The ability to react quickly to new part orders or new product development efforts is an integral component of modern manufacturing. Beckwood offers a suite of distinct, yet related, technologies which serve low volume / high mix forming operations, research & development groups and LEAN manufacturers alike.
Beckwood’s arsenal of rapid part development tools includes:
Imagine the following Scenario:
It’s 2:30 in the afternoon and a new part order arrives in your company’s inbox with a delivery timeline of “ASAP.”
You upload the supplied part drawing and material specifications into the Pam-Stamp 2G forming simulation software. Over the next 2 hours, the tooling design, blank design and forming process variables are simulated, refined and simulated again. The tendency for the material to tear is addressed by modifying and simulating a gentler tool radius, and the ideal pressure for preventing a problem wrinkle is found – without wasting a single blank.
It’s 4:30 p.m. and you’re ready to make your tool, and cut your engineered blanks.
The tool design generated within Pam-Stamp is sent to your in-house 3d printer. The printer immediately goes to work, adding layer-after-layer of high-performance material, designed to withstand the high forming pressures associated with sheet hydroforming. The print job continues into the night and by the time you walk back into your facility the next morning, the finished tool is ready.
After removing the tool from the printer and gathering your new blanks, you walk to your Triform sheet hydroforming press. You load the tool and blank before programming the ideal forming pressure, which you learned during simulation. You cycle the press with the confidence of someone who has formed this part before. The tool and blank designs which were optimized during the simulation process perform as planned.
You remove the net shape part from the press after a single cycle. It’s 8:30 a.m. and you’re ready to send the finished part to shipping, and out to your customer.
Forming Simulation Software
Beckwood is an official supplier of the Pam-Stamp 2G forming simulation software, by ESI. Pam-Stamp allows users to verify their forming process prior to tools being manufactured, blanks being cut or the press even being cycled. These simulations offer ‘experience in a box,’ giving users the ability to more quickly discover the ideal tool design, blank design and other process variables. The result is significantly reduced part development costs, and an expedited part development process.
Rubber Pad Forming
Hydraulic press rubber pad forming is the process of forming shallow parts with a rubber or urethane pad (or pads) which are confined within a pressure chamber attached to the press ram. Rather than attaching the tooling to the ram, as in traditional hydraulic press forming, pad forming tools are placed, unsecured, onto the flat surface of the lower platen. This allows the downward pressure of the pad to form the material around the tool. Multiple parts can be run in a single cycle, as long as the tools & blanks fit into the working area of the press. Beckwood’s rubber pad presses are uniquely designed for short run parts with low up front tooling costs.
The rapid part development characteristics of the rubber pad forming process are amplified in Beckwood’s line of Triform sheet hydroforming presses. Like rubber pad forming, sheet hydroforming is associated with inexpensive tooling and fast changeover times. But unlike the rubber pad forming process, which typically offers ~1,000 PSI of forming pressure on the part, Triform presses provide 5,000 – 10,000 PSI of evenly-distributed forming pressure. The result is net shape part production, which often eliminates the need for manual handwork, allowing parts to be formed more quickly and inexpensively when compared to other processes.
3D Printing (Additive Manufactured Tooling)
3d printing is no longer a technology of the future. Manufacturers across the world are applying additive manufacturing for a variety of processes. One application that is closely related to Beckwood’s core product offerings is the 3d printing of press tooling. Use of additive-manufactured tooling can help expedite new part development and greatly reduce expenses. The combination of Beckwood Presses and 3D printed tooling is game changing for those manufacturers looking for a competitive edge.