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The Mind-Blowing Machines that Stamp Millions of Metal Parts - Smarter Every Day 288

SmarterEveryDay・50 minutes read

Destin from Smarter Every Day explores the complex process of sheet metal stamping in American manufacturing plants, focusing on T&C Stamping in Athens, Alabama. The series highlights the precision and intricacy involved in manufacturing, emphasizing the skilled trades like tool and die making as valuable career choices, while showcasing the production of various metal parts through stamping processes.

Insights

  • The manufacturing process of a lawn mower engine in America involves intricate sheet metal stamping at T&C Stamping, showcasing the complexity and precision required in transforming raw steel coils into finished parts through progressive stamping dies.
  • The skilled trades, like tool and die making and CNC machining, are highlighted as valuable career choices, with individuals like Brandon and Cody exemplifying the practical experience and self-taught dedication needed in these fields, emphasizing the importance of investing in learning and skill development for successful manufacturing operations.

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Recent questions

  • What is the focus of the Smarter Every Day series on manufacturing?

    The Smarter Every Day series delves into the manufacturing processes of a lawn mower engine made in America, specifically focusing on sheet metal stamping and the intricate geometries involved in the production.

  • How are metal stamping dies created in the manufacturing process?

    Metal stamping dies are meticulously designed and machined from raw steel at T&C Stamping in Athens, Alabama, showcasing the complexity and precision of manufacturing. The facility houses a tool shop with machinists and operators who create stamping dies for transforming raw steel coils into finished parts through a press and die process.

  • What is the significance of progressive stamping in manufacturing?

    Progressive stamping in manufacturing involves maintaining material attachment in stamping dies, forming parts until completion through piercing, forming, and cutting operations. This process allows for the creation of intricate metal parts with precision and efficiency.

  • How do CNC machines contribute to manufacturing intricate parts?

    CNC machines, controlled by computers, are essential in manufacturing intricate parts as they require an understanding of speeds and feeds to create desired shapes. Cody, a CNC programmer, self-taught himself using Master Cam and invested in learning at home to operate these machines effectively.

  • What is the primary goal of T&C Stamping in manufacturing?

    The primary goal of T&C Stamping in Athens, Alabama, is to provide value to customers by automating manual operations and keeping jobs in the United States. Specializing in making tooling for stamping parts, the company focuses on producing high-quality products while maintaining a commitment to American manufacturing.

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Summary

00:00

"American-made Lawn Mower Engine Manufacturing"

  • Destin from Smarter Every Day explores the manufacturing process of a lawn mower engine made in America.
  • The engine components are manufactured in various locations, with sheet metal parts made at a specific facility.
  • The focus is on sheet metal stamping, a complex process involving intricate geometries and small-scale production.
  • The series delves into manufacturing processes, starting with progressive metal stamping.
  • T&C Stamping in Athens, Alabama, specializes in sheet metal manufacturing and tooling.
  • The facility houses a tool shop with machinists and operators creating stamping dies.
  • Metal stamping involves transforming raw steel coils into finished parts through a press and die process.
  • Progressive stamping dies maintain material attachment, forming parts until completion.
  • The process includes piercing, forming, and cutting operations to create intricate metal parts.
  • Stamping dies are meticulously designed and machined from raw steel, showcasing the complexity and precision of manufacturing.

11:43

Tool and Die Making Process Overview

  • The process involves creating pilot holes and openings in a part that falls out easily.
  • Progressing to a 45-degree angle, the part is then bent to 90 degrees at a later station.
  • Different engineers may opt for a 45-degree angle before adjusting it to 90 degrees.
  • Side actions involve a pad that pushes the part, converting vertical motion to lateral.
  • The tool has 54,000 parts and requires reworking to maintain sharpness.
  • Overseas tooling is often monolithic, unlike the modular design for maintenance ease.
  • The die, built in the '70s, has inserts for sharpening and longevity.
  • The die withstands 500,000 to 600,000 hits annually, showcasing its durability.
  • AnyDesk is highlighted as remote desktop software for seamless editing and accessibility.
  • The skilled trades, like tool and die making, are emphasized as a valuable career choice.

23:08

"Mastering Machining: Journey to Skilled Trade"

  • Brandon learned machining through practical experience and is close to becoming a journeyman in skilled trade.
  • Machining involves subtractive manufacturing, where material is cut away to create a desired shape using cutters on a mill.
  • Bridgeport mills are iconic in machining, known by machinists since World War II.
  • CNC machines are controlled by computers and require understanding of speeds and feeds for creating intricate parts.
  • Cody, a CNC programmer, self-taught himself using Master Cam and invested in learning at home.
  • Wire EDM machines use electrically charged brass wire to make precise cuts in metal parts.
  • Boyce, with 45 years of experience, specializes in EDM work and programs the wire EDM machine for intricate parts.
  • T&C stamping produces millions of blender blades annually using stamping equipment in Athens, Alabama.
  • Tabitha oversees the production of blender blades, from stamping to washing, drying, and packaging.
  • The plant uses a variety of stamping presses, including a 160-ton press, with coiled steel being straightened and fed into the press for production.

34:33

Metal Recycling Factory: Stamping Safety and Efficiency

  • Scrap metal is melted down and recycled in a progressive stamping job.
  • Yellow bars on the sides of presses act as a safety measure called a light curtain.
  • A 200-ton press in the factory produces automotive parts, including aluminum brackets.
  • The 200-ton press can make about 24,000 parts a day and is loud due to its age.
  • Tim, a worker, has been at the factory for 10 years and enjoys his job.
  • Different parts are made using various presses, including a heat shield for V-twin engines.
  • A 275-ton press forms parts for V-twin engines, including back plates.
  • Manual assembly is done, including inserting nuts into parts for assembly.
  • Servo presses use electric motors for stamping operations, offering more control over stroke speed.
  • Safety precautions are taken, such as cages around tools to prevent loose parts from shooting out during stamping.

49:12

Efficient servo presses automate stamping operations.

  • Servo presses can slow down the press stroke to draw material without tearing it.
  • A servo press can control the strain rate by adjusting the speed of the stroke.
  • Pendulum motion in a servo press allows for more efficient energy use compared to a mechanical press.
  • The proximity sensor in the press ensures proper material feeding by measuring distances.
  • The company in Athens manufactures an electric motor mount with three parts: U shape mount, square part, and bearing.
  • The company's mission is to provide value to customers by automating manual operations and keeping jobs in the United States.
  • T&C Stamping specializes in making tooling for stamping parts, with the majority of tooling being built in-house.
  • Customers own the tooling used for stamping parts, and T&C Stamping runs the parts based on customer orders.
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