Design Tips

• Material ½ Hard Stainless Wire
• Original Design
  • Tooling could not overform enough to close part to grip on 1.14 D mating part.
  • Area of concern was the large radii between dimples
• Modified Design
  • Replaced large radii with a series of flats
• Over 10 million pieces produced

• Material is an Alloy C17200 Beryllium Copper
  • RB 88-96
• After 4 different tool designs the smallest the .31R can be formed to is .40
• Proposed new design – did not fulfill functional requirements
• Part is never put into production

A ratio of material width to thickness of less than 10:1 presents additional challenges.

• Material may exhibit dish. Dish is crown across the width of the material.
• Reduces the number of potential suppliers because it is considered a difficult slit. Increases cost and decreases availability.
• When this situation cannot be avoided evaluate the cost and suitability of using flat wire.

• Material .024 thk C1050 annealed spring steel. Austempered to Rc 40-46
• Original design did not have gusset at 88º angle or rib along length.
• The post production heat treat process bowed the part and changed the angle.
• After addition of the rib and gusset heat treat distortion in these two areas was eliminated.

• When a consistent closed form is needed add a dovetail
• The adjacent part made of cold rolled steel needed the 2” diameter held to a tolerance of +-.005.
• Do to the variation in the material we chose to accomplish this using a dovetail instead of a straight seam.

• Material is .024 Thk ½ hard stainless
• .110 wide trim off the top and bottom of the part induced a .150 bow in the blank before it was formed.
• In tempered material when long narrow trims are taken off the top and the bottom of the blank, the blank will tend to bow.
• The bow is impossible to remove in the tooling.