These rings are transmission synchronizer cones stamped from coil material in thickness from .085 to .180”. These materials range in makeup from precision micro-alloys to precision rolled high strength low alloy CRS. We run these parts from coil steel utilizing precision transfer tooling, then they are heat treated. These rings are produced to angles within ±5 minutes and roundness to .001” per inch diameter after heat treat. This transfer tooling allows formation of flat strip material not economically achievable with progressive die capabilities.

The clutch Separator Plates shown here are produced from 1075 spring steel with the material thickness tolerances held to ±.0008”. These parts are run through a progressive die with the main feature being the concentric coined detail on both sides of the part. These coined details are .0008 ±.0004” deep while maintaining flatness within .004” after post heat treating thru hard to Rockwell C58. Following heat treat, the parts are then coated with a fine manganese phosphate plating. The coin details required extensive development and high tonnage to meet print requirements, while also minimizing tool component wear during production.

These clutch Separator Plates are produced from 1008/1010 low carbon steel with the thickness tolerance held to within ±.0008”. These parts run in a progressive die with the “cross hatch” pattern being coined into both sides of the part. The coining requires high tonnage to coin to the correct depth, while maintaining proper thickness and flatness of the part. Coining to this degree creates a thicker part which must be coined and flattened to proper thickness. Following the stamping operation, the parts are then heat treated to Rockwell C48 minimum while maintaining flatness of .004”.

These parts shown are examples of a wrench bracket to hold a jack handle for an automobile. This annealed spring steel coil material ranges from .020 to .060” thick. The parts are run in progressive die tooling. They are formed complete upon passing through the die, and are packaged for shipment to the heat treat facility. Tempering is done to Rockwell C42-44 leaving the parts with a very high spring property to them.

The clutch plates shown here are produced from 1075 Blue Tempered Spring Steel at a hardness of Rockwell C43-47. These parts are stamped in the pre-hardened condition, eliminating post heat treating which can be a cause of part distortion. This type of steel requires very robust tooling components, and is the result of over 14 years of running blue tempered spring steel. Minimal burr requirements of .002” and flatness of .006” are some of the critical features of these parts.

These are serrated blades which are installed into tape dispensers for the tape cutoff. The parts run in progressive dies in automatic presses with the raw material being low carbon coil steel that is nickel plated. The tooling required to run these parts must be built to accommodate volumes up to 25 million parts per year. The parts are tested during production for blade sharpness by measuring the amount of force required to cut the tape. Surface finish, blade sharpness, and flatness are critical features that require close monitoring.

This motor lamination is stamped from CRS or special electrical steel in thicknesses ranging from .025 to .090”. We have stamped laminations from copper up to .187” thick in the past. This particular lamination blank is indicative of similar parts we run for motors from DC servo motor size to table saw motors, up to generator lamination segments and eddy current brakes used in oilfield drilling and ocean going vessel power generation.

This component is used within a computer tape backup system. The parts are produced out of .008” thick mylar material. The tooling is produced with less than .0002” clearance between the punch and die which is critical in meeting the stringent burr/shaving requirements.

These parts are used as filler necks for radiators used in Truck, Automobiles and Off-Road Vehicles. The parts are produced on a transfer tool that is unique in that each station can be individually adjusted. The raw material used is Alloy 260 Brass. The overflow tube pictured in 1 of the parts is cut, formed and soldered to this part. Parts are then 100% tested for any leaks. We produce a number of variations of these types of parts.

These parts are heat sinks used for automotive tail light and turn signal assemblies utilizing LED technology. The parts are produced with the tabs being partially punched through the raw material and holding the heights to within .004” total between all tabs. The raw material is Alloy 5052 H32 material, which is run through a progressive die. The parts are then etched, cleaned and stacked for safe shipment.

These parts are Synchronizer Inner Cones used in automobiles. The material used is a high strength low alloy that is run through a transfer tool to aid in being able to fully form and resize the part prior to the heat treat and machining operations. One unique feature of these parts is the edge condition of the lugs which is nearly the same as a fine blanked edge. The lugs are critical as the edges are the engaging feature in the part function and require a high degree of surface area perpendicular to the top surface. The tool development resulted in over 90% of the edge being land area to achieve this desired condition.