Here's the thing about fixed-stroke mechanical presses... Inefficient and outdated stamping operations can cause production bottlenecks in your stamping operations. This can result in downtimes and backlogs. One of the possible culprits is the use of fixed stroke presses that are only compatible with the type of forming for which it is designed. The problem? Instead of using one machine for multiple types of forming, some fabrication shops are using a separate fixed stroke press for each type of forming. The disadvantage? Downtimes from scheduled maintenance and unexpected repairs or press replacements. To illustrate the effects of downtime, let's say you have 1 stamping press and 1 blanking presses in your multi-application metal forming shop. One day, the stamping press stops working, leaving you without a backup press. Unfortunately, a fixed stroke press does not offer the versatility of an adjustable stroke press. So, when one press is down, you have no backup. This causes backlogs and forced downtime while you wait for repairs or a replacement. The solution? One adjustable stroke press can serve as a back up to several fixed stroke presses, eliminating backlogs and downtime mentioned in the previous example. Since certain jobs require a specific stroke length and die height, adjusting the stroke length for the desired job allows for a variety of jobs to be performed on a single press. An adjustable stroke press is multiple machines in one-- stamping, blanking, coining, drawing, and bending. While your operations were once limited to the type of fixed stroke press you owned, an adjustable stroke press offers this kind of versatility. Implications of adjustable stroke press on reducing production bottlenecks in your stamping operations Increased floor space When you replace a fixed stroke press with an adjustable stroke press, you free up floor space previously occupied by single-job presses. Return on investment With an adjustable stroke press, you can produce more parts per minute without damaging the press frame and tools. This results in the benefit of less downtime and repair costs. Learn more Have questions? Contact us to speak with an expert about eliminating production bottlenecks with an adjustable stroke press.
Recently, ART Metals Group (ART) shared their experience with us. If you’ve ever doubted whether an adjustable stroke press has the ability to positively affect your company’s bottom line, you’ll want to keep reading this case study about how an adjustable stroke stamping press drives business growth. Chad Wyan, Director of Engineering at ART, located in Fairfield, OH, had a problem. ART was receiving a lot of requests for short-run production jobs and could not take them because of high tool costs in relation to the job size. Chad’s solution? A low-tonnage adjustable stroke press from Sangiacomo Presses. ART purchased a Sangiacomo T-50 C-frame flywheel punch press. This press is well suited for applications with higher production speeds for increased productivity, such as blanking and stamping. The T-50 C-frame press features the following, plus standard features not listed here: 15.75-inch max die height (table to ram distance) 140 strokes per minute (variable speed available as an option) 0.47-4.33 inch adjustable stroke length 2.76 ram adjustment (slide adjustment) 500 kN max pressure (capacity) Chad explains, “Since I joined the company, we were seeing estimates with a lot of lower volumes that didn't justify a multi-out approximately $50,000 tool to run 10,000 pieces a year. With the Sangiacomo press and the lower tonnage press, we decided we could make a single-out tool where we could interchange some components in one master die, make various parts with that tool, and be competitive on these lower volume quotes that nobody else really wants. So, even if it was a lower volume quote that nobody else wants to take, we can increase margin and lower tool costs, and it made good business sense.” Chad continues, “The adjustable stroke was key, giving us the ability to take a variety of parts and put more parts into that press than if I went with, say, a straight-sided press. With a straight-sided press, we would need to slow down the speed and go with a larger stroke to accommodate the same amount of parts.” “Once I could show that I can cover 80% or 85% of the quotes we're seeing that we typically just no-quote or pass on, and have the opportunity to bid on them and win some new customers, along with adding more business with existing customers, then higher management was all in on the adjustable stroke Sangiacomo press”, Chad explains. “Probably the other big thing about the Sangiacomo Press was the adjustable stroke on the press because we do mainly round work, but we do a large variety of it, and we kind of did the master die concept.” “Looking at it, we could run pretty much anything under four inches in diameter. And with the adjustable stroke, I can run faster on the smaller parts and slower on the larger parts, but I've got the flexibility to go between the two. Some of the other presses we have here are fixed strokes, so I'm running say a one-inch part, but I've got a six-inch stroke. Obviously, I'm wasting a lot of time. I'm only running 70 strokes a minute whereas, on the Sangiacomo adjustable stroke stamping press, I can crank it up to 180.” “So, with the feed line and everything, it fits into our existing floor plan. Now that we have it here, everybody likes the less expensive tooling. We can get a part into production in a lot quicker lead time because I'm not building a big die”, concludes Chad. Click here to see the full technical data on the Sangiacomo T-50 C-frame flywheel press. To view the full line of Sangiacomo presses, download our product brochure. Check out other time-saving and productivity-increasing advantages of an adjustable stroke press here. For more background on this story, check out this article that was featured in the September 2022 issue of MetalForming Magazine, written by Brad Kuvin. About ART Metals Group ART Metals Group is a full-service global supplier of precision metal stamping and assemblies, thrust bearings, and coining services. Based in Ohio, they serve numerous industries of Auto, Truck, Bus, Solar, HVAC, Military, AG, and more. ART specializes in providing quality products produced on time and under budget. Check out some of their past projects here. Interested in making ART your supplier? Contact them here: Email: sales@artmetalsgroup.com Phone: 513-942-8800 Fax: 513-942-3200 Address: 3795 Symmes Road, Fairfield, OH 45015
In a previous article, we discussed why using the shortest stroke possible yields the best results for the parts formed on a stamping press. Many stamping operations don't operate to their full potential. If it gets the job done, why change anything, right? Not exactly... In this article, we'll explain some common reasons for these less-than-ideal conditions as well as ways to overcome obstacles to implementing improvements in your stamping operations. Reasons for less than optimal conditions Biases and assumptions in the tool design or equipment selection are causes that are difficult to detect and change. More obvious reasons for less-than-optimal stamping processes are: Equipment is not used for its intended purpose: Make a job work on equipment available Purchased equipment that “would do the job” Purchased new equipment at discounted price Repurposed existing equipment 2. Operating conditions/Trade-off values have changed dramatically: Production Volumes/Lot sizes have changed significantly Product Specifications/Part tolerances have been tightened Production requirements for quality, certifications, packaging, and delivery have changed 3. Equipment is outdated: Newer technology not utilized Automation Lack of spare parts Decreased serviceability 4. Equipment lost its precision from when it was new: Damages due to operating error Material fatigue, improper repairs Normal wear Past modifications How can stamping processes be improved? Efforts to optimize start with an open mindset and a willingness to allow discoveries to effect change. It requires an environment where assumptions are replaced with reason, and prior decisions are re-evaluated based on changes in the operating conditions. Hiring an outside expert that provides unbiased analysis and technological insights can be helpful. Sometimes simple remedies can make a significant difference. If this article was helpful, please let us know by subscribing to our newsletter to get instant notifications whenever a new blog post is published. Our sales team is always happy to answer any questions and discuss your stamping needs. Contact us today!