Page 42 - MetalForming September 2019

The Science of Forming
behind the choices made. Potential areas for cost savings include part con- solidation leading to structural improvements, and balance of the grade selection against the selected lubricant. Suppliers included in the part-design process provide the great- est impact on cost and quality.
Stamped parts are joined using welds, rivets and other means. Fewer stamped parts mean not only fewer stamping and assembly resources needed, but result in cost and weight savings due to the elimination of flange surfaces for joining. Fewer joints improve structural integrity and reduce the opportunity for fatigue and vibra- tion issues.
Several approaches result in struc- tural improvement. One: tailor welded blanks, where flat sheets of the proper combination of grade, thickness and coating are welded together and then stamped. This contrasts with attempt-
ing to join already-formed parts, each with different levels of dimensional accuracy. Hydroforming is another mature process capable of facilitating part reductions using appropriate designs, with 50-percent fewer parts and 20-percent lighter weight having been documented on automotive radi- ator supports and engine cradles.
Applying engineered lubricants facilitates the use of a lower-cost metal grade having lower formability. While an engineered lube may cost more per gal. than the current approach, many of today’s lubricants are designed to function at very low application levels. This reduces consumption, with the additional benefits of a safer plant floor and lower OSHA-compliance costs.
Equivalent structural performance may be achievable with substitution of higher-strength metals, at reduced thickness, into the design. This approach saves weight, and perhaps
without a significant cost penalty. While the higher-strength metal likely costs more per lb., its reduced thickness means less to purchase. Proper lubri- cants help overcome any decreased metal formability.
An internal team with knowledge of part development and die process- ing helps, as does access to forming and structural simulation software. Even with no necessary skills available inhouse at the metal supplier, several companies have the experience and expertise to assist with these chal- lenges. Partner and learn from them to grow the talent within your com- pany. Over time, you will see best practices while honing your skills. Soon you will become the indispen- sable partner sought out by potential customers.
Interested in certain topics for future columns? Let me know at ScienceOf- Forming@EQSgroup.com. MF
Celebrating Female Achievers
We are looking for women in leadership positions or on the shop floor, those who represent dedication to their company and the industry, and demonstrate excellence in meeting their workplace responsibilities. And we need your help.
MetalForming magazine, in conjunction with Women in Manufacturing, is seeking nominations for its 4th Annual Women of Excellence in Metalforming section, to run in the November issue.
Nominees should be employed by a manufacturer of metal parts and components or a supplier to the industry. While past winners are not eligible, past honorable-mention honorees can be nominated. Nominations can be submitted by visiting MetalFormingmagazine.com/excellence.
Nomination deadline is September 20, 2019.
Please nominate only one person from your company.
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