Case Studies

Design & Manufacturing of Progressive Die with Nut Insert

A customer in the automotive industry contracted A-G Tool & Die, a division of Seilkop Industries, Inc. to design and manufacture a progressive die that would incorporate a nut into a stamped part, thereby eliminating a secondary operation that welded the nut to the part. Working with the customer, our experienced designers were able to develop a concept and design a tool that would make a part to our customer’s specifications. Using our in house software, we were able to simulate the entire process and were able to recommend changes that would make the part more formable. After the customer apporved the changes and the die design, we quickly started machining operations. Programmers and CNC machinists processed the various details through machining cells that were developed through our Lean initiative that streamlined the milling, grinding and EDM operations. Die sets, parallels, and hot roll burnouts, were supplied by our sister company, Hamilton Precision LLC. The die was then carefully assembled, set in our press, and adjusted to make a quality part which was inspected on our CMM to verify that the part was dimensionally accurate.

Dimensions of the completed part was 6” in length, 4” in width, and a height of 2”. The tightest tolerance of ± 0.003” was held throughout fabrication. This is an unconventional product for this industry. This part was a challenge for many die shops, a challenge that Seilkop has the substantial experience and technical ability to accept without issue. Turnaround time for this unit was 18 weeks, producing 200,000 parts annually. For more details about the fabrication of this custom automotive progressive die with nut insert, or the precision manufacturing solutions available please see the table below or contact us directly.

Design & Manufacturing of Progressive Die with Tapped Holes

A manufacturer in the automotive industry selected A-G Tool & Die, a division of Seilkop Industries, Inc. to design and build a progressive die that incorporated tapped holes into a stamped part that would eliminate tapping the holes in a separate, off-line operation. Our on site, design staff worked with the customer as well as the tapping unit supplier to develop a specialized die to the customer’s standards, including mechanical design and simulation of the entire part forming process. Utilizing state-of-the-art wire EDM and milling techniques, the A-2, D-2, and cold rolled steels were experty manipulated and assembled to their final configurations. A tight tolerance of ±0.004” was held throughout the part, having overall dimensions of 6” in length, 2” in width, and 3” in height.

Integrity and accuracy were ensured with comprehensive dimensional and functionality testing. Turnaround time for this project was 18 weeks, with 150,000 units produced annually. Seilkop is an experienced producer of specialized manufacturing solutions, prepared to collaborate with customers to execute their complex or unusual requests. For more details about this progressive die with tapped holes, or any of our other capabilities please see the table below or contact us directly.

Custom Manufacturing of a Set of Transfer Tooling

A customer approached A-G Tool & Die, a division of Seilkop Industries, Inc. about building a set of transfer tooling. With our experience & working with customer specifications, our designers developed a concept & design for the set of tooling. Using our in house simulation software, we simulated the entire process. From the simulation we suggested necessary changes to the part to make it better & more producible.

The customer approved the designs and the job was released for production. Programmers & CNC operators produced the various details through our 2D, grinding, EDM wire and 3D cells. The cell concept was developed through our LEAN initiative. The completed details were then married up with purchased components on assembly carts. Die sets, parallels, & hot roll burnouts supplied by our sister division, Hamilton Precision LLC were machined in our large 3D cell. The dies were assembled, debugged, & married up with the mounting plates, bars, & fingers of transfer system. We were than able to simulate the running of the tool on our in house simulator & got the buy off from the customer.