name: Stator contact
Challenge: To fabricate an extremely complicated stamping, involving several
forming operations, including two 180 degree bends, one of which at a
45 degree dihedral angle, and the insertion of two threaded inserts, while
maintaining close geometrical tolerances.
Solution: This part was produced in-the-flat using a progressive die that
punched all seven holes. The material was fed into the die with a CNC
servofeed to ensure a consistent feed rate.
The part then
went through 8 different secondary operations involving 4 different pieces
of tooling. To minimize stress on the material and reduce the likelihood
of cracking, each 180 degree bend was performed in two 90 degree steps.
The accuracy of each operation depended upon the accuracy of the previous
operation, so in-process inspection was critical.