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 Expert  108355

Expert in Metal Stamping Die & Press Work: Consulting, Training, & Troubleshooting

Available for your Consulting and Expert Witness Needs

Michigan (MI)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness

Summary of Expertise: Listed with other top experts in: 
Expert has many years of experience in the theory and practice of deep drawing of carbon and stainless steels, as well as nonferrous and exotic alloys. He has a background in shop floor analysis of the problems involving metal formability, strains, and process optimization, as well as die surface and lubrication conditions.

cold metal drawing


deep drawing


deep-drawn sheet metal


metal drawing


sheet-metal drawing


sheet steel

Expert is a Journeyman Tool and Die Maker with extensive experience. He is a specialist in following and troubleshooting tooling programs in vendors' shops as a contracted employee. As the editor of the SME "Die Design Handbook," he has many contacts in the industry, as well as being able to provide on-site help.

die making


die steel


tool and die making


tool design

Expert notes that die stamping covers four major operations: 1) cutting (including shearing), 2) bending, 3) drawing (including deep drawing), and 4) squeezing (including coining and swaging). Expert has extensive experience making problem stamping processes work, starting with failure mode analysis and leading to a resolution of the problem in a rational fashion.

metal die stamping


steel stamping

Expert's hands on experience with this tool goes back to its inception some years ago. He routinely uses it, and teaches the concept in conjunction with the Circle Grid Analysis (CGA) of major and minor strains to clients. He has taught these subjects in formal classroom settings in-plant to engineers, technicians, and diemakers.

forming limit diagram


metal coining

Expert has many years of shop floor experience in troubleshooting the process of metal bending and curling.

cold metal bending


metal bending


metal curling


metal shearing


curling die

Expert has many years of shop floor experience in troubleshooting the process of metal blanking. He developed a published formula for the process and what is considered to be the definitive work on energy control in heavy cutting operations. He notes that blanking includes the cutting of irregularly-shaped blanks for subsequent operations including the application of lubricants.

metal blanking


steel blanking

As President of Expert's Firm, Expert is a consultant on metal stamping process and press damage problems for all sizes and classes of work. These services are delivered to many Fortune 100 and 500 companies, as well as many small firms engaged in metal stamping. He is proficient in the core group of operations regarding die stamping. Additionally, he provides customized training course manuals and/or in-plant training in a variety of pressworking topics.

aluminum stamping


cold forming


hot-rolled steel


machine press


metal forming


metal press forming


metal stamping


sheet metal forming


anvil (device)

Expert's knowledge of this area encompasses Forming Limit Diagrams as well as CGA cited earlier, and goes beyond that to include all the process input factors and variables. He has spent several decades performing metal forming analyses on problem processes.

perforated metal


signature analysis

Expert is the editor of the "Die Design Handbook," 3rd Edition, published by The Society of Manufacturing Engineers. This 928-page book is considered to be the best standard reference work in the field. If a client wishes, Expert is willing to fax portions of it to them; he has done this in the past on a regular basis. Expert also provides in-plant training on a variety of pressworking topics.

metal pressworking die design

Expert has extensive experience in metal punching, especially in very fast or heavy work.

material punching


metal punching

Metal sizing is a subset of squeezing operations which Expert knows extremely well.

metal sizing

Expert notes that flanging is a transitional process between bending and drawing. He has many years of troubleshooting the three classes of flanges (i.e. straight, stretch, and shrink).

metal flanging


aluminum flanging

During Expert's many years of troubleshooting, his specialty has been understanding the proper application and theoretical design requirements of this area. To this end, he has developed testing techniques to rapidly determine the process capability of presses using electronic load cells.


Expert notes that this class of die work is most often applied to irregularly shaped drawn parts, such as large automotive and appliance panels. He is extremely skilled and knowledgeable in this area.

sheet-metal drawing die

Expert has done extensive work in this area starting in 1965 at Ford Motor Company in 1965 with the Danly licensed system, where internal papers were published. Starting in 1988, he has been doing extensive independent consulting and training in this area. He has conducted or chaired several popular public seminars through SME each year on the topic of "Diesetting Principles and Techniques with Emphasis on Quick Die Change and Setup Repeatability." He is the author of a best-selling work, "Quick Die Change," published by SME. and developed the video training series, "Quick Die Change," also published by SME.

quick die change


die setting

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Detroit, Michigan;  Warren, Michigan;  Flint, Michigan;  Sterling Heights, Michigan;  Lansing, Michigan;  Ann Arbor, Michigan;  Livonia, Michigan;  Dearborn, Michigan;  Cleveland, Ohio;  and Toledo, Ohio.

Often requested
with this expert:

High Volume Metal Stampings and Progressive Die...
Metal Stamping, Metal Forming, Stamping Dies, Stamping Die...
Sheet Metal Fabricating, Stamping
Tool & Die Industry, Sheet Metal Stamping Dies, including...

Year   Degree   Subject   Institution  
1975   Associate of Applied Science   Electronics Technology   Monroe County Community College  
1965   Journeyman Tool & Die Maker   Tool & Die Technology   Western Electric Company  

Work History:
Years   Employer   Department   Title   Responsibilities

1987 to







In 1987, Expert formed Expert's Firm, a sole proprietorship providing metal stamping, power press, and allied consulting services. This developed into a full time job, which included reference publications, writing, and video development. Providing customized training course manuals and in-plant training on a variety of pressworking topics is a specialty.

1965 to 1988


Ford Motor Company


Metal Stamping


Diemaker and Die Tryout Group Leader


His employment commenced with Ford Motor Company as a diemaker from 1965 through 1988. Expert served much of his career as a die maker and die tryout group leader. There, he successfully completed many specialized assignments involving metal formability, electronic instrumentation of the stamping process, and quick die change involving progressive, tandem die and transfer press tooling. He is still active with Ford as a consultant and trainer.

1960 to 1965


Western Electric Company


Columbus Works


Tool & Die Apprentice and Diemaker


The apprenticeship involved a rigid program of very traditional instruction requiring mastery of all tasks before advancement and graduation. The apprenticeship involved making new dies and repairing the dies for the operations listed above performed in the pressroom. Operations included profile surface grinders work using toolmakers microscopes. The wire spring relays had many wires each of which had to bent to exceeding close tolerances involving 20 or more operations.

Career Accomplishments:

Expert is a member of SME, ASM International, Precision Metalforming Association, Fabricators and Manufacturers Association, SAE International, the Society for Experimental Mechanics, and the Audio Engineering Society.

Professional Appointments

He is the editor of the third edition of the "SME Die Design Handbook." He also developed the video training series, "Quick Die Change," published by SME.

Publications and Patents Summary

Expert has developed standard reference publications, technical papers, and customized training workbooks and video; most of these published works were developed in cooperation with SME.

Selected Publications and Publishers  
 - Society of Manufacturing Engineers  
 - SME  
 - The Society of Manufacturing Engineers  

Consulting Services:
Selected Consulting Examples:
  • Expert has provided both in-plant consulting and training services on topics relating to sheet metal formability, die maintenance, press maintenance, diesetting skills, vendor selection, vendor relationships, basic pressworking, and tool engineering. The courses are custom designed for each client.
  • Expert usually delivers training on site or at a local conference facility. Each attendee is provided with a custom developed course manual. The size of the course manuals vary depending on the type and amount of training provided. The goal is to provide each attendee with excellent reference material that will be of lasting value for reference when solving problems.
  • Some clients wish to provide on-the-job training or conduct it formally over a period of weeks or months. In these cases, Expert will work with the client to provide the required manuals at a reasonable cost. This is a popular option for many clients.
Recent Client Requests:
  • Stamping tool expert for consulting on troubleshooting issues.
  • Sheet metal expert for consulting on deep drawn sheet metal issues.
  • Metal stamping expert for engineer training on dies and toolmaking.
  • Quick die change expert for consulting on ODM.
  • Deep draw expert for consulting on drawing punch and die design.
  • Expert for consulting on Thread Roll Consulting
  • Expert for consulting on New Processes for Stamping and Drawing Stainless and Copper
  • Expert in stamping presses to assist with new equipment selection.
  • Die expert for consulting on automotive stamping die problem.
  • Expert in aluminum stamping requirements for consulting on the manufacturability of a new beverage container.
  • Expert in metal working for consulting on production and materials.
  • Expert in steel stamping problems for consulting on troubleshooting stamping process start-up.
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
Expert provides expert witness services in selected cases where a persuasive showing of wrong done to a client is demonstrated. This includes personal injury due to defective tooling designs, and poor vendor sourcing and oversight in both state and federal courts. He also works with steel vendors and users to resolve problems without litigation. He does not seek out expert witness work and will only serve when convinced of a rightful claim.
Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:
Supplier and Vendor Location and Selection

Expert has experience locating vendors of machine shop work, tool & die construction, metal stamping contractors, tool & die components, and press & die sensors. He also has access to Thomas Register, databases, industry contacts, and trade associations and their databases.


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