PMA's Education Program

October 1, 2015

FAbtechThe FABTECH 2015 Education Program provides valuable learning experiences for every member of your team. Technical sessions are presented by the Precision Metalforming Association (PMA), Fabricators & Manufacturers Association, Society of Manufacturing Engineers and Chemical Coaters Association International. Among the topics covered: cutting, finishing, forming and fabricating, management, job-shop solutions, automation and robotics, stamping, and tube and pipe. And, the American Welding Society presents a comprehensive lineup of welding education, including the Resistance Welding School.

PMA’s technical sessions allow attendees to learn from leading industry experts, exchange best practices and explore new technologies. Here we present highlights from PMA’s metalforming sessions scheduled during FABTECH 2015.

Monday, November 9

8:00-10:00 a.m.

Software Solutions for Metalforming I

Predicting and Responding to Variations in Sheetmetal Stamped Parts

This presentation will discuss and define specific mechanical properties relevant to computer simulation of forming processes, and introduce the fundamentals of material-behavior modeling as required for simulation. Learn methods to predict and address sheetmetal springback during design and engineering, such as finite-element analysis, and define reasonable expectations of springback prediction and production stamping-process repeatability.

Eric Kam, AutoForm Engineering GmbH


Press Technology I

Press Maintenance: A New Approach to an Old Problem

As manufacturing has evolved so has the need for updated maintenance procedures and record-keeping. This presentation will discuss methods to make your press-maintenance process lean by reducing costs and increasing overall effectiveness. Learn how to use existing press systems such as tonnage monitors, brake monitors, lubrication systems and die protection as effective tools to monitor overall machine condition.

Jeff R. Fredline, Industrial Maintenance Co., LLC


10:30 a.m.-12:30 p.m.

Design Guidelines for Stamping Aluminum

This presentation will address common misconceptions and challenges regarding aluminum stampings, while providing process guidelines and practical solutions. Topics include product design guidelines, material selection, tool-steel and surface-coating selection, establishing proper punching and cutting clearances, and lubrication selection.

Peter Ulintz, Precision Metalforming Association


Press Technology II

Advancements in Servo Technology: A Technical Brief on Different Servo Options in the Automotive Press Industry

This presentation will touch on the latest advancements in servo technology not only in traditional mechanical-press applications (transfer, blanking, progressive, tandem and asymmetrical presses), but also new advancements in hot-stamping technologies moving to mechanical servo.

Gorka Ibanez, Fagor Arrasate S. Coop


Servo Force, Velocity and Position

This presentation will address servo technology, enabling users to rethink the way they design their processes, tackle the challenges of higher-strength steels and other advanced materials, overcome part-quality problems, and reduce issues regarding press wear. Attendees will walk away with a better understanding of how to improve their processes, overcome current and future challenges, and optimize efficiency from their investment.

Darrell Quander, Hyson; Jim Landowski, Komatsu


1:30-3:30 p.m.

Value-Added Technology

The Advantages of In-Die Fastener Installation

By combining the fastener-installation process with the stamping process, the secondary operation of fastener installation can be eliminated. This increases productivity by improving throughput, reducing costs, reducing WIP and increasing quality. A full description of the individual elements of an in-die system and how they function together to form a complete system will be reviewed. This multimedia presentation includes detailed graphics, functional animations of the internals of the die tooling, and photographs of typical and unique projects.

Roger Patton, PennEngineering


Press Technology III

Advances in Hydraulic Press Technology—Case Studies

Multiple case studies with videos and samples of customer parts will be presented in a wide variety of applications, such as deep drawing, coining, punching, ironing, powder compaction and assembly. This informative presentation will explore the following core metalforming technologies: basic deep-draw technology including programmable cushion functions; high-speed servo hydraulics; quick die change; press automation including automated blank handling, servo transfers, indexing and robotics; and in-die sensing and data acquisition including OEE tracking.

Jon Schmidt and Jon Boardman, Neff Press, Inc.


Tuesday, November 10

8:00 a.m.-10:00 a.m.

Software Solutions for Metalforming II

Making Simulation a Reality: Mapping the Effects of the Production Stamping Environment to Computer Analysis

In this session, participants will identify common sources of variation in the stamping environment and relate them to the common inputs and assumptions made during the engineering process and stamping simulation. Participants will be introduced to methods and practices that can inform engineers as to the repeatability of the simulation results in reality and validity of the computer simulation.

Eric Kam, AutoForm Engineering GmbH


Error Proofing I

Die Protection and Sensor Basics

This session introduces attendees to the basics of in-die sensing for die protection. Starting with an overview of the many types of sensors commonly used for die protection, attendees will learn how to select and properly apply the right sensor for any application. Using real-world examples, the advantages and limitations of each sensor type, as well as tips and tricks on sensors selection, installation and wiring, will be highlighted.

Jim Finnerty, Wintriss Controls Group


10:30 a.m.-12:30 p.m.

Advanced High-Strength Steel (AHSS) Technology I

Production Applications of the Future Steel Vehicle (FSV) Program

Newly developed AHSS grades have increased in tensile strength, and innovative processes have made application of these grades more effective. Further, 3G (gauge, grade and geometry) design optimization has been applied to generate significant mass and cost savings. This presentation will review current production examples of lightweighting of body sheet components using these new technologies, which were first introduced in the FSV program.

David Anderson, Steel Market Development Institute


Error Proofing II

Advanced Die Protection and Error-Proofing, with Case Studies

This session will focus on the implementation of a serious die-protection and error-proofing program for metalforming and assembly companies. Included in this session will be the uses of electronic sensors for die protection, in-die part-quality monitoring and automatic self-adjusting tooling with servo motors.

George Keremedjiev, Tecknow Education Services, Inc.; Beth Roberts, Automatic Spring Products; Harold J. Didricksen, Kenmode Tool & Engineering; Bill Schell, Art Technologies; Dirk Holcomb, A Raymond Tinnerman


1:30–3:30 p.m.

Advanced High-Strength Steel (AHSS) Technology II

How Higher-Strength Materials Affect Pressroom Equipment and Die Maintenance

This presentation examines a number of different material types (aluminum alloys, high-strength steels and stainless steels) commonly used in commercial, automotive and aerospace products, and the effect they have on the stamping process. Guidelines for designing dies, selecting pressroom equipment, and implementing appropriate die-maintenance routines based on specific material properties and their influence on the stamping process will be discussed.

Peter Ulintz, Precision Metalforming Association


Die Material Coatings and Tooling for High-Strength Steel Stamping

Stamping dies for AHSS applications face a variety of challenges, including galling of the surface of drawing dies and cracked cutting edges of trim dies. At the same time, stampers must prepare dies quickly and efficiently to satisfy the timelines of new model launches. This session addresses solutions to these challenges, including new die materials, coating technologies and tooling technologies.

Tom Bell, Hitachi Metals


Error Proofing III

Quality Management for Press Shops: In-Die Process Validation, Post-Stamping Check Stations and Error

For management, quality engineers and supervisors in stamping operations, part quality can be a source of frustration. Teams need to identify quality issues early and adjust quickly so that they can have zero defects shipped to customer. This is readily accomplished through in-die process validation, electronic measurement and part tracking. Through real-world examples, we will discuss how press shops are successfully implementing 100-percent inspection of finished parts regardless of automation level.

Will E. Healy, III and Dave Bird, Balluff Inc.


Wednesday, November 11

8:00-10:00 a.m.

Lubrication Technology

Lubrinomics—The Science of Lubrication and Economics in Metal Stamping

Lubricants can make a major impact on the success or failure of a stamping operation. Understanding the different compositions available and how to best apply them to specific operations is important, to ensure the greatest success rates and process compatibility. Not all lubricants are created or perform equally. Determine how to evaluate different lubricants during a trial, learn industry best practices, and understand important metrics for overall success and improvement to the bottom line.

Steve Lowery, Tower Oil & Technology Co.


Understanding Chlorinated Paraffins in Metalforming Lubricants

Learn how extreme-pressure additives affect the workability of stamping lubricants. This session will cover the future of metalforming lubricants, government action on chlorinated paraffins, understanding the global regulatory system and the use of extreme-pressure additives in metalforming lubricants.

Steve Lowery, Tower Oil & Technology Co. and Jim MacNeil, Qualice LLC


10:30 a.m.-12:30 p.m.

Pressroom Safety and Performance

Installation Technology to Improve the Performance of Metalforming Presses

This presentation will explore the relationship between installation methods and their effects on machine productivity and the surrounding environment, using technical illustrations and case studies. The characteristics of a wide variety of isolators and mounting systems will be covered including elastomeric (rubber) and steel-coil spring systems.

Keith Leatherwood, Vibro/Dynamics Corp.


OSHA 1910.147—Control of Hazardous Energy, Risk Assessment and Alternative Control Measures in Stamping Applications

Providing a risk assessment allows employers to meet the requirements of OSHA’s “general duty” clause (5A1 of the act), which requires employers to keep the workplace “free from recognized hazards.” This presentation will provide guidance on the process and steps for performing a risk assessment for the overall safety of stamping machines, and to assist in the application of OSHA 1910.147 control of hazardous energy. Also explained are the additional benefits to be gained as a result of upgrading production equipment for use with alternative control measures as they apply to the control of hazardous energy.

Ted Sberna, White Horse Safety


1:30-3:30 p.m.

Eddy-Current vs. Variable-Frequency Drives

Eddy-current and variable-frequency drives have been employed for many years to provide variable speed control for machines. This session focuses on applications for mechanical metal-stamping/metalforming presses, and argues that eddy-current drive technology best serves applications for presses.

David H. Stroner, DSI Dynamatic
Industry-Related Terms: Alloys, Blanking, Case, Coining, Core, Die, Drawing, Form, Forming, Hydraulic Press, Model, Surface, Tensile Strength, Blank
View Glossary of Metalforming Terms


See also: Precision Metalforming Association

Technologies: Training


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