Gimme three steps:

The basics of troubleshooting die problems

In my career as a consultant, I have experienced numerous die-related problems.
Some were complex, and some were easy to solve. But most were solved by
following basic die design and troubleshooting guidelines. For a stamping die to
function properly, you have to follow three basic die design guidelines, and follow
them in order. Disregarding these rules or taking them out of sequence can cause
problems such as inconsistency, die damage, misfeeding, and inaccurate
dimensions, to name just a few.
Step 1: Locate the Part/ Strip Accurately
To ensure part dimensions are completely correct, you first have to locate
accurately within the boundaries of the die. To do this, place gauging within the
perimeter of the part or blank, locate the part on a punch replicating the shape of
the part, or use pilot pins to locate the part or blank. Pilot pins are used commonly
in progressive dies to locate the part. They typically are hardened and ground,
cylinder-shaped tool steel pins that enter into pre-pierced holes and register the
location of each part or the strip within the boundaries of the die. The pilots are
placed a consistent distance apart. This distance is called the pitch or the
progression length. Pilots don’t always have to be round, but they must enter into a
pre-pierced hole that fits the pilot point and geometry precisely. The clearance
around the pilot pin is a judgment based on the thickness of the metal, the size of
the part, and the tolerance requirements for the part. For medium to large
progressive dies, the pilots typically are 0.002 to 0.003 inch smaller than the pre-
pierced hole they enter. The pilots must be dimensioned

so they locate the part accurately without sticking to the part material. The pilots
must extend beyond the surface of the pressure pad enough to locate the strip or
parts accurately before the pressure pad holds the material down tight to the die.
However, if the pilots extend too far from the surface of the pressure pad, you
might have difficulty stripping the metal from the pilots. The accepted rule is that
the bearing surface of the pilot—the point at which the taper turns into a diameter,
which is very close to the pre pierced hole size— should extend beyond the
pressure pad about two times the material thickness. Keep in mind this is just a
guideline
and doesn’t work for every application. If the material is very thin or very thick, the
rule won’t work. It is good practice to place low-pressure spring pins around each
pilot used in the die. These small, low-pressure spring pins help to strip the
material from the pilot points as the die opens to ensure that the strip or part
remains on the bottom die and does not come up when the upper ram raises. If
you are using perimeter gauges, make sure they fit accurately around the outside
of the part while still allowing the part to be placed easily on the die and removed. If
you are using the shape of the part as a means for locating it, make sure it fits very
closely to the punch on which it sits and does not move or tip at all.
Step 2: Hold and Control
Pressure pads, which hold, strip, and control the metal flowing into the die, are
critical. If the pressure pads are not holding the material properly or not holding the
part tightly to the die, the part or strip may move or become distorted while being
formed or cut. The pressure pads must have enough force to prevent the material
from shifting during cutting or forming. The amount of force required under the pad
is a judgment based on the type, thickness, and deformation taking place. The
pads must fit the shape of the part and die very accurately. A bent or distorted
pressure pad might not control the metal, allowing parts to move out of position. If
the pressure pad does not fit the geometry of the part accurately, it might cause the
part to distort while the cutting punches are stripping
from the metal. In drawing operations, the draw pad must fit very closely to the die
face to prevent the metal from wrinkling while it is being drawn into the cavity. Pads
used in bending operations must hold the material tight enough to the die so that
when bending occurs, the metal is not allowed to shift on the die or pad surface.
The pads must distribute the holding force as evenly as possible throughout the
entire part. Use springs of the same force underneath the pad or nitrogen gas
springs plumbed to a common control pressure box to ensure uniform pad
pressure.
Step 3: Perform Work
Perform whatever duty or task the station was intended to perform. This could
include cutting and various types of forming.
The Logic Behind the Sequence
Each one of these steps must happen in sequence. If you try to perform work
before the part or strip is located properly, the work performed will likely be in the
wrong location. Items such as bend lines and pierce holes will be mislocated and
out of position. If you attempt to draw metal before locating the blank properly, the
form will be out of time with the edge of the blank, and splitting might occur. Too
much metal outside of the punch on one side of the part may cause a resistance
for the metal to flow, resulting in splitting. On the opposite side, too much metal
might flow into the tool, causing wrinkling. If you attempt to hold the parts tightly to
the die before locating them, you will have difficulty locating them.
As a result, the pilots or the gauge will have a lot of trouble moving the part or strip.
If you try to locate the parts and then form or cut, the material will not be clamped
down tightly to the die. This most likely will result in part distortion and
nonconforming geometries, as well as the inability to feed the tool accurately.
Following these three steps in sequence can prevent a lot of die problems and
headaches. Take the time to ensure your parts are precisely located. Take the time
to ensure that your pressure pads fit properly and are exerting enough force to
control and strip the material. Until next time … best of luck! S
Art Hedrick is president and senior consultant of Dieology, 8730 10 Mile Road SE,
Rockford, MI 49341, 616-894-6855, dieology@pathwaynet.com,
www.dieology.com.