Flexibility key to metalforming success.
Ty-Wood Corp has 'Ultra' formula for growing its business
It's not only the strongest machine shops that survive, it is also those that are flexible and provide quality work. Holliston, MA-based Ty-Wood Corp knows this, and it is reaping the fruits of its labor.
Ty-Wood Corp is both a subcontractor One who takes a portion of a contract from the principal contractor or from another subcontractor.
When an individual or a company is involved in a large-scale project, a contractor is often hired to see that the work is done. of precision sheet metal components and assemblies as well as a fabricator fab·ri·cate
tr.v. fab·ri·cat·ed, fab·ri·cat·ing, fab·ri·cates
1. To make; create.
2. To construct by combining or assembling diverse, typically standardized parts: of fiber optic cabinetry cab·i·net·ry
Cabinetwork: finely detailed cabinetry.
Noun 1. cabinetry - the craft of making furniture (especially furniture of high quality)
cabinetwork . To meet market demand for higher quality and to maintain flexibility for changing product requirements, the company has expanded its turret punching operations with five machines, and with it a new approach to tooling the machines.
The company started adding machines after purchasing its Amada Octo in 1985. It added an Amada Pega in 1986, a Finn Power TP 2000 in 1992, an Amada Vipros in 1996, and another Amada Pega in 1998. While Ty-Wood has added capacity with the new machines, it has been the company's recent approach to retooling them that's really helped improve tool life, part quality, and productivity.
Doing it better with its turret punching operations is important at Ty-Wood as it strives to meet its customers' ISO (1) See ISO speed.
(2) (International Organization for Standardization, Geneva, Switzerland, www.iso.ch) An organization that sets international standards, founded in 1946. The U.S. member body is ANSI. 9000 requirements. Finding new ways to improve its turret punching operations has paid off with more customers and larger orders.
"We're punching 12 to 15 tons of sheet metal a week," reports Gary Dellicker, engineering manager for Ty-Wood. "That's 12 times what we were processing three years ago. The complexity and size of parts have grown along with the quality requirements."
Experience leads to changes
Recent advances in tool design led Mr Dellicker to test Mate Precision Tooling's new Ultra system.
"We were interested in the system when we first heard about its long life features," says Mr Dellicker. "With the amount of sheet metal we punch, we recognized the importance of getting as much out of our tooling, not only from an initial investment standpoint, but also to reduce setup times and to reduce machine downtime The time during which a computer is not functioning due to hardware, operating system or application program failure. due to tool maintenance.
"We tooled our Amada Vipros model 358 first with Mate's Ultra and we were surprised with the increase in tool life--as much as 50% to 75%--over the tools we had been using."
Ty-Wood started with Ultra toolholders with 1/2", 1 1/4", and 3 1/2" station punches and dies for basic, round, square, and rectangle punching operations in one machine to see how it performed against the tooling in the other machines. After a year of use, many of the Mate tools did not need sharpening For image sharpening, see .
Sharpening is the process of creating or refining a sharp edge on a tool or implement. The term has a wide application but can be expressed as the creation of two intersecting planes which produce an edge that is sharp enough to cut through the target while comparable tools in the other machines had been sharpened sharp·en
tr. & intr.v. sharp·ened, sharp·en·ing, sharp·ens
To make or become sharp or sharper.
sharp several times.
Mr Dellicker estimates that many of the tools have produced more than 3 million hits and are still operating "good as new," an accomplishment he attributes to Mate's tool steel. Mate's 1 1/4 B station punches, for example, are made of 61 Rockwell hardness premium high M-2 speed tool steel in NC controlled furnaces using exclusive processes developed by Mate. This results in punches with superior compressive strength Compressive strength is the capacity of a material to withstand axially directed pushing forces. When the limit of compressive strength is reached, materials are crushed. Concrete can be made to have high compressive strength, e.g. especially suited to retain size and accuracy and withstand high operating temperatures for longer tool life and better piece part quality.
The tool steel in Mate's dies is equally durable. The Ultra 1 1/4 B station dies are made of hardened A2 5% chrome (jargon) chrome - (From automotive slang via wargaming) Showy features added to attract users but contributing little or nothing to the power of a system.
"The 3D icons in Motif are just chrome, but they certainly are *pretty* chrome!" tool steel, 59 Rockwell C optimum material and hardness for maximum edge wear without breakage. This material correctly balances the opposing conditions of hardness and toughness.
Using up tool inventory
Mr Dellicker says that retooling was done gradually as existing tool components wore out. As the new Ultra tooling proved itself and operators became comfortable using it, Ultra tools for special shapes and forming operations were added. The interchangeability in·ter·change·a·ble
That can be interchanged: interchangeable items of clothing; interchangeable automotive parts.
in features of Mate Ultra tooling makes phasing in easy. All Ultra tool components interchange with those already in the machine, so matching up punches, dies, strippers Notable strippers of the past
Ty-Wood's range of fiber optic cabinetry and custom parts are fabricated fab·ri·cate
tr.v. fab·ri·cat·ed, fab·ri·cat·ing, fab·ri·cates
1. To make; create.
2. To construct by combining or assembling diverse, typically standardized parts: from various materials in many thicknesses. The company punches cold rolled steel, aluminum, brass, copper, and other materials from 11 to 28 gage. In a typical 8 hr shift, as many as eight different punches could be used to punch parts in different materials and thicknesses. Many of the tools, supplied with the press when purchased, required length adjustment to punch the different materials properly.
With the old tooling, to adjust the tool length the operator shut off the machine and inserted and torqued down two Allen bolts within the tooling, then removed the retainer A contract between attorney and client specifying the nature of the services to be rendered and the cost of the services.
Retainer also denotes the fee that the client pays when employing an attorney to act on her behalf. rings and inserted the correct shim. Mr Dellicker estimates to adjust each tool took 30 to 45 sec, and to adjust eight tools seven times during an 8 hr shift took a total of 40 mins. This didn't include additional time required by the operator to check correct punch penetration in the particular material being punched. Even after doing the shimming operation, it was necessary to test the tools to check for correct penetration into the material.
With Mate Ultra tooling, Mr Dellicker says his operators were able to reduce the tool length adjustment time per tool to 5 to 7 sec each because Ultra's push-button (electronics) push-button - A roughly fingertip-sized plastic cover attached to a spring-loaded, normally-open switch, which, when pressed, closes the switch. Typical examples are the keys on a computer or calculator keyboard and mouse buttons. design allows fast and easy removal of the punch guide and other components without the use of tools and wrenches. Reassembly reassembly - segmentation is equally fast for the same reason. On an 8 hr shift with seven tool changes, each involving eight tools, Ty-Wood was able to reduce its downtime on a single Amada machine by up to 30 min.
The fiber optic cabinetry and similar assemblies manufactured by Ty-Wood require card guides, extrusions, embossings, and other complex features. After Ty-Wood's press operators saw the advantages of Mate's Ultra punching system using standard squares, rounds, and ovals, they began phasing in Mate's new Ultraform tooling with even more benefits over the forming tools they had been using.
To start with, just one adjustable length holder was needed to handle a variety of forming inserts (embossings, card guides, etc). Advantages also include reduced tool cost because fewer tool components are needed. More flexibility is achieved because the forming inserts are interchangeable and the tools do more. Also, the assembly length can be preset preset Cardiac pacing A parameter of a pacemaker that is programmed permanently when manufactured , which also saves setup time. The length adjustment is easily made at the machine without having to remove the tool to reset it. Ty-Wood press operators noted that length adjustments of 0.002" (0.05mm) per "click" of the punch head could be made quickly and easily while angle settings were possible of 0, 90, 180, and 270 deg.