Ultra implemented two significant changes to this manufacturing process that reduced costs and improved production times.

First, we designed and built the crimping operations so crucial to this metal shell into their progressive stamping dies.

Second, Ultra reduced the customer's capital tooling costs by consolidating their progressive dies from FIVE to TWO. This was feasible due to the uniform shape and design of the shells. The key to these dies was the last station. It was designed and built for easy changeover to one of five different custom stations to finish the stamping process.

Our Toolmakers and Die Designers performed a detailed assessment of the die block. They immediately recognized a weakness with the dowel pins and holes. Dowel pins, a type of industrial fastener, and dowel holes align the tooling in its proper location so that it can operate correctly on the production line. The customer's current dowel components were lacking in strength and quality. This was causing the issues the customer had continuously been experiencing on the production floor.

The current threaded dowel pins weren’t made to withstand constant wear and tear. They were built with a tapped hole going through the center of the pin which made them inherently weak. Also, the flat end surface of the dowel pins limited their ability to adjust in the hole; and this increased the scraping and washing out of the dowel holes. This dowel system established no lead-in or angle for placing and removing the tooling on and off the risers.

The image below displays the condition and design of the customer's die block with the dowel holes before Ultra got involved.

Machine open the dowel block and install replaceable inserts with dowel holes. These hardened inserts will establish a more solid base for the dowel holes and pins to align. Also, the newly designed center hole on this insert will improve line up with the location pin on the tooling. Ultra's customized solution included redesigned dowel pins composed of a hardened liner. Also, the end surface of the dowel pins is now curved allowing for better lead-in and fit into the dowel hole.

Experienced CNC Machinists utilized their technical skills, 3D design software and our CNC equipment to precisely build this replaceable metal insert with its drilled holes. This image below shows inside the CNC where the insert is placed in an established location to ensure accurate and consistent drilling operations.

The four small pierced holes labeled in the image are smaller than the actual material thickness. This presents a problem because the continued force of the punch going through the material creates a higher probability of the punch breaking off or becoming off target. And three of these four holes are on non-flat surfaces which also makes the piercing operation more challenging.

Design and build a subtool for this piercing operation in the progressive stamping die. This design presents two key benefits.

The subtool in the stamping die keeps the piercing operation separate;
localizing the force of the punch to this specified area. Then the remaining
stations on the tooling die strip aren’t at risk of damage during
production. This also helps keep the entire die strip aligned in the correct
position from operation to operation during production.
This provides our Toolmakers the ability to efficiently remove the
subtool if needed to perform adjustments or repairs in Die Maintenance.
And the subtool can easily be placed back in the correct location on the
progressive stamping die.

After the piercing operation is completed, a bubble of material is created
and then formed to match the other designed features of the breather
cover.

The customer designed "an island" between the rows of slots to establish better strength in the water tray. Ultra performed a stress test analysis utilizing FEA (Finite Element Analysis) simulation software. This identifies areas with high levels of stress so that we can reduce as needed. As shown in the image below, the green-colored area indicates the newly designed "island" contained high levels of stress and this was unacceptable.

A newly designed tray needed to reduce the centralized area of stress while maintaining the functionality of the water tray. Per the customer's request, this meant minimal changes to the overall form and dimensions of the tray as it needed to fit in the deaerator equipment.

Ultra removed the designated "island" and added in troughs with strengthening ribs to keep their shape. A new stress test provided evidence that this design was feasible as shown in the image below.

Stretching the stainless steel to .400 of an inch without snapping or breaking off the troughs would be the most challenging aspect to attain during production. The stainless steel would need to be stretched with perfect timing and distributed equally throughout the forming process. The final manufacturing process was finalized during prototyping.

The sheer length, 31 ½ inches, and weight, 54 pounds, were key factors in the customer selecting Ultra as the supplier of their ramp. Our 800-ton Minster metal stamping press combined with our secondary operations proved Ultra could handle the ramp’s production all at ONE facility.
The ramp is produced utilizing a progressive stamping die that includes only ONE forming station to complete that stage of production. We designed this forming station to include five different operations to be performed in ONE hit. The edges, top, sides, lips are being formed along with coining on the top of the ramp. This forming station is made of bronze material to better protect the cosmetic integrity of the ramp.

The edge quality of the ramp is of critical importance for it to correctly operate on the elliptical equipment; and it can also be clearly seen by the end-user. A detailed finishing process is followed to ensure the edges are smooth and meet cosmetic standards.

Deburring of sharp edges.
Polishing of edges with hand sander.
Washing the ramp in hot, soapy water and drying with microfiber cloth.
Removing the protective coating for final assembly.

Watch the 800-ton press stamp this heavy-duty metal part.

Case Study: Die Maintenance Services

A Security Systems Manufacturer was finding it difficult to perform scheduled preventative maintenance on its metal stamping dies for two main reasons.

Decreasing workforce
Increasing inventory of dies

This was leading to a decline in the precision and quality of service being performed on their stamping dies. Their plan was to locate a tool & die shop that could successfully handle the quantity and diversity of their stamping dies for regular preventative maintenance and unexpected service issues. With 50 years of die building experience, five Toolmakers solely dedicated to Die Maintenance and the support of a full-service Tool Room this Security Systems Manufacturer selected Ultra to service their stamping dies.

Reassembling a stamping die in the correct manner is of critical importance to return to high-quality and consistent production. Clearances are also re-checked to ensure there will be no issues once metal stamping resumes at their manufacturing facility.

The length of the die and the number of components determine the repair time. Standard turnarounds have been set with this customer to keep their production running as scheduled. Modifications can be made when production emergencies arise; such as unexpected breakdowns and rush orders. For example, we were able to return a serviced stamping die back to their manufacturing facility within two days.

Case Study: Providing Innovative Tooling Dies

This customer needed a different design intent for the filter cutting component of a die utilized in an existing assembly machine. The current design was causing cutting and maintenance issues; leading to a decrease in the quality and consistency of their final product.

Our design team reengineered this die and the cutting component with a focus on improving the cutting action and the component’s accessibility for maintenance and changeout.

The new design went from being a multiple-piece component to a single-piece component. It was critical during the redesign to ensure the quality and precision of the filter cutting operation wasn’t sacrificed. This involved evaluating each piece’s role in the performance of the component to verify the degree it could or couldn’t be modified as well as its physical location. And with this new design, changeout and maintenance would be easier and quicker with a more compact shape. The customer could now just remove the component via two bolts versus pulling out many different pieces. This also helped make realignment easier and more precise for a quick return to the equipment operating as scheduled.

Case Study: Customizing Parts with Metal Fabrication

This customized, low-volume project successfully merged the technology of our fiber laser cutter with the hands-on work of the cut-off saw.

Ultra manufactured six different components for the customer with specific measurements and established for each. The component pieces consisted of either a base plate or a tube.

The three different base plates were cut with a specific design dependent on their final position on the finished product.
The three tubes were cut at different lengths for correct alignment on the finished product as well.

Ultra has provided the customer with interchangeable components to arrange as different parts for use on the final product. This is less costly when design changes occur and increases flexibility as well.

Welding the base and tube together was critical to ensure the functionality and fit were attained as designed. A customized fixture was designed and built to better stabilize the components during the welding process, resulting in greater precision and higher-quality welds.

An example of two parts made from the various components.

The customer designed the fan blades with four individual bends to better draw in the air during operation and to utilize standardized tooling on the press brake versus more costly customized tooling.
The blades present two key challenges to manufacture as designed.

1. Managing the overbends and underbends that naturally occur in materials during metal forming.
2. The exact placement and size of the four tabs on each blade. These tabs are critical to successfully align with the slots on the disk.

Utilizing the capabilities of the CNC press brake, our Fabrication Technicians consistently apply their material knowledge and manufacturing experience to match the blade's design print.

The most critical feature in laser cutting these disks is the slots. Their placement needs to be exact and within a tight tolerance to ensure correct alignment with the blade’s four tabs.
With Ultra's prototyping standards, we were able to establish the correct programming for the fiber laser prior to final production. We also ensure the blades are being laser cut to their design prints with regular quality checks. This includes a set-up check and in-process checks during laser production.

Ultra implemented two significant changes to this manufacturing process that reduced costs and improved production times.

First, we designed and built the crimping operations so crucial to this metal shell into their progressive stamping dies.

Material thickness was key to controlling the weight of the part and this is a challenge because of the natural variation that occurs in metals. Ultra established two methods to control this variation and meet weight requirements.

Utilize tighter tolerance material to minimize the degree of variation.
Ultra's Die Designers developed a plan that allowed for an adjustment in the stamping die to ensure the correct weight was attained during production. The tab feature on the governor weight, located between the two legs, can have its length changed to meet the required part weight.

The second phase of this manufacturing process focused on establishing a productive and low-cost method to verify the weight of the parts and inspect each leg. A team of Designers, Engineers and Toolmakers designed and built an innovative Governor Sort Machine. This is an automated process that precisely inspects 1,000 parts per hour.

Governor weights are introduced into the inspection system through a large bowl feeder. This process verifies the two legs are positioned correctly by aligning the governor weights as they would be placed in an engine. A governor weight identified as a defect is removed immediately.
The approved parts then move on for weight verification. One by one each part is placed on a scale in an enclosed area; removing defective parts as needed. Acceptable governor weights are then packaged for delivery.

Robotic welding improved the accuracy and quality of the welding process and met the manufacturer's growing production demands. The robotic arm of the welder operates with exact precision versus the inherent variability of a human welder. And the programming establishes welding at a continuous pace and increases production rates.

Each footboard required eight “1- inch” welds so Ultra designed and built a customized welding fixture. This established a stable location for the robotic arm to weld more consistently and at a faster rate.

And with two robotic welders, CNC Panasonic Robotic Welder and the Genesis Robotic Welder, Ultra can produce two footboards at a time – DECREASING downtimes and INCREASING production rates.

A customized functional gauge designed and built at Ultra tests the placement of the welded hinges ensuring the footboard is ready for assembly.

In addition, the Metal Stamping of both footboards was completed at Ultra. Our Value-Added area completed this manufacturing process with visual inspections of the footboards.

Case Study: High-Volume Metal Stamping

Watch this metal stamping deliver cost-savings.

Other Case studies

Forming a Metal Part With the 800-Ton Press

Comprehensive Die Maintenance Services

Providing Innovative Tooling Dies

Customizing Parts with Metal Fabrication

Precision Metal Fabrication Components

Case Study: Establishing Production Consistency and Minimizing Downtimes

Manufacturing Issues

Customer’s Goals

Redesign Process

Ultra's Solution

Customer Outcome

Other Case studies

Improving the Production Process

Reducing Costs with a Progressive Stamping Die

Outdoor Power Equipment Metal Stamping Case Study

Prototyping to Production

Meeting Design Challenges

Case Study: Delivering Quality with Innovation

Manufacturing Issues

Customer’s Goals

Manufacturing Process

Customer Outcome

Other Case studies

Improving the Production Process

Reducing Costs with a Progressive Stamping Die

Outdoor Power Equipment Metal Stamping Case Study

Prototyping to Production

Meeting Design Challenges

Case Study: Producing a Robust and Precision Metal Part

Manufacturing Issues

Customer’s Goals

Testing Process

Prototyping Process

Manufacturing Process

Customer Outcome

Other Case studies

Improving the Production Process

Reducing Costs with a Progressive Stamping Die

Outdoor Power Equipment Metal Stamping Case Study

Prototyping to Production

Meeting Design Challenges

Case Study: Forming a Metal Part with the 800-ton press

Watch the 800-ton press stamp this heavy-duty metal part.

Other Case studies

Achieving Tight Tolerances Metal Stamping

Reducing Costs with a Progressive Stamping Die

Outdoor Power Equipment Metal Stamping Case Study

Meeting Design Challenges

Streamlining Production and Improving Quality

Case Study: Die Maintenance Services

Service

Customer Outcome

Other Case studies

Forming a Metal Part With the 800-Ton Press

Delivering Cost-Savings for a Metal Stamped Part

Achieving Manufacturing Cosmetic Standards

Improving the Production Process

Prototyping to Production

Case Study: Providing Innovative Tooling Dies

Other Case studies

Forming a Metal Part With the 800-Ton Press

Comprehensive Die Maintenance Services

Providing Innovative Tooling Dies

Achieving Manufacturing Cosmetic Standards

Prototyping to Production

Case Study: Customizing Parts with Metal Fabrication

Other Case studies

Forming a Metal Part With the 800-Ton Press

Comprehensive Die Maintenance Services

Providing Innovative Tooling Dies

Robotic Welding a Stamped Metal Part

Prototyping to Production

Case Study: Precision Metal Fabrication Components

Blade Production

Disk Production

Customer Outcome

Other Case studies