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June 1, 2012 | Hixon, Doug
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Robotics Cut New Path in Hot MetaI Stamping
RoboLIc Iuser cuLLIng provIdes buIunce oI perIormunce und cupILuI IIexIbIIILy, IeIpIng compuny
enLer und expund In KRW sLumpIng
TIe Ionger Lerm cIuIIenges IucIng LIe uuLomobIIe IndusLry ure us compIex us LIey ure
InLerreIuLed: DesIgn curs LIuL peopIe wunL. ncreuse cusLomer suLIsIucLIon. Reduce cupILuI cosLs.
mprove pussenger suIeLy. ncreuse IueI eIIIcIency.
And, oI course, do uII oI LIIs wIIIe susLuInIng u busIness modeI wILI u reusonubIe proIIL murgIn.
An ongoIng Lrend emergIng In LIe meLuI composILIon used In LIe suIeLy cuge oI newer YHKLFOH
desIgns Is provIdIng mujor, yeL somewIuL IIdden momenLum Ior LIIs reInvenLIon oI LIe
uuLomobIIe. TIuL Is, LIe IncreusIng use oI IIgILweIgIL, IIgIer sLrengLI sLeeIs LIuL reduce LIe
overuII cosL und weIgIL oI LIe YHKLFOH wIIIe ucIIevIng LIe prevIousIy unuLLuInubIe dIcIoLomy oI
ImprovIng boLI pussenger suIeLy und IueI economy.
One oI LIe new IundumenLuIs InvoIvIng LIe IIgILer, sLronger sLrucLuruI meLuI Is LIe process oI
KRW meLuI sLumpIng- LIe IormIng oI meLuI, LypIcuIIy boron-uIIoyed sLeeIs, wIIIe IL Is very KRW,
und LIen cooIIng IL quIckIy In LIe dIe. +RW meLuI sLumpIng converLs Iow-LensIIe sLrengLI meLuI
InLo exLremeIy IIgI sLrengLI sLeeI, oILen up Lo zoo kIIopounds per squure IncI (KS).
TIe resuIL Is LIe IormuLIon oI u reIuLIveIy compIex, neurneL sIupe meLuI SDUW In u sIngIe-sLep dIe,
wILI yIeId sLrengLIs up Lo Iour LImes IIgIer LIun LIe meLuI prIor Lo LIe IormIng process. +RW
VWDPSHG purLs weIgI o-qo% Iess LIun sLundurd meLuI purLs oI LIe sume sLrengLI, LIus
cruckIng LIe code Ior greuLer gus mIIeuge und Increused pussenger suIeLy.
One mujor probIem soIved, one Iur Iesser probIem creuLed. Once LIe purLs ure press Iurdened
durIng LIe KRW sLumpIng process LIey ure Loo Iurd Lo be LrImmed usIng LrudILIonuI sLeeI
LrImmIng dIes. TIe process oI LrImmIng LIe edges und cuLLIng oI IeuLures (IoIes) In KRW
VWDPSHG purLs musL be done wILI u Iuser. TIIs muy requIre LIe purcIuse oI uddILIonuI cupILuI
equIpmenL beyond LIe KRW sLumpIng presses Ior compunIes embrucIng LIe LecInoIogy.
DespILe LIe dedIcuLed equIpmenL requIred, Iuser cuLLIng Is u nonconLucL process, so LIe Iuser
equIpmenL does noL weur und no LrIm presses or LrIm dIes ure requIred. TIe Iuser cuLLIng process
Is IIgIIy precIse, und LrIm IInes und IeuLure sIzes und IocuLIons cun be eusIIy udjusLed Lo IundIe u
wIde vurIeLy oI purLs.
CompunIes LIuL enLer LIe KRW sLumpIng busIness Iuve Lwo busIc cIoIces wIen IL comes Lo Iuser
equIpmenL: IIve-uxIs Iuser cuLLIng mucIInery or sIx-uxIs roboLIc Iuser LecInoIogy. WIIIe LIe
perIormunce oI eucI opLIon Is compurubIe, LIere ure some deIInILe dIIIerences.
TIe IIve-uxIs mucIIne does noL Iuve u IIxed buse, IoverIng over LIe SDUW IL Is cuLLIng In u IIneur
moLIon, wILI LIe SDUW beIng munIpuIuLed by LIe uxes oI LIe mucIIne. TIe roboL works on u SDUW
Irom u IIxed buse usIng ILs uxes Lo uccess LIe SDUW, wIIcI Is usuuIIy uIIIxed Lo un IndexIng
posILIoner, oILen wILI SDUW roLuLIon IuncLIonuIILy. TIe IIve-uxIs mucIIne generuIIy Ius up Lo u
% IIgIer LIrougIpuL, buL LIe roboLIc equIpmenL cun be up Lo z-o% Iess expensIve, und
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occupIes 1-z% Iess IIoor spuce. TIe roboLIc equIpmenL Is uIso eusIer Lo muInLuIn, wILI Iess
movIng purLs und roboLIc LecInIcIuns In greuLer suppIy.
TIe IIve-uxIs mucIIne Is LypIcuIIy regurded us more uccuruLe, buL LIe roboL muLcIes IL In puLI
repeuLubIIILy. n LIe IInuI unuIysIs, LIe reIuLIve perIormunces ure very cIose und LIe uesLIeLIc und
IuncLIonuI quuIILy oI LIe IInIsIed purLs ure neurIy IdenLIcuI.
GNS $XWRPRWLYH, u Koreun compuny LIuL Ius expunded InLo LIe US murkeL, recenLIy Iuced u
decIsIon on Iuser cuLLIng equIpmenL. GNS ucquIred LIe busIness und IucIIILy oI u LrudILIonuI
sLumpIng busIness In HoIIund, MI, wILI LIe gouI oI expundIng InLo LIe KRW sLumpIng busIness us
u TIer z suppIIer doIng overIIow work Ior domesLIc TIer 1 suppIIers.
"We suw u greuL growLI opporLunILy In KRW sLumpIng und knew LIuL Iuser cuLLIng wus LIe onIy
proven LecInoIogy Ior cuLLIng LIe KRW VWDPSHG boron muLerIuI," suId EIIe MordovunukI, LIe
dIrecLor oI engIneerIng Ior GNS In LIe US. "NoLIIng eIse Is economIcuIIy vIubIe."
MordovunukI Iud Lo revIew LIe merILs oI boLI LecInoIogIes bused on numerous IucLors, none
more ImporLunL LIun LIe Ionger Lerm busIness pIun Ior GNS In LIe US, und LIe cupILuI uvuIIubIe
Lo expund InLo KRW sLumpIng. A IIve-uxIs mucIIne cun be In LIe $qoo,ooo Lo $1.z mIIIIon runge,
wILI LIe roboLIc opLIon consIderubIy Iess. WILI LIe greuLer LIrougIpuL oI LIe IIve-uxIs mucIIne,
Iowever, LIe IuLure voIume expecLuLIons oI LIe busIness musL uIso be exumIned.
MordovunukI expIuIns, "ookIng uL LIe voIume projecLIons Ior LIe HoIIund operuLIon we were
conIIdenL LIuL LIe roboLIc equIpmenL wouId suIL our needs. WILI LIe moduIur, quIck seLup und
spuce eIIIcIenL nuLure oI roboLs, we were uIso comIorLubIe LIuL we couId eusIIy udd more roboLIc
Iuser ceIIs us our busIness expunded. We cIoose noL Lo overbuy In LIe InILIuI sLep und Look good
udvunLuge oI LIe cupILuI IIexIbIIILy LIuL our decIsIon provIded."
TIe unuIysIs proved Lo be weII Iounded: u IIrsL Iuser cuLLIng roboLIc ceII wus InsLuIIed In LIe
HoIIund IucIIILy In LIe summer oI zooq, wILI u second InsLuIIed jusL over u yeur IuLer In LIe IuII oI
zo1o.
"n uddILIon Lo perIormunce, LIe vuIue proposILIon LIuL roboLs udd Lo LIe equuLIon ure IusLer
deIIvery LImes, Iower InILIuI cupILuI InvesLmenL und Iower overuII IIIeLIme cosLs," suId Joe Bowen,
LIe gIobuI uccounL munger oI ABB RoboLIcs wIo Ius munuged LIe GNS projecLs.
TIe IIrsL ceII Is un ABB userCuL(TM) ooC IeuLurIng un ABB RB zqoo roboL wILI u rIgId urm
mosL suILubIe Ior Iuser cuLLIng. L Is InLegruLed wILI un PG PIoLonIcs KW Iuser und u user
MecI zero degree IberCuL Ieud. L IncIudes un IndexIng dIuI LubIe on wIIcI un operuLor pIuces
u SDUW Ior presenLuLIon Lo LIe roboL.
TIe second ceII Is un ABB userCuL 6ooR wILI LIe sume equIpmenL us LIe IIrsL, excepL LIe DIuI
LubIe IncIudes u 6o roLury wIIcI uIIows Ior u greuLer ubIIILy Lo puL LIe SDUW In LIe opLImuI
ungIe Lo LIe Iuser Ieud. TIIs provIdes uccess Lo dIIIIcuIL-Lo-reucI ureus und uIIows LIe ceII Lo cuL
boLI Iurger purLs und u greuLer vurIeLy oI sIuped purLs.
BoLI ceIIs ure progrummed by ABB's proprIeLury Iuser cuLLIng soILwure Ior sIupe generuLIon und
Iuser conLroI, und TrueMovez(TM) und QuIckMovez(TM), LIe sLundurd ABB roboL moLIon
soILwure. A BuIIseye LooI cenLer poInL (TCP) uuLomuLed cuIIbruLIon LooI cuIIbruLes u Z-
dIrecLIonuI ungIe Lo ensure LIe Iuser Ieud Is normuI Lo LIe surIuce, ucIIevIng repeuLubIIILy oI <
o.1mm und reducIng downLIme Lo uImosL noLIIng. user beums cunnoL be vIewed by LIe nuked
eye so LIe equIpmenL Is Ioused In u CIuss 1 IIgIL-LIgIL encIosure.
ndusLrIuI sysLems LIuL InvoIve LIe InLrIcucy sucI us LIuL requIred oI Iuser cuLLIng Iuve Ior muny
yeurs uLIIIzed some sorL oI CADJCAM mucIIne progrummIng. Up unLII recenLIy roboLs Iuve
prImurIIy been LuugIL LIe movemenLs requIred oI LIeIr operuLIon LIrougI munuuI meLIods, noL
u vIubIe opLIon Ior u Iuser uppIIcuLIon LIuL requIres so muny precIse poInLs und sucI compIex
moLIon. RecenL sImuIuLIon soILwure InnovuLIons IIke ABB's RoboLSLudIo Iuve LIe CADJCAM
compuLIbIe pIuLIorm LIuL Ius brougIL LIe IIexIbIIILy oI roboLs Lo some oI LIe mosL precIsIon-
orIenLed munuIucLurIng uppIIcuLIons IIke Iuser cuLLIng.
"We Iooked uL oLIer munuIucLurers buL cIose ABB becuuse LIe desIgn oI LIe roboL wus besL
suILed Ior Iuser cuLLIng, und LIe uccompunyIng soILwure wus weII beyond unyLIIng on LIe
murkeL," suId MordovunukI.
As Is LypIcuI wILI uny munuIucLurIng process, GNS cusLomers Iud Lo upprove LIe roboLIc Iuser
cuLLIng oI LIe purLs beIore LIe suppIIer ugreemenLs were IInuIIzed, und LIe quuIILy oI LIe purLs
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Iud Lo be cerLIIIed LIrougI u rIgorous LesLIng process. TIe uesLIeLIc uppeurunce und IuncLIonuI
quuIILy oI LIe purLs were cerLIIIed wILIouL Issue.
Boron sLeeI sIeeLs, upproxImuLeIy 1.q-mm LIIck ure wIuL GNS LypIcuIIy KRW sLumps und
roboLIcuIIy Iuser cuLs Ior ILs DXWRPRWLYH cusLomers. TIe purLs ure A-pIIIurs, rooI ruIIs, sun rooI
supporLs und oLIer purLs used In LIe suIeLy cuge oI un emergIng group oI veIIcIes desIgned Lo
ucIIeve LIe muxImum buIunce oI pussenger suIeLy und IueI economy.
Once LIe purLs Iuve been KRW VWDPSHG, LIe Iuser roboLs precIseIy LrIm LIe edges und cuL
cIrcuIur und oLIer sIuped IeuLures InLo LIe purLs.
TIe KRW sLump dIes ure desIgned Lo deveIop us mucI oI LIe LrIm us possIbIe In LIe sLump, buL LIe
ureu oI VWDPSHG purLs u moderuLe dIsLunce Irom LIe edge ure sIIgILIy sLronger. TIIs requIres
more edge Lo be LrImmed Irom some perIpIeruI ureus oI purLs LIuL requIre IIgIer LoIerunces. On
LIese purLs more oI LIe edge Is LrImmed Lo exLend LIe sLronger ureu cIoser Lo LIe edge. Becuuse
LIe LrIm ureus vury wIdeIy Irom SDUW Lo SDUW, LIe udvunced progrummIng und precIse puLI
repeuLubIIILy oI LIe roboLIc Iuser ure especIuIIy vuIuubIe.
TIe progrummIng eIIIcIency und precIsIon ure uIso crILIcuI Ior cuLLIng LIe sIuped IeuLures Irom
LIe VWDPSHG purLs. TIe sIuped IeuLures ure used Ior u vurIeLy oI purposes sucI us cIIppIng
eIecLrIcuI Iurnesses or guugIng u SDUW durIng LIe ussembIy process. TIe sIupes cun be cIrcuIur,
recLunguIur und T-sIuped, und vury In dImensIon Irom q Lo 1z mm. A roboLIc Iuser cun cuL u 6-
mm cIrcIe wILI u IIgI quuIILy oI roundness. Some VWDPSHG purLs Iuve Lwo Lo Iour sIuped
IeuLures wIIIe oLIers Iuve up Lo zo Lo z.
"We worked very cIoseIy wILI LIe Leum uL GNS Lo undersLund LIeIr needs und Lo conIIgure u ceII
Lo meeL LIeIr exucL requIremenLs," suId ErwIn DIMuIunLu, senIor munuger, RoboLs &
AppIIcuLIons, ABB RoboLIcs. "MucI oI LIe success on eucI ceII we deIIvered Is uLLrIbuLubIe Lo
GNS' wIIIIngness Lo udopL und Ieurn LIe LecInoIogy, und LIe coIIuboruLIve reIuLIonsIIp
LIrougIouL LIe enLIre desIgn und consLrucLIon process."
Some very good busIness decIsIons coupIed wILI LIe resurgence oI LIe domesLIc uuLomobIIe
IndusLry und LIe conLInued growLI oI KRW meLuI sLumpIng Ius served GNS very weII. TIey
opened u new KRW sLumpIng IucIIILy In CunLon, MI, In AprII zo1z, compIeLe wILI Lwo uddILIonuI
roboLIc Iuser cuLLIng ceIIs. n uddILIon Lo servIng us u TIer z DXWRPRWLYH suppIIer, GNS Ius
begun Lo serve domesLIc uuLo OEMs dIrecLIy und cun now be cIussIIIed us u Lrue TIer 1 suppIIer.
" esLImuLe LIuL upproxImuLeIy 1o-zo% oI LIe meLuI purLs In domesLIc uuLomobIIes ure currenLIy
KRW VWDPSHG. beIIeve IL won'L be Iong beIore LIuL number Increuses Lo qo%, und perIups
beyond," suId MordovunukI.
RegurdIng LIe perIormunce oI LIe roboLIc Iuser cuLLIng sysLem MordovunukI udded, "TIe ubIIILy
oI LIe ABB sysLem Lo LeucI ILseII LIe perIecL IoIe Is Lremendous. And LIe ABB sLuII Ius been
compIeLeIy Iunds-on LIrougIouL LIe enLIre process."
"WIIIe LIe InILIuI ceII wus beIng ussembIed we senL our own LecInIcIun Lo ABB In Auburn HIIIs,
MI, Ior exLensIve sysLem LruInIng. Now we Iuve our own In-Iouse experL."
TIe need Lo meeL LIe NuLIonuI HIgIwuy TruIIIc SuIeLy AdmInIsLruLIon's (NHTSA) sLrucLuruI
requIremenLs Ior YHKLFOH suIeLy wIIIe uddIng us IILLIe weIgIL us possIbIe Lo LIe YHKLFOH cerLuInIy
expedILed LIe emergence oI KRW sLumpIng In LIe uuLo IndusLry. ookIng Iorwurd, LIere Is greuL
poLenLIuI Ior KRW sLumpIng Lo grow beyond LIe uuLo IndusLry.
"ndusLrIuI Iusers Iuve become even more reIIubIe und cosL eIIecLIve In recenL yeurs, mukIng LIem
u perIecL muLcI wILI roboLs LIuL ure weII-known Ior reIIubIIILy und IIexIbIIILy," suId DIMuIunLu.
"SIx-uxIs roboLIc Iuser cuLLIng Is Iere Lo sLuy."
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Doug HIxon
RoboLIc user WeIdIng & CuLLIng SpecIuIIsL ABB RoboLIcs
Copyright Society of Manufacturing Engineers Feb 2009. Provided by ProQuest LLC. All inquiries regarding
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