Removing the Guesswork from New Part Development
Forming Simulation Software Gives Aerospace Parts Manufacturer a Competitive Edge
A U . S . -based forming operation built their business around fulfilling challenging aerospace contracts . Their production success involved both long-term , repeating part orders as well as lowvolume / high-mix forming work . Typically , the high-volume projects were completed on hydraulic presses with traditional male / female tooling , while the low-volume work was performed on the company ’ s Triform sheet hydroforming press .
When considering a new contract , the organization began searching for a digital forming simulation tool to help them better understand the potential ramifications of accepting new work . They ultimately chose Pam-Stamp 2G forming simulation software by ESI .
This complete , integrated solution allows users to simulate the forming process before projects are quoted or tooling is developed . These simulations offer an
‘ experience in a box ,’ maximizing the capabilities inherent in their press while lowering costs .
By simply inputting standard CAD data , properties of the material being formed , and the forming strategy ( drawing , hot forming , stretch forming , sheet hydroforming , etc .) the software generates a simulation of the part being formed . Based on the results of the simulation , engineers may modify the part design to optimize formability .
Pam-Stamp gave this company two new weapons to combat the competition : predictability through simulation and speed through stable production . From quotation and die design through formability and try-out validation , this company was able to eliminate the guesswork from new part development , minimize start-up costs , and begin production faster than ever before .
Sikorsky Parts Supplier Uses Rubber Pad Press to Improve Production Time by 20 %
Since 1947 , Milford Fabricating has produced custom parts and assemblies for global aerospace manufacturers including Sikorsky and GKN . The 62,000 sq . ft . facility located in Milford , Connecticut specializes in laser processing , punching , forming , machining , welding , heat treating , and assembly of aerospace components .
When the time came to replace their aging press , Milford looked to Beckwood Press Company for a cost-effective yet versatile forming solution for their low-volume , high-mix family of parts . Beckwood ’ s aerospace forming experts reviewed Milford ’ s part family and future growth plans and proposed a custom high-performance rubber pad press . Size , pressure , daylight , pad box depth , ram speed , and pad durometer were all factored into the final design .
With 400 tons of force and 15 ” -deep urethane pads , Beckwood ’ s rubber pad press is able to provide ample forming pressure on parts up to 5 ” tall without excessive stress to the pads . The fully encapsulated rubber pad box generates maximum pressure transfer , improving the overall part quality and reducing scrap rates . Additionally , the mechanical pad extraction system makes pad changes faster , safer and more reliable .
“ We run anywhere from 30 to 40 different part numbers on the press in a given day ,” said Joe Connolly , Operations Manager at Milford . “ We estimate we are saving 20 % or better in production time for each part .”
The press ’ 38 ” x 60 ” rubber pad acts as a universal female die , conforming to any shape placed within the forming area . With such a large bed , Milford can form multiple parts in a single cycle , ultimately reducing the overall cost per part .
“ Beckwood ’ s design assistance was the tipping point for our purchase decision ,” said Connolly . “ If I was ever in the market for another machine I wouldn ’ t even consider anyone else . I ’ d go straight to Beckwood .”