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strategy and engineering activities, from design through launch for all new vehicle programs.
Ryska’s talk sets the table for all that follow, spearheading an agenda fit for just about anyone and everyone in the industry—from company presidents and CEOs to engineers and engineering managers, die designers and tooling engineers, plant and operations man- agers, and tool and die makers.
Continuing the Industry 4.0 theme, Hyunok Kim, Ph.D., technical director at EWI, follows Ryska with a presenta- tion that dives deeper into Industry 4.0 for metal stamping.
“Industry 4.0,” Kim says, “is the cur- rent trend of automation and data exchange in manufacturing technolo- gies. It aims to improve a given process and product quality by collecting and using all process-related information available from factory equipment via network-connected sensors, software and cloud computing.
“This presentation will introduce applications of Industry 4.0 in metal stamping,” Kim continues, “with emphasis on sensors, close-loop process control and machine learning to improve final part quality. By adopting these emerging tools, manufacturers can improve business performance, boost product quality and optimize production.”
Dynamic Considerations for Optimized CNC Milling Parameter Selection
Following Kim is a talk by Tony Schmitz, a professor with the University of Tennessee Knoxville, aimed at those working in die-build shops. Schmitz will discuss the importance of consid- ering the structural dynamics of the tool holder, spindle and machine when selecting milling parameters.
“The relationship between the structural dynamics, cutting force, chatter and part accuracy will be described,” Schmitz says. “I will show how chatter-free milling parameters can be chosen at the process-planning
stage to help provide first-part-correct performance.”
Next up: a talk on additive manu- facturing (AM) applications for metal stamping processes and dies, by a pair of researchers working on the R&D staff at Oak Ridge National Lab- oratory: Mark Noakes and Andrej Nycz. Noakes and Andrej will present their findings regarding the use of AM for die production, specifically the ability to reduce the required machin- ing process by as much as 50 percent. AM also finds use, they say, for pro- totyping and for fabrication of quick- run parts, “capabilities that automak- ers need,” Noakes says, “during vehicle development, which allows for shorter lead times and quicker reaction to changes.
“Producing metal stamping dies using additive processes reduces lead times when manufacturing tooling,” Noakes adds. “It also makes North American tool and die makers more competitive in the market. Reducing raw material needed to produce a stamping die by adding metal to near net shape rather than removing mate- rial to net shape offers advantages in material and cost savings as well.”
Welding Tool Steel Effectively
Wrapping up day one is a talk by Berth Nilsson, from Uddeholm AB, on the welding equipment and techniques required to successfully weld tool steel. Nilsson will explain to attendees how to choose the correct filler material, and the important parameters that require close attention during the welding process. He’ll also discuss what happens if recommended weld- ing procedures are not closely fol- lowed, and the resulting effect on tool life.
Breakout Tracks Highlight Day Two
The second day of the conference kicks off with a Tool and Die Industry Update and Forecast, from renowned industry expert and speaker Laurie
Harbour, president of Harbour Results.
“Manufacturing is in the midst of a marketplace evolution,” Harbour says. “From the growth of automated and intelligent technology to new consumer demands, the industry faces many challenges that will require a change in the way suppliers do business.”
Harbour will provide insights col- lected through the Harbour IQ Pulse Study, looking at performance across different manufacturing sectors. She also will show data proving, on average, that most shops are not prepared for the changing landscape of manufac- turing. Harbour then will provide best practices for delivering future success, specifically in the areas of talent, sales and technology.
A presentation on the history of alu- minum auto-body sheet metal follows, provided by Laurent Chappuis, presi- dent of Light Metals Consultants, LLC. Then, attendees will select among con- current track sessions addressing var- ious technology topics:
• “Trog-Die” (transfer + progressive) Transfer Systems
• Effect of Edge Condition on an In- Plane Expanding Hole of Aluminum Sheet
• Transfer Die Simulation and Opti- mization
• Advances and Applications in Fric- tion Stir Welding
Last but not least, stick around to hear a rousing, crowd-pleasing pres- entation by drummer, motivational speaker and trainer Adam Argullin, titled Mistaken Identity—Are You Your Job? Work-life balance is the discussion topic, focused on the stress placed on ourselves as we become our jobs.
“I’ll discuss healthy techniques, as well as unhealthy habits,” Argullin says, “commonly used to reduce stress, with the ultimate goal of achieving a happy work/life balance.”
To learn more and register to attend, please visit www.pma.org/mstd-con- ference. MF
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