toolTears tag off from the bottom of the sheet which sticks into die
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Slug Pulling: Die Retention
Notches Cut Into Die FaceDiamond file or power toolTears tag off from the bottom of the sheet which sticks into die
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Slug Pulling: Die Retention Rocklinizer®
Planning for the Future
Continuing Your SuccessTrack your sucesses
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Track Your Successes Make small samples using the many varied tools you
have and create a library of them for future reference. Even make them in differing materials. Even though you
may recognize you wouldn’t use the tool in production without a coating or some other enhancement you would of at least determined if it works.
I’ve seen companies take up an entire room with samples while others go virtual and take photographs and put them in an internal website.
Successful companies also find ways of using their tools for products or orders other than those it was initially purchased.
Know what can be done in your PressIf you don’t know you can……you will never will
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Bend
• Can bend beyond 90°
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Bend
Most tool types
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DeburringDeburring ball
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DeburringDeburring ball
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Fastening Technology
Round Shear in a Clip
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Fastening TechnologyRectangle Shear in a Clip
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Fastening Technology Zip-Tech® Replaces
conventional welding and grinding, spot-welding and other fastening methods
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Fastening Technology - Tapping
VIDEO
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Fastening Technology –Thread Forms & Loops
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Hinges
Closed Style Open Style
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Mark Sheets : ID-Stamps
•Reduces the number of tools
needed to mark parts
•Adjustable material range of
0.125” [3.2mm]
•Uses 1/8” characters
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Mark Sheets : Scribe
•120° Scribing Diamond Insert
•150° Scribing Diamond Insert
•90° Carbide Dot-Matrix Insert
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Mark Sheets : Scribe
Limited only by the user’s imagination!
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Inkjet Printing
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Mark Sheets : Rolling Logo
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Texture Sheets : Rolling Knurl (Texture)
This is a cosmetic knurl for appearance or sticker adhesion.This does not create a non-slipping surface!
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Progressive Tooling
These parts go into some of our guide assemblies
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Progressive Tooling
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Progressive Tooling
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Forging WheelsStacking forged shapes allows you to achieve new heights
Ask for more…………..
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More from your tooling partnerWhat is it you need? Maybe a tooling line we don’t currently support Fool proof tooling LEAN audit Tool training or seminars Design advice Kaizen support or Kaizen participation Programming help or advice
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More from your Machine manufacturerWhat is it you need? Tool technology support through programing Wheels ID Stamp Multi Tools Deburr Tools Multi Tools The one you actually want to buy!
Retractable Die Station like Murata, Prima or Trumpf Forming Station like Amada
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Never stop asking Progress never stops
Scott TachenySpecial Applications EngineerWilson Tool International, Inc.
Punching Division – White Bear Lake, MN USA
For more information visitWilson Tools Website
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http://www.wilsontool.com/MediaCenter.aspx