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Lamination Production by: John Roberts / SkoDie, Inc

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Page 1: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Lamination Productionby:  John Roberts / Sko‐Die, Inc

Page 2: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Presentation Mission

• Understand the construction for magnetic cores

• Chose the best methods for producing

Page 3: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Magnetic cores are constructed

• From soft magnetic materials

• Consist of stacking thin laminated sheets

• Completed stack must represent a nearly unified structure…

Page 4: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Stator lamination & stator core

Page 5: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Lamination production requires both Accuracy and Precision

Page 6: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Two basic concepts for production exist

• Laminations may be cut ( machined ) from steel sheet materials

• Laminations may be stamped from sheet, or coil materials…

Page 7: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

The following processes exhibit these two concepts

• Laser cutting

• Water jet cutting

• Electrical Discharge Machining ( EDM )

• Other

• Metal stamping methods

•Progressive dies•Steel rule dies•Fine blanking….

Page 8: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

The typical stator lamination

• All of the cutting methods involve tracing the perimeter of the part until all scrap material is removed from the part contour…

• There is approx  54”total perimeter in this stator lam..

8

Page 9: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Laser cutting video

Page 10: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

There are some disadvantages with the laser cutting process

• Production rates are not extremely fast• There is minimal likelihood for improvements in production rate…as throughput is determined by part geometry…particularly total perimeter inches.

• Cost reductions from process improvements are minimal…

• Precision parts are not as good as one would like for core stacking

Page 11: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Large & small Stator cores

Note : the surface condition on the OD contour for each of these cores….

Large core exhibits condition we call a “saw tooth”surface

Page 12: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

There exists some significant advantages to this type of processing

• Usually there is minimal “set‐up”requirements to start production…

• Little, or no capital expense for tools, or fixtures..

• Changes with part features are easily…and economically made… usually with simple program modifications…

Page 13: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Stamping laminations as  production alternative..

The basic concept for stamping production…is 

Pushing a hardened steel punch through material…and into a 

matching die cavity…

Page 14: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

This is a high impact process…

• The punch penetrates the material to a certain depth of thickness…shearing contour to match the geometry of the punch…

• The die cavity has matching contour to the punch…but is a bit larger…

• As the force of impact reaches tensile strength of material…a break will occur in the die block releasing the sheared material…

Page 15: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Die on die block…matching punch in punch holder

Page 16: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Two important stamping references

• Piercing operations…typically produce features in parts

• Blanking operations…typically remove parts from the sheet…

Page 17: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Piercing operations in laminations

• Typically would put ID contours in stators….shaft holes in rotor lams

• Slots in both stator and rotors

• Vent holes in rotors

• Bolt holes for assembly

Page 18: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

High Speed Piercing Operations

• Pictured is a high speed indexing press…

• Blank is inserted on the driver…

• Press indexes a programmed number of times piercing equal number of rotor slots

Page 19: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Typical slot die for high speed notching

• This die produces one slot with each press stroke..

• High speed notching presses can run up to 1500 SPM

• slotting operations may produce 24 to 110 slots per lam

Page 20: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

The Blanking Operation

• The blanking operation removes parts from the sheet…

• The blanks pass through the die block

• Dimensions are formed by the contour of the die…

Page 21: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

A section lam produced from a blanking operation

• At right is a stamped lamination that is produced solely from a blanking operation…

• This part is entirely produced in the die cavity…

• There are no pierced features in this part

Page 22: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Compound Stamping Operations

• Compound stamping dies perform both the blanking & piercing operations with one stroke…

• At the right…is a “donut” produced from a compound die process… ID is pierce, OD is blanked…

Page 23: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Compound die construction 

Page 24: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Compound stamping OPwith automated parts unloading

• Compound stamping with parts unloader…

• video 

Page 25: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

There are some real advantages with stamping production of

lams

• Improved process rates

• Better production throughput• Lower piece part costs• Better accuracy on part features• Higher level of precision…….  

Page 26: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

There is a downside to this production method

• There will be some capital expense involved for tools

• Separation of parts from scrap can be difficult

• Finished parts need to be collected, sorted, oriented…

• Without automation, process can be labor intensive…

Page 27: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Pick and place automation

• Robotic video….

Page 28: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

The Progressive Die

• The progressive die performs multiple operations with each stroke

• Operations are performed within incremental sections…called progressions, or multiples

Page 29: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx
Page 30: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Progressive Die

Page 31: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Progressive Die Stripper Plate• The stripper plate mirrors the punch configuration

• Stripper plate makes first contact with the stock strip

• Stripper plate is last to release before strip progresses

Page 32: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

The strip layout

• The strip layout shows the operations being performed in each progression.

• This strip shows five stations, plus a cut‐off…• Pilot holes assist with positioning of the multiple…

Page 33: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Progressive Die with Strip Layout

Page 34: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Advantages with progressive die stamping ops• High speed processing rates….

• Better throughput capabilities…provides for lower labor costs

• Parts are removed in an organized, orderly fashion…little,  or no sorting is required

• Multiple operational options can be built into the stamping die….

Page 35: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Progressive die in action

• Video clip…progressive die stamping..

Page 36: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Disadvantages to prog die production

• There can be considerable upfront capital expense for tooling

• Tools can be extremely complex, require complicated monitoring, and significant maintenance…

• Lower volume production requirements can be more costly than with simpler processes…

• Changes in part features can be nearly impossible, and/or costly to achieve…

Page 37: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Estimating budgetary costs

• Raw materials

• Presented in sheet form…

• Presented in coil form…

• Ready for production…

Page 38: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Frame the part into squares/rectangles

• Assume 4.5” stator lamination…

• Frame by square sheet…

• Square to be 4.75” x 4.75”

• Calculate volume of material…

• Assume lamination thickness to be 0.025”

• Assume typical electrical grade silicon steel

• Calculate 4.75 x 4.75 x 0.025 x 0.284 =  0.160#

Page 39: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Estimated cost for material

• Each lam will required 0.160# of raw material to make…

• Alternate thinking would be that 1000 laminations would require 160# of material…

• One can expect to pay $ 1.00 to $ 1.20 for ranges of fully processed steel grades M15‐M47

• Lower M grades reflect better mag properties.

Page 40: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Review and dollarize our processes• The laser cutting process must trace the part perimeter each time a lam is produced…

• Assume average cutting speed to be 40 ipm

• Our 18 slot stator lam of 54” is expected to take 1.35 min to cut…

• Without interruptions to process… we should produce approx 44 lams per hour…

• We can usually expect 10 mins interrupted process time… reducing out yield to 36 / hr 

Page 41: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Estimated cost to produce

• Boss says that the laser work center must return capital at the rate of $ 65 / hr…

• This rate will compensate labor…overhead…engineering program/set up…i.e. all costs to produce these parts

• Very simply… $ 65 / 36 =  $ 1.81 / lam

• Addition of material cost $ 0.18 / lam

• Total cost to produce:  $ 1.81 + 0.18= $1.99/ea

Page 42: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Now reviewing our laser cut video

• After we have completed the laser cut blank…we will pierce the slots on our indexing notching press…

• Load/unload/ pierce 36 slots…200 pc / hr yld

• Workcenter cost is $ 110 /hr… stamping cost is $ 0.55 / ea…

• Material cost for 25 “ blank is $ 4.85

• Laser cut cost for 32 / hr is $ 1.85

• Together with stamping… lam price is $ 7.25

Page 43: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Laser cutting this part completely

• Would have added 400” to laser program…i.e. 36 slots plus ID of lam…

• Part yield would decrease to approx 5 /hr…and cost $13 / ea..

• With material… added total lam price would be $ 17.85… instead of the $ 7.25 from last analysis…

Page 44: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Capital cost for tools• Piercing die for this operation costs around     $ 5,000 to be “production ready”

• 475 lams completely laser cut would be around $ 8,475

• 475 lams @ $ 7.25 /ea + $ 5,000 for tools gives total costs of $ 8,450…

• Merely from the economies of this situation…can you determine which course for action may be decided….?

Page 45: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Taking it up a level…

• Review our laser cut and pierced stator lam @ $ 7.25 / ea

• The first op of laser cutting blank contributed approx $ 1.85 of cost to this production…

• Consider construction of compound blanking die to produce this lam….

Page 46: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

This die to cost some $ 30,000 !!!

• This tool would provide throughput at a rate around 800 pcs per hour…

• Workcenter costs to run this production would be at $ 200 / hr…

• Cost to produce this blank is $200 /  800 pcs 

• Compare this cost… $ 0.25 / ea with that of laser cutting… $ 1.85 / ea…

Page 47: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Payback period….

• Cost reduction of $ 1.60 /lam..

• Break even quantity is 30,000 / 1.60 

• Tooling amortized at apporx 19,000 pcs…

Page 48: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

The ultimate…progressive die• Production rates for progressive tools can range from 3,000 pc / hr… up to 30,000 pcs / hr

• Workcenters capable of stamping with progressive tooling typically generate $200 / hr upwards to $ 500 / hr…

• Costs to produce lams under this format can be as low as pennies per each…

• Complex progressive dies can cost hundreds of thousands of dollars to construct

Page 49: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Brief summary……

• Material costs are driven by size and shape of laminations…generally processing is not a factor affecting material requirements…

• Processing costs are dependent on process throughput…

• Consideration for demand should be analyzed to determine compatible process…

Page 50: Sko-Die Lamination Production - eDrive Online · PDF file• Workcenters capable of stamping with progressive tooling typically generate $200 / hr ... Sko-Die Lamination Production.pptx

Tooling costs….

• In general…tooling costs will be driven by size of tools…

• Costs will be driven by complexity of tools….

• Costs will be driven by capability demands at the workcenter….( i.e.    The press machinery )

• Avoiding “over engineering” will control capital costs for tooling...