Laurie Harbour

    

President & CEO 
Harbour Results Inc.
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Keynote: The Manufacturing Renaissance: Driving Continuous Improvement

Manufacturing was the foundation on which the country was built. Although the industry continues to be unpredictable, it is experiencing a renaissance. Companies are leveraging technology and process improvements to drive continuous improvement and the forecast for tooling is on the rise. Laurie Harbour will provide a snapshot of the current state of the die building and metalforming industry, best practices for continuous improvement, and the forecast for 2024 and beyond.

    

    

Corey Chamberlain

    

Developer 
T-Sim Solutions LLC
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Transform Your Pain into Gain! (How to use transfer simulation technology to become a world-class metal stamper)

We don’t have time for that; we’re way behind schedule! There is no way that this job will ever run at the quoted strokes/min. These phrases are uttered in nearly every major production facility in the world. Most metal stampers are working three shifts, six to seven days a week, burning out their employees and paying thousands of dollars in overtime. On top of that, they deal with staffing shortages, upset customers and impossible deadlines. It can begin to feel hopeless when this continues unchanged, day after day.

But there is hope… proven techniques and strategies that can take much of that pain away… and the best part is, you can experience it in far less time than you might imagine. This presentation will address how to use transfer-simulation software to reduce stress in your workplace and become more profitable than you ever have been.

Several techniques and strategies will be covered for increasing OEE (Overall Equipment Effectiveness) and freeing up capacity by optimization of your existing tools; planning to ensure that new tools launch smoothly and at the highest possible production rate; and getting the most out of your transfer-simulation software (uses you may not have realized).

See results immediately, make your future projects far less stressful, and increase your bottom line!

    

    

Will Healy III

Global Segment Manager 
Universal Robots
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Automation for In-Feed Part Handling in the Press Shop: Destacking, Bin Picking, Employee Retention & More!

Idle equipment and missed deadlines are frustrating situations for press shops, and high operator turnover and open positions are driving automation investments for shops big and small. How do you decide what automation project to select for your best return on investment? In this presentation, Will Healy will review automation applications around large and small presses and how automation technology is being used to improve revenue per employee, boost parts per shift and make work more engaging for press operators. With real-world case studies, in-feed part-handling applications such as destacking, bin picking, press tending, material handling and more will be discussed. The presentation will wrap up with straightforward and actionable concepts for boosting employee engagement, reducing turnover, and improving outcomes for business leaders and frontline workers alike.

    

    

David Kinnard

Senior Sales Engineer 
Tower Metalworking Fluids
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Clint Weber

Sales Engineer 
Tower Metalworking Fluids
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Balancing Lubrication Consolidation—Safety and Performance

This presentation will explore methods and considerations that influence lubricant consolidation while achieving the best possible performance. Attendees also will explore how lubricant health/safety profiles and application methods will help lower costs and improve operational environments.

    

    

Jeff Bennett

President 
Tool Planners Inc.
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Building a World-Class Tooling Information System

The presentation explores the benefits of managing special tooling assets located internally and at supplier locations. Dies, molds, fixtures, gauges and automation-system capability affect part quality, material usage, labor cost and sourcing decisions. Attendees will learn how to use web-based technologies to quickly and efficiently document, manage and maintain special tooling to lower supply-chain risk and improve performance.

    

    

Mark Fabischek

Global Executive Vice President of Technical Development 
KIRCHHOFF Automotive
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Cheng Zeng

Research and Development Manager 
KIRCHHOFF Automotive
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Welding and E-Coating Corrosion Protection for High-Strength Steels

In this presentation, the spot and gas-metal-arc (GMA) welding process-parameter development and quality evaluation of uncoated and zinc-coated 980- and 1180-MPa 3rd Gen steels will be presented. The risk of liquid metal embrittlement (LME) in welding zinc-coated 3rd Gen steels will be addressed and investigated. Kirchhoff Automotive’s (KA’s) results show that while welding zinc-coated 3rd Gen Steel without LME is possible with proper parameter setting, there still might be a risk of LME depending on materials, coating thickness, joint configuration and welding conditions.

One safe solution is to weld uncoated 3rd Gen steels where corrosion protection is needed. Good e-coating adhesion at the weld seams and heat-affected zone (HAZ) is possible only when parts are cleaned properly. Different cleaning methods were investigated regarding their advantages and disadvantages. Results show that pickling is a good option, especially for hollow structures, but pickling 3rd Gen 1180 MPa brings the risk of hydrogen embrittlement. Newly developed so-called silicate-less welding plus using optional additional cleaning process such as laser cleaning for weld HAZ can be a good solution. KA’s self-developed corrosion demonstrator shows good comparison results.

    

    

Christopher Kristock

    

Vice President, Automotive Program 
American Iron and Steel Institute
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Keynote: The Impact of Modern Steel Grades on the Science and Art of Metal Stamping

The science and art of metalforming will benefit from the continuing development of new Advanced High-Strength Steel (AHSS) grades, which have significantly improved material properties compared to the steels of only a few years ago. Recent advancements in metallurgical processing equipment and technology at steel mills now produce steels with very high tensile strength and sufficient ductility to support cold stamping of parts. While designed primarily for efficiently lightweighting automotive body structures, these new steel materials are making their way into other applications requiring steel processing and forming for design applications. The latest family of steel grades with these unique property combinations, referred to as 3rd generation (Gen 3) AHSS, now bring to the forefront a need for knowledge advancement in the science of stamping equipment, tooling and metal flow control technologies. In addition, some basic material processing techniques for personnel and equipment must be considered to ensure successful usage of these newer grades.

This presentation will highlight some of the developments in both steel processing and stamping and tooling technology as innovations to achieve successful conversion of AHSS and Gen 3 AHSS sheet into stamped parts. The material will be presented in a summary manner with recommendations for training and self-study opportunities given along the way. One section will focus on a plain-language explanation of the methods employed by steel producers to deliver the range of mechanical properties available within the AHSS class of materials. These steelmaking methods, collectively recognized by their resulting multi-phase microstructures in steel products, have led to an expansion of material formability terminology now segmented into categories of global versus local formability aspects. The rationale for this delineation and the ramifications on tooling, die and part designs will be explained in the presentation. There also will be a review of material handling and tool processing technologies that are adjunct to metal stamping but necessary for high-yield, low-cost and safe operation with AHSS. Finally, the root causes of dimensional conformance issues (edge cracking and springback) will be presented for guidance in applying countermeasures via blank and stamping tooling designs.

    

    

Colton Sampson

    

Commercial BD Director 
Machina Labs
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The Robotic Craftsman: Rapid Digital Sheet Metal Forming

The combination of AI and robotics has led to the groundbreaking innovation known as roboforming—dieless, digital sheet metal forming. Roboforming technology is enabling manufacturers to unlock speed and agility by producing large, curved, complex parts in just a few hours. Using material- and geometry-agnostic technology, roboforming eliminates custom, costly tooling to allow for near-zero-lead-time production. Roboforming also enables optimized, deep draw designs that were not previously manufacturable. This allows manufacturers and end customers to realize higher performance, lighter weight and more efficient products using virtually any metal from aluminum and steel to titanium and nickel alloys.

    

    

David Diaz-Infante

    

Servo Press Scientist 
Nidec Press Automation
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Getting the Most Out of Your Servo Press

A servo press is a powerful machine if used with the proper strategies. This presentation will explore practical tips and techniques to make the most of servo presses. Discover setup optimization, explore the fine-tuning of press parameters, and learn how to optimize performance and increase productivity. Considerations when pairing a transfer or a progressive die with a servo press also will be reviewed.

    

    

Peter Ulintz

    

Technical Director 
Precision Metalforming Association
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Methods and Tips for Solving Progressive Die Problems

Progressive dies are routinely reworked, modified or adjusted in the press when production problems occur or quality issues arise. In many instances, the die is not the root cause of the problem and, therefore, the problem resurfaces or new problems are created. This presentation examines key elements for solving progressive die problems, provides tips for success and offers validating solutions.