One-day Workshops

Computer Simulation of Sheetmetal Forming

Instructor: Dr. Stuart Keeler

• Why use computer simulation—styling to production
• Types of simulation codes—one step and incremental
• Knowledge prerequisites
• Validation of simulation results
• Applications for computer simulation
• Implementation techniques
• Simulation examples

Designing & Building Dies for High-Strength Steel Stampings

Instructor: Peter Ulintz

• Understanding material behavior
• Evaluating current equipment capabilities
• Material handling requirements
• Coil feeding requirements
• Bending, forming, flanging, cutting and punching
• Draw forming
• Die sets and components
• Computer simulation
• Transfer die considerations

Higher Strength Sheet Steels – Solving the Problems

Instructor: Dr. Stuart Keeler

• What are higher strength steels?
• The new Advanced High Strength Steels (AHSS)
• Designing parts and tooling for higher strength steels
• Measuring and reducing forming severity
• Computer simulation of higher strength steels
• Case studies

Increasing Productivity... Solving the Problems

A one or two-day Workshop available in English or Spanish.
Instructor: Robert Braswell

• Methodology and ideology for increased productivity
• Integrated Systems and plant layout
• Process monitoring
• Quick Die change and automation
• Personnel effect on productivity
• True efficiency measurement
• Analysis of current process and laying out a plan to increase productivity

Making Flat Rolled Flat – So it Stays that Way

Instructor: Eric Theis

• Limits of the producing mill process & slitting process.
• Mechanical metallurgy, stress/strain diagrams, etc.
• The meaning and importance of “Yield Strains”
• Flatteners, straighteners and levelers.
• Shape compensation.
• Shape control and material stability
• Coil vs. Sheet or Blank fed Flatteners, Straighteners and Levelers

Safety in the Pressroom

Available in English or Spanish
Instructor: Robert Braswell

• Safety diagnostic of your pressroom
• Introduction to pressroom safety
• Personnel impact on plant safety
• Mechanical press overview
• General safety requirements
• Full and/or part revolution presses
• Discussions and recommendations

Sheetmetal Forming — Understanding the Properties

Instructor: Dr. Stuart Keeler

• Relating stretching, bending and drawing to metal properties
• Why blanking operations reduce edge stretch
• Inconsistencies of forming metal (springback, etc.)
• Selecting steel grades to meet forming needs
• Understanding nonferrous metals
• Making the steel grade work
• Surfaces, surface coatings and friction

Successful Die Planning, Quoting and Sourcing

Instructor: Dr. Stuart Keeler

• Die fundamentals for quoting
• Determining best die type
• Rapid die conception techniques
• Understanding die and press specifications
• Setting rates and margins for quoting
• Estimating tools, software, die and production part cost
• Pricing considerations
• Quotes management
• Die/part sourcing

Troubleshooting Formability Problems

Instructor: Dr. Stuart Keeler

• Introduction to troubleshooting
• General sequence of steps for all problem solving
• Five general troubleshooting tools
• Computer simulation as a troubleshooting tool
• Specific problems in tool design, press, and lubrication
• Improving consistency in product dimensions
• What material can and cannot contribute to problem solutions

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Two-day Workshops

Best Practices in Sheetmetal Forming

Instructor: Dr. Stuart Keeler

• Foundations for change to meet competition
• Determining current level of deformation and forming severity
• Tracking through die tryout and production
• Different parameters control different forming modes
• The die responds only to mechanical properties of the sheetmetal
• Understanding steel, aluminum and other metal grades
• A quick look at press and tooling interactions
• Various troubleshooting practices for problem solving
• Tryout in the virtual press shop

Designing & Building Metal Stamping Dies

Instructor: Peter Ulintz

• Processing the Part and Station Layout in Progressive Dies
• Cutting and Punching the Part
• Forming, Flanging and Flattening the Part
• Pressure Pad Design
• Drawn Shells
• Cam Slides and Other Sliding Devices in Stamping Dies
• Recent Advances in Computer Simulation
• Performance-Based Die Engineering Strategies

Forming Difficult Stampings with Better Consistency

Instructor: Dr. Stuart Keeler

• Data collection
• Defining the stamping and allowable deformation
• Forming modes and forming limits
• Tracking your forming process
• Computer forming simulations
• Effect of process changes
• Case studies and team problem solving

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Three-day Workshops

Forming Sheetmetal More Effectively

Instructor: Dr. Stuart Keeler

• Measuring deformation and determining forming severity
• Basic forming modes
• Blanking, shearing, trimming
• Press shop analysis techniques and lubrication
• Forming analysis applications and parameters
• Fundamentals of steel
• Circle grid analysis
• New forming technologies
• Team problem solving

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Workshop Fees

(reimbursement of instructor’s travel costs billed separately)

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