The fact that 25% of the annual metal production in the electric motor manufacturing industry never makes it into products but is scrapped through the supply chain shows that metal forming technology in the electric motor industry has great potential to reduce metal waste. The main environmental impact of the metallurgical industry comes clearly from the primary production of metals from ores, which are highly optimized processes. The downstream metal forming process, which had been tuned for maximum output, turned out to be very wasteful. Probably about half of the metal produced in the world each year is unnecessary, and a quarter of the metal produced never reaches product and is cut off and scrapped after blanking or deep drawing.
Design or machine higher strength metals
Using advanced processing, such as servo presses and controlled rolling can reduce material loss and produce higher strength parts, hot stamping expands the applicability of high-strength metals to parts. Where traditional sheet metal forms complex geometries, advanced cold forging reduces material waste by forming more difficult shapes, meeting better performance and reduced machining requirements. The Young's modulus of metal materials is basically determined by the basic chemical composition, with little change at all, and innovative processing in composition and thermomechanical aspects significantly increases the strength of metals. In future developments, improved component designs will enable increased stiffness along with increased strength as processing techniques continue to evolve. For metal forming (manufacturing) engineers to achieve high stiffness, high strength, low cost parts work with component designers to design lighter and stronger product shapes and structures, and with materials scientists to develop stronger and stronger economical metal.
Reduce Yield Loss in Sheet Metal Supply Chain
Currently blanking and stamping waste dominates the use in the motor manufacturing industry, with an average of about half of the plates ultimately used in the motor industry, with an industry average yield of 56% and best practices of about 70%. Material losses not involved in processing can be reduced relatively easily, for example by nesting different shapes along the coil, which is already a common practice in other industries. Stamping losses related to useless strips at the finish of deep drawing may not be completely eliminated and may be reduced in the future. The use of double-action presses is being replaced by alternative methods to form net-shape parts, the possibility of axisymmetric parts made by rotation, this technology opportunity has not been fully studied, and the need to continue to reduce defect rates in stamping technology and product and process design loss.
Keep products in service longer before replacing them
Most products are replaced and last longer before they "break", and the drive to innovate to do this depends on new business models where all metals are developed and maintained by companies focused on optimizing the life of the material.
Design or machine higher strength metals
Using advanced processing, such as servo presses and controlled rolling can reduce material loss and produce higher strength parts, hot stamping expands the applicability of high-strength metals to parts. Where traditional sheet metal forms complex geometries, advanced cold forging reduces material waste by forming more difficult shapes, meeting better performance and reduced machining requirements. The Young's modulus of metal materials is basically determined by the basic chemical composition, with little change at all, and innovative processing in composition and thermomechanical aspects significantly increases the strength of metals. In future developments, improved component designs will enable increased stiffness along with increased strength as processing techniques continue to evolve. For metal forming (manufacturing) engineers to achieve high stiffness, high strength, low cost parts work with component designers to design lighter and stronger product shapes and structures, and with materials scientists to develop stronger and stronger economical metal.
Reduce Yield Loss in Sheet Metal Supply Chain
Currently blanking and stamping waste dominates the use in the motor manufacturing industry, with an average of about half of the plates ultimately used in the motor industry, with an industry average yield of 56% and best practices of about 70%. Material losses not involved in processing can be reduced relatively easily, for example by nesting different shapes along the coil, which is already a common practice in other industries. Stamping losses related to useless strips at the finish of deep drawing may not be completely eliminated and may be reduced in the future. The use of double-action presses is being replaced by alternative methods to form net-shape parts, the possibility of axisymmetric parts made by rotation, this technology opportunity has not been fully studied, and the need to continue to reduce defect rates in stamping technology and product and process design loss.
Keep products in service longer before replacing them
Most products are replaced and last longer before they "break", and the drive to innovate to do this depends on new business models where all metals are developed and maintained by companies focused on optimizing the life of the material.
