Engineering Services
Pyramid Mouldings has an in-house engineering group with extensive technical capabilities available to assist customers with the concept, design and final production of their components.
Design Services
By engaging our engineers in an early stage, you can avoid costly oversights and errors in the design and manufacturing process that can save you in the finished production of your parts.
Our engineers will consult with your engineers from design through production and finishing to make sure the manufacturing process at Pyramid has been successful. Our engineering services include…
- Assistance in component concept design
- Guidance in material selection and specifications
- Overseeing tooling needs
- Design and manufacturing of custom dies
- Coordination with customers' engineers from start to finish
- Project management through product development teams (PDT's).
PDT's are formed as soon as your purchase order is received. Members of our sales, engineering, and manufacturing operations are brought together to manage the tooling design and production start-up for your parts. Frequent meetings provide updates against established GANTT charts and action items at each step of the process.
Roll Form Design Considerations
Bend Radii:
- Best practice is a one metal thickness inside radius
- May need slightly larger in high strength steels
- Sharper corners can be obtained at the expense of tool life
- Scoring the inside of the strip can help make sharper corners in some cases
Deep Sections:
- Require more passes, larger machines and larger rolls and dies
- Risk overstressing the edges of the material
- Typical machines – 100 mm max
Short Legs:
- Three times metal thickness is a good minimum leg length
Wide Sections:
- Apply ribs to offsets to wide panels
- Helps prevent wrinkles, "oil-canning"
- Often wide material has appearance issues
Cross Section Tolerances:
- Typically +/- .25 mm to +/- .75 mm
- Tighter tolerances are achievable: a) different approach to tooling and b) special quality materials
- Angular tolerances; typically +/- 1 degree
Length Tolerances:
- Influenced by factors, including length of part, speed of rollformer, measuring system, cutoff system and material properties
- Commonly available: +/- 0.8 mm
- Special equipment and tooling: +/- 0.25 mm
- Long parts (3M or more): +/- 3.0 mm and up
Straightness:
- Bow (up or down)
- Curve (side to side) – 1.0 mm per meter
- Twist – 1 degree per meter
Flare:
- Typically avoid measuring the cross section within 50 mm or ends
- Flare can be controlled with special attention
Technical Process
Our technical expertise includes...
- Finite Element Analysis
- Prototyping
- Cost Reduction Strategies
- Failure Mode & Effects Analysis (FMEA)
- CAD - cadkey, autocad, translation ability
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