Introduction (Narrator)
Narrator (with a dramatic, deep voice):
“Welcome, folks! It’s time for another installment of the AI Steel Cat Nekoshou and Extraordinary Keni manufacturing showdown. Today’s topic? A pesky burring defect that’s been causing havoc. Get ready for a battle of wit, wisdom, and wild humor. Can they solve it while cracking jokes along the way? Stick around to find out!”
AI Steel Cat Nekoshou and Extraordinary Keni’s Dialogue
AI Steel Cat:
“Keni the Amazing, today we have a case of the barreling process turning into a ‘bamboo spear’! Are we talking about samurai warriors or something? Sounds like a ‘barreling attack’ to me!”
Keni the Amazing:
“Hold on, AI Steel Cat! Are you stuck in some old Japanese war movie from the Showa era? It’s not a bamboo spear; it’s a defect! The shape is slanted—diagonal!”
AI Steel Cat:
“Ah, I see! The barreling shape is like a bamboo spear. So, charging forward with it is a no-go, huh?”
Keni the Amazing:
“Exactly. If you charge forward, the product will collapse! That collapsed part narrows the diameter and can even lead to cracks.”
AI Steel Cat:
“That’s a serious issue… But I’ve heard barreling can be pretty stubborn. Once it gets messed up, it’s not easy to fix, right?”
Keni the Amazing:
“Exactly. Operators often think the issue lies with the alignment between the initial hole and the barreling position, but adjustments rarely fix it. So, I decided to investigate the causes one by one.”
Keni the Amazing:
“First, I checked the mold precision—±0.02. No problem there. But the material gets compressed unevenly, and the barreling collapses. Weird, right?”
AI Steel Cat:
“Hmm… Could this be… ‘an inside job’? Some hidden flaw in the mold structure?”
Keni the Amazing:
“Good thinking, AI Steel Cat. You’re right. There’s a record showing that this phenomenon occurred even during the startup phase. The root cause was the looseness in the stripper.”
AI Steel Cat:
“Looseness!? Wobbly looseness causing the bamboo spear? This isn’t just a wobbly joke, is it?”
Keni the Amazing:
“Cut it out! The central spring in the stripper was off-center, causing it to tilt during processing, which made the punch go askew.”
AI Steel Cat:
“Ah, so the punch enters at an angle, then returns to its original position, leaving the defect behind. Got it!”
Keni the Amazing:
“Exactly. So, for the solution: keep the barreling shape as-is, fix the stripper’s looseness, and upgrade the spring from green to black to account for deformation.”
AI Steel Cat:
“Incredible! Keni the Amazing, you’re like the doctor of barreling! This should solve the problem, right?”
Keni the Amazing:
“Of course. This solution should work. Now, how about you brush up on your technical knowledge instead of cracking jokes?”
AI Steel Cat:
“Yes, sir… But I can’t stop joking—it’s my mission in life!”
Summary (Narrator)
Narrator (with a knowing smile):
“And so, thanks to Extraordinary Keni’s sharp analysis and AI Nekoshou’s… unique perspective, the burring defect mystery was solved. Stay tuned for more adventures in manufacturing wisdom, with plenty of laughs along the way!”
[Burring Defects and Their Solutions – A Technical Breakdown]
- Problem Overview
A defect in burring caused the shape to become slanted like a bamboo spear. The defect also led to narrowed diameters and occasional cracking. - Background
- Similar issues had occurred since production began, but because the burring was for internal use, they were overlooked.
- This time, however, the shape distortion was too severe to ignore.
- Process and Observations
- The process involved progressive die stamping: a pilot hole was punched, followed by an upward burring step.
- Defects appeared after several hundred shots, despite the die’s positional accuracy being within ±0.02.
- Root Cause Investigation
- The punch and die alignment showed uneven material flow due to tilting in the lower stripper.
- The central spring (Φ25×40) between the burrs failed to provide even support, causing tilt and misalignment during processing.
- Countermeasures
- The burring shape was kept as a rounded dome.
- Stripper clearance was tightened to maintain proper positioning.
- The spring was upgraded from a green type to a stronger black one, accounting for deflection and durability.
