Coil Fed Press

Coil Fed Press Image The following lesson outline details the tasks needed to be an operator and die-setter machinist on a Coil Fed Press. Some of these tasks require the trainee to explain how something works to insure they have the required understanding of the processes and are not simply memorizing procedures. All of the tasks listed will be a part of the Performance Test within each lesson. To learn more about these tests and the training process itself, see the Philosophy section.

This program was specifically designed to train setup operators of a Coil Fed Press. The instructional technique employed will enable individuals to learn to setup and operate the machines with little difficulty. The trainee will also learn the measurement techniques needed by press setup operators. Both existing personnel and new trainees can utilize these training materials to develop or improve their performance.

Lesson 1: Component Identification [ Top ]

After completing this lesson the operator will know the following:

  1. Overview of coil fed stamping line: showing several types of presses, uncoilers, straighteners and feeds.
  2. Four primary functions of coil fed press lines: uncoil, straighten, feed and stamp.
  3. Uncoilers: major types of reels and cradles, components used in reloading a coil in an existing set up.
  4. Straighteners: review of parts, their purpose and how they work.
  5. Feeds: Roll feeds and Air Feeds, their purpose and how they work.
  6. Presses: components of straight side and OBI presses and how they work.
  7. Dies: progressive, blanking, transfer and common die parts and what they do.
  8. Punches: cutting, forming, combination.

Lesson 2: Proper Dress and Operator Controls of the Press [ Top ]

After completing this lesson the operator will know the following:

  1. Dress for safety: jewelry, clothing, glasses, shoes, hearing, other clothing.
  2. Press controls used by the operator: identification and usage.
  3. Main power disconnect
  4. Four modes of operation: inch, single stroke, continuous, automatic single stroke: when and how to use each mode.
  5. Two common safeguarding devices: light curtains and barrier guards.

Lesson 3: Operator Controls of Uncoilers, Straighteners, and Feeds, and Coil
Handling Procedures
[ Top ]

After completing this lesson the operator will know the following:

  1. Loop control devices: types available and their function.
  2. Reels: basic components and operation of both plain and powered reels.
  3. Cradles: basic components and operation.
  4. Straighteners: five categories, their components and controls.
  5. Feed Controls: those commonly used in reloading coils.
  6. Servo-Driven roll feeds: typical control functions.
  7. Coil handling equipment: lifting devices / lifting tools and safe lifting practices.

Lesson 4: Operating Existing Setups and Adverse Coil and Meterial Conditions [ Top ]

After completing this lesson the operator will know the following:

  1. Operator production duties: primary functions: monitor the operation, perform QC checks, load new coils.
  2. Three main reasons to monitor press operation: prevent die damage, check piece part quality, service the line.
  3. Automatic malfunction detectors and their purposes.
  4. Electrically interlocked safety blocks and their function.
  5. Three adverse coil conditions and how to identify them: squatting, clockspringing, and telescoping their effects on production.
  6. Five adverse material conditions: excessive coil set, camber, crown/crossbow, coil break, and edge wave their effects upon production.
  7. Slack Loop: its importance in the coil fed press line "No Loop Faults" and "Excessive Loop Faults".

Lesson 5: Loading Coils Into Existing Setups [ Top ]

After completing this lesson the operator will know the following:

  1. Loading the stock reel: locking lever, brake control, brake pressure adjustment.
  2. Loading the cradle: powered and non-powered plate adjustments, pinch rolls.
  3. Adjusting the straightener.
  4. Loading stock into the feed: air operated bridge or open throat grip feed, or mechanical roll feed.
  5. "Walking the strip" through the die -- manually or using inch or jog control.

Lesson 6: Operations Performed and Indicators of Incorrect Operation [ Top ]

After completing this lesson the operator will know the following:

  1. Three major die operations: cutting, forming and drawing.
  2. Five types of cutting: piercing/slugging, lancing, blanking, cutoff, and trimming.
  3. Five basic types of forming: bending, joggling, cupping, coining, and embossing.
  4. Parts of a sheared edge: edge radius, cut band, break.
  5. Three stages in a shearing operation: plastic deformation, penetration, fracture.
  6. Indicators of incorrect shearing and forming.
  7. Examples of sharp and dull/worn tooling.
  8. Inspecting finished piece parts.

Lesson 7: Measuring and Gauging Piece Parts [ Top ]

After completing this lesson the operator will know the following:

  1. Overview of Statistical Process Control -- the operator's role.
  2. Using micrometers and calipers -- the basics.
  3. Checking parts on jigs and fixtures -- gauge tickets and gauge masters.
  4. Indicators: mechanical, electronic and micrometer heads.
  5. Using common gauging devices: plug gauges, bar gauges, window gauges, and GO/NO GO pin gauges.

Lesson 8: Changing Progressive and Blanking Dies [ Top ]

After completing this lesson the operator will know the following:

  1. Determining the size and adjustment limits of the press and other basic preparations.
  2. Cutting and removing coil from previous set up.
  3. Disconnecting or removing auxiliary equipment from the die area.
  4. Unclamping the die and removing it from the press.
  5. Loading, aligning, and clamping the new die.
  6. Adjustment of striker arm.
  7. Adjusting press shut height.
  8. Adjusting air counterbalance pressure.

Lesson 9: Uncoiling and Straightening Procedures [ Top ]

After completing this lesson the operator will know the following:

  1. Loading and adjustment of reels and cradles.
  2. Coil set: what is it, three basic purposes for removing it.
  3. Adjustment of slack loop sensors.
  4. Purposes for straightening.
  5. Threading and adjusting an independent powered straightener.

Lesson 10: Air Operated Grip Feeds [ Top ]

After completing this lesson the operator will know the following:

  1. Bridge Grip Feeds:
    1. Identifying basic feed components and the three basic adjustments: feed timing, feed length, feed speed.
    2. Two systems for feed timing: mechanical system and electro-pneumatic system.
    3. Loading stock into the feed and setting the pilot pin release timing.
  2. Open throat grip feeds with pull through straighteners:
  • Basic components and explanation of basic functions.
  • Adjusting the height of the feed.
  • Adjusting the timing of the feed cycle and of an (electro-pneumatic) pilot pin release.
  • Rough adjusting the feed length (progression), feed advance speed, and feed return speed.
  • Loading stock into the feed.
  • Lesson 11: Mechanical Roll Feeds [ Top ]

    After completing this lesson the operator will know the following:

    1. Servo-drive electronic roll feed -- basic principles.
    2. Basic components and operation of the three major types of mechanical press-driven roll feeds: rack and pinion driven, bellcrank driven, cam driven.
    3. Basic components and their function.
    4. Adjusting feed height and feed length.
    5. Adjusting stock guide width.
    6. Adjusting feed timing.
    7. Setting pilot release.
    8. Adjusting feed roll pressure and other adjustments.

    Lesson 12: Producing the First Part [ Top ]

    After completing this lesson the operator will know the following:

    1. Performing safety checks along the entire line.
    2. Checking control positions and slack loop content.
    3. Walking the strip through die and adjusting pilot pin release timing.
    4. Visually comparing the first few production parts to an approved sample part.
    5. Obtaining part approval from QC inspector.
    6. Connecting, adjusting, and activating malfunction detectors, auxiliary equipment, and point of operation safeguarding.
    7. Obtaining final approval for production from supervisor and beginning production.