Achieving Tight Tolerances in a Progressive Die Case Study

Customer
Motor Vehicle Parts Manufacturer
Part
Thrust Ring

Manufacturing Issues

  1. Unable to consistently maintain the inside diameter during production.
  2. Not meeting tight tolerances and inaccurate positioning of the tabs is leading to thread misalignment.
  3. Inefficient assembly operations.

Customer's Goals

Locate a high-quality, reliable supplier to accurately metal stamp this part to match its design. This is necessary for the thrust ring to precisely fit in its required position during assembly and for perfect thread alignment in the final mechanism.

It would be ideal for this same supplier to handle final assembly for less interruption and reduced costs.

Design and Manufacturing Process

Collaborative sessions with the customer helped Ultra fully understand the functionality and features of the thrust ring and established a productive setting for die designing and building. The part's tabs required a tight tolerance of no more than .062” to achieve correct alignment with threads during the multi-assembly process. A total of seven individual parts needed to function individually and interact together for the final mechanism to work perfectly.

Ultra designed and built a progressive die based on coining operations because this method is better suited for attaining features with very close tolerances as well as maintaining an exact inside diameter. Both these factors were of critical importance in the functionality of the thrust ring. Ultra designed and built a station in the die after forming was complete to keep the ring open to its specified inside diameter for the remainder of the production process.

This metal stamping process allowed for greater precision and accuracy in the formation and placement of the tabs on the thrust ring. It also allowed for adjustment to the tabs as needed for consistency on each thrust ring. The tolerance of no more than .062 on each tab was critical to eliminate backlash during assembly with the threaded part.

We also provided the customer with the opportunity to assemble the final mechanism at Ultra for continued consistency and quality. A step-by-step manual assembly process took place in our Value-Added department. Our Tooling department designed and built customized inspection equipment to ensure the final mechanism operated correctly.

Customer Outcome

The customer was able to keep a majority of the manufacturing process at Ultra’s facility for quicker lead times, greater consistency and higher-quality results.

Their custom progressive die continuously produces thrust rings that meet the design print at a reduced cost.

Final Assembly and Inspection Process:

We also provided the customer with the opportunity to assemble the final mechanism at Ultra for continued consistency
and quality. A step-by-step manual assembly process took place in our value-added department. Our tooling
department designed and built customized inspection equipment to ensure the final mechanism operated correctly.

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