1. Case Study: Lance and Form Bridge (Form Height)

2. Case Study: Lance and Form Bridge (Form Height)
Problem:
Bridges do not achieve nominal form height.
What is the root cause?
Answer: unknown- not enough information
Material related issues
Process or machine related issues
Tooling related issues

3. Case Study: Lance and Form Bridge (Form Height)
Material Related Issues:
Material can only stretch so far.
Material thickness thinner or thicker than what the tool was designed for.
Material choice impacts springback
Plastic coatings have a thickness.

4. Case Study: Lance and Form Bridge (Form Height)
Process or Machine Related
Programmed depth
Shims installed in die holder
Repeatability of stroke control
Running on a different machine
Tonnage limits
Others..

5. Case Study: Lance and Form Bridge (Form Height)
Tool Related
Tool Length
Tool wear
Tool was sharpened (see red lines)- Upper and lower without sharpening or removing material from ejector.
Debris in lower or upper (metal, dirt, plastic coatings)
Damaged springs in lower
Define nominal height +/- 0.xx mm (Standard tolerance is +/-0.004”(0.1mm)
Ejector