Conference Tracks

Monday, March 26, 2007

MORNING
(8:00 a.m. to 12:00 noon)		 AFTERNOON
(1:00 p.m. to 3:00 p.m.)
M1 Sensors and Control Systems M7 Tutorial: Sensor Fundamentals
M2 Tooling M8 Die Clinic: The Tooling
M3 Safety M9 Assembly
M4 Press Technology M10 CNC Machining
M5 Welding    
M6 In-Die Value Added    

8:00 a.m. to 12:00 noon
Select 1 of 6 concurrent tracks

Track 1: Sensors and Control Systems

Sensors and controls are explored in-depth, from implementing a basic die-protection program to using integrated electronic systems to recall press parameters, provide production information, troubleshoot and prompt press operators.

Implementing a Basic Die-Protection Program
Scott Heitman, Application Engineer, ODM Tool & Manufacturing Co. Inc.

  • Practical solutions for starting an in-die sensing program
  • Proper planning to maintain tight strip-position tolerances
  • Presentation of first-hand experiences with advanced sensing functions

Designing Sensors in the Tooling
Steve Helton, Sensor Applications Specialist, Bachman Machine Co.

  • Examples of real-life uses of sensors in a manufacturing company
  • Technical presentation explores successful design, development and implementation of electronic sensors and controls
  • How to avoid obstacles during implementation of in-die sensing

Integrated Electronic Systems
Tom Mascari, Vice President of Engineering, Link Systems
White Paper (19k pdf)

  • How integrated electronic systems store and recall process parameters, provide information and prompt press operators
  • How this technology reduces setup time and makes complex systems more understandable and manageable for operators
  • The operation and benefits of a plant press network system

In-Die Force Monitoring-Getting to the Point
Rick Wilhelm, President, Helm Instrument Co. Inc.

  • Principles of in-die force sensors
  • Design of force sensors and their selection
  • Typical locations of force sensors in progressive dies, transfer tooling and secondary operations
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Track 2: Tooling

The latest advances in tool steels are covered, including alloys that work best in high-speed applications. Find out the root causes of piercing and blanking failures and how to overcome them; and learn how simulation software optimizes tool design, build and use.

Alternatives to D2 Steel
Ed Tarney, Chief Product Metallurgist, Crucible Service Centers

  • Reviews tool steels offering higher levels of properties for situations where D2 is inadequate
  • How to recognize limitations of D2
  • How to find tool steels that may perform better in certain situations

Die Forensics-Piercing and Blanking Failures
James Loffler, Manager Product Management and Applications, Dayton Progress Corp.

  • Identifies types of piercing and blanking failures
  • Explores the root causes of various failures and how to reduce failures
  • Presents case studies

Advances in Metalforming Analysis
Peter Ulintz, Advanced Product Engineer, Anchor Manufacturing Group, Inc.

  • Discussion of recent advances in optimization tools used in metalforming-simulation software
  • How these tools allow users to evaluate much more than just the formability of the stamping
  • How these tools perform progressive-die and transfer-die simulation, trim-line development, tonnage predictions, die-structure analysis and material optimization

Advances in High-Speed Tool Steels
Brett Krause, Technical Manager, Bohler-Uddeholm Corp.

  • How high-speed tool steels outperform standard tooling materials
  • Outlines improvements in wear resistance, chipping resistance and heattreatment
  • Explores advances in trim-die steels and forming-die steels
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Track 3: Safety

Attendees of this track learn how modern control technology can improve safety while enhancing productivity, how the new ANSI Mechanical Power Press Safety and OSHAS 18001 standards affect stampers; and how stampers can benefit by teaming with OSHA.

Safety and Productivity Enhancements in a Metal Fabrication Shop
David Sullivan, Product Manager, Rockwell Automation

  • Metal fabrication processes viewed from the perspective of personnel safety requirements
  • How modern industrial control technology can improve safety while enhancing productivity
  • Application examples showing how technology improvements aid safety and productivity

Mechanical Power Press Safety-2007
Dennis Cloutier, President/Consultant, Cloutier Consulting Services, LLC

  • Reviews the ANSI B11.1 Safety Standard for Mechanical Power Presses
  • Describes revisions to be included in 2007 version
  • Revisions include language reflecting changes to NFPA-79 electrical standard, language addressing complexities presented by servo-driven presses, broader use of risk assessment and risk reduction, requirements for slide locks and safety blocks, and additional language addressing transfer presses

OHSAS 18001 Is Coming-Are You Ready?
Rodney C. Dahlin, President, Dahlin Consulting Services, LLC

  • OHSAS 18001 is an international standard for health and safety. What does it include?
  • How does it relate to ISO 9001, TS 16949 or ISO 14001, and how does it relate to OSHA's VPP and SHARP programs?
  • When will my customers require it?

Enhancing Workplace Safety through OSHA's Cooperative Programs
John Newquist, OSHA Assistant Regional Administrator for Cooperative and State Programs; Cynthia Weaver, OSHA Industrial Hygienist; Richard Sbroglia, Safety Director/HR Manager, E & E Manufacturing Co. Inc.

  • John Newquist and Cynthia Weaver provide an overview of the various OSHA programs available to help small businesses improve workplace safety and health
  • Richard Sbroglia discusses how his company was the first automotive stamping company in the nation to receive OSHA's Star Award
  • Sbroglia also discusses how his company has benefited from working together with OSHA
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Track 4: Press Technology

Hydraulic- and mechanical-press technologies are covered, including what type of technology works best for your applications, how best to support machinery on the shop floor and how to maintain it.

How to Decrease Costs and Increase Capacity Through Hydraulic Press and Automation Technologies (2 hours)
Dale Nichols, Managing Director, AP&T North America, Inc.

  • Overview of factors of whether a hydraulic press is the best press for an application and criteria that is critical to press selection
  • Discussion of hydraulic-press benefits, and how various specifications affect purchase price
  • What automation can do to solve metalforming challenges

Employing Proper Press Support With Vibration Isolation/ Damping Systems
Phil Littlewood, Engineering Manager, AirLoc

  • Learn vibration-damping methods
  • Learn vibration-isolation methods
  • Explore case histories and benefits of vibration isolation/damping

Improving Press Preventive-Maintenance Inspection
Peter Campbell, President, Campbell Press Repair

  • Reviews predictive-maintenance technologies
  • Shows how these technologies can track critical parts and components of a press
  • Shows ways to rebuild and modernize presses for increased productivity and reliability
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Track 5: Welding

Learn about the benefits of welding automation and how resistance welding can serve a variety of applications. Also, learn about new capabilities in welding-process simulation and what technologies are available to meet newer more stringent weld-fume regulations.

Welding Automation-A Smart Productivity Move
Geoff Lipnevicius, Engineering Manager, The Lincoln Electric Co.

  • How technology improvements counter challenges of rising labor, material and energy costs
  • Overview of advancements in power electronics, digital communications and waveform control
  • Discussion of new welding processes and equipment technology in specific applications, backed by successful case studies

Resistance Welding Technology and Applications
Paul Haynes, Global Automotive Manager, Miyachi Unitek Corp.

  • Introduction to resistance welding
  • Examples highlight diversity and scope of applications and the broad implementation of resistance-welding technology across manufacturing
  • Latest innovations in weld monitoring to ensure weld quality and system verification

Numerical Welding Process Simulation: A Tool for the Prediction of the Consequences of Welding Processes
Y. Gooroochurn (San), Technical Manager, Heat Treatment, Welding & Welding Assembly Solutions, ESI North America; Olivier Morisot, Marketing Manager, ESI North America

  • Overview of numerical simulation as a tool to simulate welding processes
  • Such simulation allows for designing for manufacturing and evaluating different welding sequences and clamping conditions, and allows tool designers to understand how the assembly will react during the welding process
  • Information and a case study describe the capabilities of numerical welding process simulation

Addressing Today's Welding Fume Recovery Needs
Tim Rosiek, Environmental Resource Manager, The Lincoln Electric Co.

  • In 2006, OSHA made exposure limits for welding fumes more stringent
  • Various methods for controlling weld fumes are examined, with advantages and disadvantages described for each
  • Educational materials will be provided
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Track 6: In-Die Value Added

More and more action takes place within the tooling, and this track runs it all down, from in-die welding, clinch fastener installation and other assembly methods to tapping.

In-Die Welding of Hardware to Strip
George Keremedjiev, President, Tecknow Education Services, Inc.

  • Overview of current best practices in in-die/in-tool welding of hardware components to stamped parts
  • Examples of progressive-die, transfer-die and slide-tooling-based welding will be showcased
  • Presented in detail are challenges involved in design of the tooling, selection of power supplies, timing, magnetism, etc.

Implementation of In-Die Clinch Fastener Installation
Roger Patton, Engineering Manager, Penn Engineering

  • How installing clinch fasteners in-die can give a company a significant edge over the competition
  • How to implement in-die clinch fastening
  • How to determine return on investment and minimize risks associated with advanced in-die technologies

In-Die Tapping
Tom Hutchison, President, Hutchison Tool Sales Co.

  • General information about in-die tapping
  • Discussion of approximate production speeds, press-stroke requirements, hole sizes for form threads and tapping-head selection for specific applications
  • Details on lubrication and broken-tap detection

In-Die Quality and Poke-a-Yoke Concepts for Assembly Machines
Jonathan Schmidt, Chief Engineer, Neff Press, Inc.

  • Integration of part-quality verification, presence of all parts in an assembly and assurance that they fit together correctly
  • Proper tracking and documentation of in-die quality
  • Case study demonstrates how these practices were implemented to gain market share and maintain customers
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1:00 p.m. to 3:00 p.m.
Select 1 of 3 concurrent tracks

Track 7: Tutorial: Sensor Fundamentals

For new sensor users and those with some experience, this track explores proper sensor selection to prevent die crashes in various applications and methods to increase sensor longevity and reliability.

 
Jim Finnerty, Product Manager, Wintriss Controls Group of Honeywell

  • Shows new sensor users how to prevent die crashes by identifying proper sensors for various applications
  • Shows intermediate sensor users how to increase sensor longevity and reliability
  • How to avoid common mistakes and pitfalls
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Track 8: Die Clinic: The Tooling

Learn about tool breakage, chipping and wear-causes and remedies.

 
Joel Cegielski, Regional Manager, Dayton Progress Corp.

  • Description of tooling and the perforating process
  • How clearance and hole-to-stock-thickness ratios affect punch life
  • Tool breakage, chipping and wear-how they happen and what can be done about it
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Track 9: Assembly

Integrating multi-slide machinery into stamping operations to ease assembly, plus the role of automation are highlighted in this track.

Multi-Slide Integration
Mike Nordmeyer, Chief Designer, Bihler of America, Inc.

  • To stay competitive, stampers must look to new technologies that can be combined with their punching and forming dies
  • How one U.S.-based manufacturer has turned the tables on offshore sourcing by offering services that low-cost labor cannot compete with
  • How multi-slide capabilities can be incorporated into your manufacturing environment

Automation: If It Doesn't Make Dollars, It Doesn't Make Sense
Robert Greene III, Automation Manager, Turner Machine Co., Inc.

  • How to calculate and communicate return on investment in automation
  • Formulas and methods that quickly and easily establish if a project makes sense
  • The role of labor savings, productivity increases and quality improvements in determining ROI
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Track 10: CNC Machining


Robert Quinn, President, RCM, Inc., Revcam, LLC, Heliforming Technologies

  • The key components to an efficient die detail CNC Milling system
  • Improving technology and efficiency in tooling
  • Integrating automation into the die build process