Precision embossing - Alternative method of forming flat parts

Precision embossing is setting new standards in cost-efficient production of cold-formed, superior-quality flat workpieces. The method meets the industry need for mass parts of truly high quality, with a good surface finish and manufactured to close tolerances. These parts are mostly ready for immediate assembly and utilised as easily exchangeable components. Naturally, it is increasingly important to choose, implement and master the optimum production method in each particular case. Parts can be formed with the most diverse of methods, which are occasionally in direct competition. It is possible to manufacture one and the same workpiece with very different techniques. Each will have its strengths but also its weaknesses, forcing manufacturers to compromise in the effort to satisfy customer needs. On their own, methods like casting, forging, hot or cold extrusion, sintering or forming will often fail to measure up to required standards. But combining these methods with precision embossing allows manufacturers to supply customers with the products they want. This paper dwells on the use of precision-embossing technology in combination with other forming operations to volume-produce parts that are practically ready for instant assembly. This can be done in a single operating sequence or in separate cycles. Examples from practice are cited to illustrate the advantages of this networked technology. A comparison of all the quality attributes of a part before and after embossing, together with a final cost-efficiency analysis, will demonstrate the capabilities of this technology. The paper highlights the advantages of combining it with other methods from problem definition right through to the optimum problem solution,This manufacturing technology is based on knuckle-joint forming press systems equipped with the extreme rigidity required for producing superior-quality components. (C) 1997 Elsevier Science S.A.