The objective of this course is to understand the inputs into a stamping operation and how to interpret
the results. The effects of parameters such as geometry, material properties, press curves, and binder/blankholder capabilities are thoroughly discussed. It teaches the fundamentals of analyzing a
part by understanding its markings and how to evaluate its severity.

In this workshop you will learn how to perform and interpret circle grid and thinning strain analysis. Through exercises with actual parts you will be performing hands-on circle grid and thinning measurements. You will review the limitations and guidelines for the use of circle grid and thinning measurements. Also included is the measurement and application of surface stretch analysis for outer panels.

Learn the fundamental design guidelines for Welding and Assembly. Emphasis will be placed on understanding the various types of assembly operations and how to ensure the design specified is feasible. Many guidelines for quality manufacture of assemblies are presented.

Learn the inputs, concepts and requirements for die design. This course provides an overview of the process of die design and the parameters that effect how the die design is established. Die design
set-up and standards for draw, trim, and flange dies are also covered.

This course provides a detailed review of the types, application, and manufacturing issues of die sensors. Many examples of die sensors will be used to illustrate how the selection, die variables, and positioning can effect the overall die performance. Cost effectiveness for low and high volume production will also be discussed. Exercises will require students to determine the type and position of a sensor for a specific function in a die.

Learn the thought process and objectives of die tryout for draw, trim/pierce, flange and cam dies. You will learn how to troubleshoot panels from each die type and the potential die countermeasures. Group exercises enable students to evaluate actual panels for quality issues and to brainstorm for die countermeasures.

Learn the thought process of how to create a draw development. This course provides the basic rules
and concepts needed to understand how to design a draw development for quality stampings. Applications for outer and inner panels, and reinforcements are used to illustrate the effects of tip
angle, drawbars, overdraw, etc. Students will work in-groups to determine and evaluate draw developments.

Learn the fundamental principals of how to manufacture parts using laser and mash tailor welded blanks. Emphasis will placed on understanding the issues involved from product design to part manufacture. Examples will illustrate how to ensure quality and consistent tailor welded blank production.

Learn the parameters that influence how a part is processed for manufacture and the effect on blank
size. You will learn how the product design will determine the press required, part orientation in the die, number of dies required, and the blank size. Examples will be presented on how to process outer and inner panels and reinforcements. Students will work in groups to process and determine the blank size for a reinforcement from a part print.

Learn to provide the basic rules and concepts to understand the design of a progressive die strip layout. It will cover the thought process for determining the strip layout from the CAD model.  Included will be: carrier connection & selection process; how to determine the number of drawing operations; division of gutting, trimming, piercing , and flanging operations; number of idle stations, as well as other types of die operations required to finish the stamping.  Production issues related to the size and length of the strip will also be discussed.  Students will work in groups to evaluate various types of strip layouts.

Learn the differences in formability and manufacture of aluminum stampings in comparison to
steel stampings. This course provides many examples of manufacturing and tooling conditions which must be considered to ensure quality production of Aluminum Stampings. Case studies
of producing an Aluminum Outer and Inner Panels will be presented to illustrate how the processing, material requirements and tooling line-up is affected.

Learn to provide various approaches to driving down material costs of a stamping through design optimization. It will include the methodology for identifying critical design points that determine the material requirements and utilization. Suggestions for Transfer and Progressive die operations will be included. Exercises will challenge participants to generate and evaluate cost savings ideas for their
own parts.

Learn the fundamentals for estimating the cost of stampings and tooling. Included will be an introduction to Activity-Based Costing (ABC) techniques as well as methods and formulas for determining piece
price and tooling costs. Students will be performing exercises to determine the piece price and tooling price for stampings. VisiQuote Enterprise, a quoting tool for the Metal Forming industry, will be demonstrated in a number of the exercises.

Learn the fundamentals for understanding the components and function of the press and die.
You will learn the how a press and die work and how to interpret the stamping produced. This course
will provide skills to evaluate panels for stamping defects and suggest potential countermeasures.

This objective of this course is to provide an understanding of the process and procedure for evaluating surface contour and reflectivity on Class “A” panels.  Also included will be trouble shooting methods for counter measuring panel defects.

Learn the process for welding and repair of draw, trim/pierce, flange and cam dies. You will learn how to repair defects on panels using various welding and grinding methods. Emphasis is placed on proper techniques for tool steel welding and in-and-out of press repair methods. Students will learn and practice the proper techniques for welding and repair using Mig, Tig and Stick applications.

Learn the the development, generation, and use of transfer/interference curves for both tri-axis
and crossbar systems. Also included is the influence that transfer curves have upon both the process planning and die design phases. Students will be challenged with exercises to verify
the transfer of a part in a die operation.

Learn how to evaluate parts for welding defects associated with resistance, MIG, and projection welding operations. Students will learn the troubleshooting skills necessary to address weld quality issues and suggest potential counter measures in the automotive manufacturing environment.

Learn the processes and equipment used in resistance (spot) welding. You will review: basic
resistance welding, how welds are made, components and mechanics of a welding system, pneumatic and hydraulic systems, testing methods and weld schedules for various materials
and coatings.