Open Manufacturing Opportunities

Opportunity #6: Steel Base Bands

An Iowa buyer is looking for domestic manufacturers to produce steel base bands to manufacture press-on polyurethane tires for the electric forklift market. Production Procedure in Detail 1) Sheets of steel are sheared to specified length and blank width. The specified blank width is the finished part width plus an additional eighth inch. The grain of the steel is to go along the length of the blank. 2) The steel blank is formed into steel hoop on horizontal hydraulic forming press using tooling designed specifically for each band diameter. 3) Clamp the steel hoop in MIG-welding fixture with the gap in the coil at the twelve o’clock position. Activate the welder and weld the coil into a band. 4) While the weld is still hot, place the band in the weld planisher. Immediately rolling the weld with a high-pressure planisher minimizes the amount of material removal necessary in the next manufacturing step. 5) Trim away excess weld hanging over the ends with the edge shearing press. 6) Excess weld is removed from the outside of the band with a hand grinder. 7) Band is placed in ID grinding fixture, band is clamped and excess weld material is removed from the inside of the band. 8) Band is then placed on the expander and expanded several times to the specified inside diameter. The specified maximum and minimum inside diameters are determined using standards set forth by The Tire and Rim Association (TRA). These standards may be found in the 2016 TRA Year Book, page 6-49. AWC checks to ensure proper inside diameter by using a pass/fail tape gauge built using a mandrel machined to exactly the proper maximum and minimum diameters for that size of band. 9) Band is then placed in a lathe and one end of the band is machined and a chamfer is placed on the inside diameter. The amount of machining required at this point is simply to clean up the face of the band. The standard chamfer AWC place on its basebands is 3/16 X 30°. 10) Band is then unchucked and reversed in the lathe and the unfinished side of the band is then faced and chamfered until the overall width of the band falls within proper tolerances. Proper tolerance for the width of all AWC bands according to TRA is the specified width +.000”/-.030”. The band is checked for proper width by using a pass/fail gauge created at AWC. 11) Band is complete and is ready to be shipped to the customer. See attached spec sheet (BASEBAND SIZES 7-15-'09) for sizing/dimension/tolerance information. AISI 1008MOD/1010 carbon steel is used in the manufacturing of basebands. The American Iron and Steel Institute (AISI) classifies this as a low carbon steel alloy with its primary elements being iron, carbon, phosphorous, manganese, and sulfur. The key components of the steel are as follows: Grade (1008MOD/1010) Carbon(0.05%-0.13%) Manganese(0.30%-0.60%) Phosphorus(0.040% max. ) Sulfur(0.050% max.) Iron makes up the majority of the material, constituting approximately 98% of the makeup of the 1008/1010 steel. Newton, IA; Brooklyn, IA
Responses Requested By: July 30, 2022

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