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PART - 1
CONTENTS
CHAPTER -01
INTRODUCTION TO
PRESS TOOL
INTRODUCTION:
PRESS TOOLS:
Press tools are special tools custom built to produce a component mainly
out of sheet metal. Press tool is of stampings include cutting operations
(shearing, blanking, piercing, etc.) and forming operations (bending, drawing,
etc.)
Sheet metal items such as automobile parts (roofs, fenders, caps, etc.),
components of aircrafts, parts of business machines, household appliances,
sheet metal parts of electronic equipments
Blanking:
Blanking is a process of producing flat stampings. The entire periphery is
cut and cut out piece is called the blank.
Piercing:
It is the operation of making hole in the stamping. Here also the entire
Periphery is cut and cut piece is waste.
Cut - off:
Cut off operation separates the work material along a straight line in a
single cut. No scrap is produced in cutting off operation. The process of
cutting off is similar to shearing in a shearing machine.
Parting - off:
The parting off operation separates the work material along a straight line
in a double line cut. The piece, which is removed by the punch, is a scrap.
Parting of
Notching:
This operation removes a small amount of material from the edges of a
strip or a blank. Notching serves to shape the outer contours, of the work
piece in a progressive die or to remove excess metal before a drawing of
forming operation in a progressive die.
Notching
Trimming:
Shaving:
Perforating:
Lancing:
Dinking:
To cut paper, leather, cloth, rubber and other soft materials a dinking tool
is used. The cutting edges penetrate the material and cut (like knives).
Broaching:
Planishing:
Serrations
Embossing:
The embossing tool is used to press letters and numbers into a sheet
metal or on pre drawn piece part. Usually the punch will have the raised form
and the die will have the corresponding cavity.
Coining:
It is the process of pressing cold material in a tool so that it flows into the
engraved profiles on the die face. Coining differs from embossing such that in
coining the metal flows, where as in embossing the metal does not change in
thickness to a great extent.
Bending:
Forming:
It is similar to bending except that the line of bend is along a curved axis
instead of a straight one. Metal flow is not uniform. It will be localized
depending upon the shape of the work piece.
Drawing:
In drawing a flat blank is transformed into a cup or shell. The parent metal
is subjected to severe plastic deformation. Shell forms produced may be
cylindrical or rectangular with straight or tapered sides.
Flaring or lugging:
Curling:
Bulging:
transmitted through a medium that will flow but will not get compressed. The
more common media are rubber, urethane, oil, or water.
Swaging:
Sub press tools blank and form very small parts. The die components are
retained in the sub press. The sub press is a small press operated in a larger
one.
Assembly tool:
Horning:
Horn tools are provided with an arbor or horn over which parts are placed
for secondary operations.
Combination tool:
CHAPTER -02
THEORY OF SHEARING
1. Plastic deformation:
The pressure applied by the punch on the stock material tends to deform it
into the die opening when the elastic limit is exceeded by further loading, a
portion of the material will be forced into the die opening in the form of an
embossed on the lower face of the material and will result in a corresponding
depression on its upper face. This stage imparts a radius on the upper edge
of the punched out material. This is called the stage of “plastic deformation”.
2. Penetration stage:
As the load is further increased, the punch will penetrate the material to
a certain depth and force an equally thick portion of metal into the die. This
stage imparts a bright polished finish (cut band) on both the strip and the
blank or slug. On optimum cutting conditions the cut band will be 1/3 rd of the
sheet thickness. This is “penetration stage”.
3. Fracture stage:
In this stage, fracture will starts from both upper and lower cutting edges.
As the punch travels further, these fractures will extend towards each other
and eventually meet, causing complete separation. This stage imparts a dull
fractured edge. This is the “fracture stage”.
CHAPTER -03
CUTTING FORCE
CUTTING FORCE:
“Cutting force is the force which has to on the stock material in order to
cut out the blank or slug ”. This determines the capacity of the press to be
used for particular tool. The cutting force is also determines the cut length
area for straight cuts are performed in the shearing and some cut off
operations, the area to be cut is found by multiplying the length of cut by stock
thickness.
The following table gives the shear strength (T max = 0.2 for tensile
strength σ max) of several materials.
Example:
Calculate the press force required t produce the following component.
Sheet thickness 2mm. Material is brass.
CHAPTER -04
CUTTING CLEARANCE
Cutting clearance:
Cutting clearance is the gap between the side of the punch and the
corresponding side of the die opening on one side of the edge, when the
punch is entered into the die opening. It is expressed in the amount of
clearance per side.
Fig shows the blank or slug made under optimum cutting conditions. The
edge radius (die roll) is the result of initial plastic deformation, which occurred
during the first stage of plastic shear action.
Highly burnished cut band results from the second stage (penetration) of
shear action. The width of the cut band is approximately 1/3 rd of the thickness
of stock material. The balance of the cut is the break, which results from the
third stage (fracture) of the shearing action.
In this the large gap between the punch and die cutting edges allows the
stock material to react to the initial pressure on a manner approaching that of
forming rather than cutting. Therefore the edge radius becomes larger and
the cut band becomes smaller.
When the cutting clearance is slightly less the condition can be identified
by greater width of the cut band. Because of steeper angle between the
punch and die cut edges the resistance of the stock material to fracture is
increased. In case of excessive clearance the burr results from dragging of
the material. While insufficient clearance compressive forces cause the burr.
Burr Side:
The burr side is the adjacent to the break. The burr side is also called
because of a noticeable burr condition develops it will occur in this side. Burr
should be practically non-existence if the cutting clearance between the punch
and die is correct and if the cutting edges are sharp.
The burr side of the blank or slug is always towards the punch (die starts
shearing) the burr side of the punched opening is always towards the die
opening.
Problems:
Clearance = c X s X tmax/10
= 0.01 X 2 X 300/10
= 0.02 X 300/10
= 0.12 mm/side
Blanking punch:
Piercing Die:
1. Determine the punch and die dimension for the component given
below. Sheet thickness 2mm MS, T max is 400N/mm and C=0.01.
Clearance = c X s X tmax/10
= 0.13 mm/side
CHAPTER -05
LAND:
The inner walls of a die opening are not usually made straight through
as the blanks or slugs tend to get jammed inside, which may result undue
stress build up. This may lead to the breakage of the punch and die.
To avoid such situation the die walls are kept straight only to a certain
amount from the cutting edge. The straight wall is called “THE LAND”.
An amount of 3mm land for stock thickness up to 3mm.
For thicker materials equal to their sheet thickness.
In special cases, the angular clearance extends from top to bottom of the
die wall completely eliminating the land.
Dies employing an ejector to clear the blanks will have straight walls
without any angular clearance, as the blanks do not get accumulated in the
die.
CHAPTER -06
STRIP LAYOUT
STRIP LAYOUT:
ECONOMY FACTOR:
The designer should try out every possible means to attain a good
percentage of any strips, without sacrificing the accuracy of the piece part.
Blanking tools produce blanks entirely from the strip or unit stock.
Blanking is a most efficient and popular way of producing intricate and
closely tolerated blanks.
Production Requirement:
Grain Direction:
The grains are found in the sheets when they are rolled.
Bending the strip along the grain direction results in crack and fracture.
Burr Side:
It is a decisive factor in laying the strip.
In blanking, burr is found on the punch.
In piercing, burr is found on the die.
Stock Material:
Here the blanks are arranged in a single row and the strip is passed
through the tool only once to the punch and blanks from it.
Here the strip width should be equal to the distance between two parallel
sides. The blanks are produced by cut off or parting off operation.
1. Contour.
2. Minimum material wastage.
3. Less tool cost.
4. No scrap strip to handle, which renders the production faster.
5. Accuracy in strip width.
6. Accuracy of the blank.
7. Flatness.
Strip layout for Cut Off and Parting Off:
Cut off and parting are the operations, which shear the strip across the
entire width either, in straight or curved lines.
The difference is cut off punch cut s only one edge producing no scrap
where as parting punch cuts two opposite edges producing the scrap.
Different layouts:
There are two ways of laying the strip, Narrow run and wide run.
Narrow run is used when the grain direction of the piece part is important.
Single row two pass method:
A two-pass tool requires minimum of two stops. The stops used for the first
pass have to be removed. Or made to disappear from the working surface so
as not to interfere with the second pass. For double pass the front and back
scrap as well as the scrap bridge should be wider than those for single pass
(about 50-100). Two pass layouts are justified only when the wastage is
considered and the stock material is costly.
Double row layout:
Further economy can be attained by double rows. Strips for double row
layout will be wider and require the back and front scrap to be more than
usual amount.
Gang die:
Some of the piece parts will be require to be laid out to an angular position
to make the layout more economical.
CHAPTER -07
ICDP TECHNICAL TRAINING CENTER
EIGEN ENGINEERING
PUNCHES
Punch:
1. Cutting punches.
2. Non – cutting punches.
3. Hybrid punches.
CUTTING PUNCHES:
HYBRID PUNCHES:
These punches perform both cutting and non-cutting operations, like shear
and form, punch-trim etc.
PUNCH GROUPS:
There are two groups of punches:
1. Segregated punches.
Self mounted punches, which are positioned and retained by means of
self-contained screws and dowels.
2. Integrated punches.
Punches depend on other component such as punch plate, to locate
and position them.
TYPES OF PUNCHES:
1) Plain punches
Advantages:
Material saving.
Machine time saving.
Easy mounting.
2) Pedestal punches
Base is offset.
Reason for offsetting
Space consideration for other components.
Machining and grinding accessibility.
Disadvantages:
4) BOSSED PUNCHES
5) FLANGED PUNCHES
6) HEADLESS PUNCHES
9) CLAMPED PUNCHES
PERFORATORS:
Similar to step head perforator. Shank dia is more than point diameter.
Pyramid perforator:
Does not have a shoulder. A whistle notch is milled on the shank for
fastening.
To prevent slug pulling, air pressure or spring pins are commonly used.
Quilled perforator:
CHAPTER -08
BUCKLING THEOREM
Buckling of Punches:
Whenever Press tool is worked upon within the press, The punches
mounted in that tool, are subjected to compression stresses. But if due
consideration of stresses are overlooked during designing of the tool, the thin
punch within the tool may fail by buckling.
Hence by maximum force, which a punch can withstand without buckling
can be calculated by using the following formula.
Fb = [² × E × I] / Lp²
Lp = Length of punch in mm
Example 1:
To find the smallest diameter of the punch to pierce 2mm Mild Steel sheet.
Fb = [² × E × I] / Lp²
800 × 10-9 = [² × 210 × I] / 0.06²
800 × 10-9 × 0.06² = ² × 210 × I
I = [800 × 10-9 × 0.06²] / [² × 210]
= [2.88 × 10-9] / [2070.516]
I = 1.389547 × 10-12 mm4
I = 1.389547 × 10-12 mm4
I = [d4] / 64
1.389547 × 10-12 = [d4] / 64
d4 = 1.389547 × 10-12 × 64
d4 = 2.8307619 × 10-11
d = 2.3066mm
~ 2.31mm
CHAPTER -09
DIE BLOCKS
FACTORS INFLUENCE THE DESIGN OF A DIE BLOCK:
DIES THICKNESS:
STOCK MATERIAL FOR DIE BLOCK LENGTH
THICKNESS IN mm upto125mm 125-200mm 200-400mm
upto 1 16 20 24
1 to 2 20 24 28
2 to 3 24 28 32
3 to 4 28 32 36
4 to 6 32 36 50
6 & above 36 40 60
DIE BUSHES:
Advantages:
Easily replaceable.
Reduces cost of the die manufacturing.
Application:
SPLIT DIES:
Methods:
NESTING:
METHODS OF NESTING:
Nesting in Die set pockets.
Nesting in Retainer Plate, which is of Mild steel.
Nesting in the above methods incorporating Liners.
DIE SECTIONS
LINER
DIE SHOE
Section X-X
LINER
LINER
LINER
LINER
NEST BLOCKS:
Advantages:
Disadvantage:
Costly compared to pocket milled Die set type nesting, as the separate
nest block has to be machined & clamped to the die set.
NESTING in Retainer Plate:
DIE INSERT:
CARBIDE DIES:
Die Material: Tungsten Carbide.
Applications:
CHAPTER -10
STOPPERS
STOPPERS:
After each and every stroke of the press, the strip has to be fed forward for
one pitch length. This can be accomplished by means of stopper.
The function of the stopper is to arrest the movement of the strip when it is
fed forward to one pitch length.
Basic stop principles:
It is essential that two basic definitions be associated with the fundamental
principles of stops,
Stop position.
Registry position.
Stop position:
This is the location of the actual stopper position surface against which the
stock strip is halted.
Registry position:
This is the exact location in which the stock strip must be established in
order that the work will be dimensionally correct. The registry position may or
may not be the same as the stop position.
Stop Categories:
Primary:
Primary stop is the first stop in the die, which act as true gauges,
registering the stock strip. This locates stock position to coincide with the
registry position.
Secondary:
The stops in between are secondary stops. The secondary stop acts as a
approximation gauge, therefore allows the overfeed when installed.
Final:
The final stop is the last stop in the die. It may or may not register the stock
strip, when mounting them locate the stopping position as required.
Stop types:
Solid stop:
The stop is the plain cylindrical pin. The stop pin is mounted in a die Block.
The pin is a light drive fit on the mounted hole. The mounted hole is generally
made to suit standard pin size (dowel size).
Disappearing stopper:
It is a spring pin located at the required stopping position disappearing
stops offer one important advantages over other pin stops is that they do not
require clearance in apposing die members
Finger stops:
The stop is actuated manually. It is pushed inward until the stop shoulder
contacts the front edge of the stripper. When the stop is in close position, the
nose of the stop extends into the stock channel, obstructing the stock strip.
The stop is held in closed position and the leading end of the stock strip is fed
against the stop. Then operator trips the press and releases the stop. The
spring returns the stop to its open position where its remains until a new stock
strip are fed into the die.
Pusher Stops:
These stops are special types of finger stop. They serve a duel purpose as
both stops and pushers–the spring forces inward where it obstructs the stock
strip channel. In operation the leading end of the stock strip is fed against the
pusher stop. After the press cycle, the stop is manually pulled outward,
permitting the strip to advance the next stop. When released, the stop in effect
becomes a pusher.
Trigger stoppers:
For the fast productions mostly trigger stopper are used. They are also
called as automatic stoppers.
CHAPTER -11
STRIPPERS
STRIPPERS:
The main function of the stripper is to strip the stock material off the
punches after each stroke. In addition the stripper may act as a guide for the
punches, as well as hold the strip flat and tight, while the strip is being worked
on.
Box Stripper:
A typical box pin stripper is shown
For the average progressive die, assuming there are no other specific
requirement, Clearance F may be 0.3 per 100mm tunnel length.
W
G
H
HOOK STRIPPER:
Hook pins are made from cold drawn steel. The function is as shown in
hook pin
figure.
SPRING STRIPPERS:
Spring stripper is a pressure pad stripper. They are used when it is
necessary or desirable to hold the stock material flat (or very nearly flat), or to
provide better visibility and access when the tool is mounted on the press.
Inverted dies have stationary punches & therefore require traveling pressure
pad strippers. Pressure pad strippers are also used for push back
applications.
Stripper
Plate
Spring
Stripper
Die
COMPENSATING WASHER:
When cutting punches are sharpened they become shorter. In many
applications, the springs are compressed a little more and are not always
desirable. A practical method to eliminate this is to install the cylindrical
washer as shown in the figure. Each time the punches are sharpened the
washer is reduced for the amount
The bolt acts to confine the spring in location so that the double spring
pocket can be eliminated
Normally, a space G Should exists between the end of the stripper bolt and
the stripper (G = 0.5mm).
STRIPPER BOLT
SPRING
GUIDE STRIPPERS:
Two typical stripper guide pins arrangements are shown in figure. The
drawings are self-explanatory.
STRIPPING FORCE:
Stripping force for most operations range from 10 to 20% of the cutting
force. If the die has more than one punch the stripping force for that die is the
sum of stripping force required for each punch.
1. Stock material: Material, which has high friction, value and material,
which tend to cling, are more difficult to strip.
The larger area of the stock material surrounding the punch is stronger and
causes the material to cling more tightly to the punches.
CHAPTER -12
GAUGES
GAUGES:
Gauges must be considered in the design of press tool because theses
component position the strip longitudinally in its travel through the die. In
second operation dies, gauges locate the previously blanked or formed part
for further processing operations.
Material choice: Finished tool steel is used for gauges in first class die. Cold
rolled steel should be used only when low production n requirements exists.
Adequate thickness: The back gauge and the front spacer must be thick
enough to avoid binding of the strip between stripper plate and die block.
Good doweling practice: Since the gauges locate the strip they should
always be doweled in position.
Back Gauge
Strip
Front Gauge Support
The gauge should be thick enough to avoid binding of the strip between
the stripper and the die block. The recommended thickness of 3mm for sheet
up to 1.5 mm and strip thickness +1.5 mm for heavier (more than 1.5mm) strip
is found to be satisfactory if automatic stops are employed in the tool. The
space between back gauge and the front spacer is made to strip width
+0.5mm if roll feeding is used and strip thickness +1mm for hand feed.
STRIP SUPPORT:
While hands feeding the strip to reduce fatigue to the operator a strip
support should be provided. The strip support should be made wider and
brought closer to the die block to provide better support and guidance. Roll
feed doesn’t require strip support.
PUSHERS:
These are provided to keep the strip firm against the back gauge during its
travel through the tool. Spring loaded pushers are often employed to achieve
this.
accessibility to the nest. Adequate lead angle should be provided around the
nesting profile for easy loading.
Unloading more difficult than loading. For low production tools simple pick
of slots machined in the nest would be sufficient to allow the operator to
manually pick the piece out of the nest. Ejection of piece parts out of the nest
ACCURACY:
The fit between the gauge part and the gauge should be perfect. For
gauging purpose it is not necessary of the nest to fit entire contour of the
piece part. All that is required to provide sufficient number of locating points.
The number of locating points required for certain nest depends upon the size
and the shape of the piece part. A minimum of three part for circular and
angular shape and 4 points for other shapes are required.
FOOL PROOFING
Any possibility of the piece part being loaded in the incorrect manner by
the operator should be prevented by the nest. Foolproof pins could easily
accomplish this as shown in the fig.
that disappearing nest pins are less accurate and should be used only if
inevitable
As a general rule, all gauging elements should be made out of tool steels
and hardened to 48-52 HRC.
NESTING IN DIE SET:
Simplest nesting method is to fit the section in to the pocket that is milled
directly in the die set. The die section should be fit tightly into the pocket but
the assembly pressure should be so great as to distort the die set. It should
be noted that nesting does not eliminate the need for the use of screw.
Liners made out of hardened tool steel facilitate easy and accurate
assembly of sectional dies into the pocket.
CHAPTER -13
PILOTS
PILOTS:
Pilots play a vital role in the operation on multiple-station dies, and many
press lines troubles can be traced to their faulty design. In applying pilots the
following factors should always be considered:
1. They must be strong enough so repeated shock will not cause fracture.
2. Slender pilots must be sufficiently guided and supported to prevent
bending, which can cause faulty strip positioning.
3. Provision should be made for quick and easy removal of he pilots for
punch sharpening.
PURPOSE OF PILOT:
The pilot positions the stock strip relation with die opening. This is termed
as registering the stock strip in the required position. Usually the stock strip is
over fed than the actual pitch length. The max over feeding of the strip is
about 0.1mm.
When the press is tripped the pilot comes down and engages the pierced
hole thus dragging the strip back into the registry position stock strip is fed by
mechanical means pilot action is the same principal. However, the direction in
which the feeding is qualified is normally reversed. Instead of being over feed
the stock is under fed.
PILOT SIZE:
The accuracy with which the work can be registered depends upon the
proper location and the diameter of pilot.
However the thick stock materials & the stock materials like aluminum and
copper need often bigger tolerances between the pilot and the pierced hole.
PILOT LENGTH:
Registering the strip must be complete before the cutting punches come
and engage the strip. Therefore the pilot must be longer than the punches. If
the pilots are too short they cannot perform their function
TYPES OF PILOTS:
RETRACTABLE PILOTS:
In many occasions especially during hand feeding misfeeding occurs due
to over shooting of the stock strip over the stoppers. This creates the problem
when a tool is having pilot s in it. Pilots may break or buckle obstructing
smooth function of the tool.
Generally retractable pilots are spring loaded in such away that they will be
lifted upwards when they come in contact with the un pierced area during
press descends. Care should be taken while selecting spring so that springs
allow more telescopic movement of the pilot.
METHODS OF PILOTING:
Direct piloting:
It consists of piloting in holes pierced in that area of the strip, which will
become the blank. All pilots decided so for have been direct pilot which are
retained in the blanking punch.
Indirect piloting:
Indirect piloting consist of piercing hole in the scrap area of the strip and
locating in these holes at subsequent operations direct piloting is the preferred
PART CONDITION:
There are seven conditions that required in indirect piloting.
Holes too close to edge of the blank: Distortion can occur in blank
because of enlargement of holes
CHAPTER -14
SIDE CUTTERS
SIDE CUTTERS:
A side cutter is a trimming punch, which trims the side of the stock
material, providing a shoulder. This shoulder is stopped against a hardened
insert provided in the spacer. In small tools the spacer may be fully hardened
to avoid the insert. The width of the side cutter is equal to the pitch. The
allowance for side cutting depends upon the type and thickness of the stock
material. Table gives the allowance for side cutting for different materials.
The size of the side cutter will be more than the pitch by 0.05-0.1 for the
purpose of registry the strip with the pilot. But in case of tools without pilot, the
side cutter is made equal to the pitch. The stop position and registry position
will be the same.
Due to the unbalanced cutting force cutting force acting on the side cutter,
the side cutters are provided with heels. The undercut provided on thee side
cutter eliminates the difficulties of feeding due to thorn formation. Thorns are
small projection, which occurs at the side of the strips due to the punch wear
out. In side cutting there is a tendency of the slugs being coming up with the
punch, causing difficulties in further punching. Slug pushers are used to avoid
this. A standard side cutter shape is shown in the fig.
SIDE CUTTER:
The side cutter is installed in the first position of the tool.this eliminates
extra stops and simplifies both construction and operation of the tool. Usually
the side cutter is located along the front edge of stock strip, because of the
fact that the strip are usually meant to gauge of the tool
Two side cutters, one on each side is used where the number of stages
are more or if pitch is less.
Side cutter
CHAPTER -15
Shedders and ejectors are used when it is not possible to remove the
blanks in the conventional method due to the following reasons.
1. Size of the blank does not allow it to conveniently pass through the
opening in the press bed.
2. Counter of the blank is such that it tends to stick and get distorted
during its travel through the die cavity.
3. Opening in the press bed fitted with die cushion, which will interfere
with the piece part disposal.
4. Close tolerance specified for the flatness of the blank.
5. Tools of Inverted nature.
EJECTORS:
In the conventional position, die is the lower member of the tool.
In inverted tools, Die becomes the upper member of the tool, being
clamped to the press ram. The expulsion of the blank is achieved by forcing
them downwards. This action is generally known as “shedding” and the
element of the tool, which sheds the blanks, is known as the “shedder”.
COMPRESSION SHEDDERS:
Shedders hacked up by compression springs; hard rubbers or disc springs
called compression shedders. Such shedders always tend to return the blank
in to the strip if employed with compression type traveling stripper.
It is obvious that any liquid or oil deposit left on the stock material will
cause the blank to stick to the face of the shedder.
Shedding pins will be more effective if applied to one side of shedder face
rather than in the center.
KNOCKOUTS:
Positive knockouts are classified in to two groups
Direct knockouts
Indirect knockouts
DIRECT KNOCKOUT:
In a knock out system if the knock out rod is directly in contact with the
shedder the system is known as direct knock out system.
INDIRECT KNOCKOUT:
As the passage of the knockout rod is through the shank, any punch which
comes in line with or near to the center line of the shank will obstruct the
knockout rod from coming in direct contact with the shedder. In such cases an
indirect knock out system should be employed.
In addition to the shedder and the knock out rod, it consists of a knock out
plate and transfer pins as shown in the fig. The location and number of
transfer pins depend on the size and shape of the blank.
CHAPTER -16
FASTENERS
FASTENERS:
The subject of fastener is an important one because these components are
applied so frequently and employed in such large quantity. Although small,
they perform important function. In design of tool and dies, fasteners are often
the weakest link in the tool and, if they are not selected and applied correctly,
they can become cause of the entire tool and die.
DIE FASTNERS:
In this exploded view of typical die for producing blank from the strip, all
fasteners have been shown removed from the components, which they locate
and hold. From this drawing it is apparent that fasteners, all though small
individually, from the substantial portion of the entire tool when taken together.
TYPES OF FASTNERS
These are the types of fasteners most commonly used in die construction.
They are
EYEBOLTS:
Eyebolts are used for lifting heavy die sets
or mould housings. It is also called as carrier blots.
NON-THREADED FASTENERS:
This group includes the elements like rivets and cotter pins.
RIVETS:
Rivets are generally used to fasten support
plate of an extension table in press tool.
They are made of MS, aluminium, copper, or brass.
COTTER PIN:
These are used to prevent the loose parts from coming out of holes.
DOWEL:
Dowel holds parts in perfect related alignment
by absorbing side pressure and lateral thrust.
also; they facilitate quick disassembly of
components and reassembly in their exact
former relationship.
REMOVABLE DOWELS:
One type of removable dowel is illustrated
these dowel are used in blind application
CHAPTER -17
Shank is an element of the press tool and acts as connecting link from tool
to the press platen.
Five ways of mounting the shank.
By Riveting
By Press fitting
By means of threading
By making it as integral part of top plate
By making flange fastening
1 2 3
4 5
PRESS RAM
FEMALE COUPLE
MALE COUPLE
Un balanced force on the tool may lead to undue wear on punch and die
as well as pillars.
The resultant forces of all cutting forces acting on many punches should
pass through the shank centre.
The position of the resultant forces of all partially cutting forces can be found
by the following methods
By calculation.
By polygon system (graphical)
By Calculation:
By Polygon System:
Polygon system:
To find the line of the action of resultant then follow the reference below:
CHAPTER -18
DIE SETS
DIE SET:
The following elements are considered before selecting the die set.
1. Make or manufacture,
2. Type,
3. Size,
4. Material,
5. Thickness of the die holder,
6. Type & length of the bushing,
7. Thickness of the punch holder,
8. Length of guidepost,
9. Shank diameter,
10. Grade of precision.
•TOP PLATE:
The upper working member of the die set is called the top plate. The upper
surface of the top plate is bears against the under side of the press ram.
Punch components are fastened to the lower finished surface. The top plate
is generally made out of MS.
PUNCH SHANK:
The punch shank projects above the top plate and it align the centre the
die with the centre line of press. In operation the shank is securely clamp to
the press ram and it drives the punch portion of the die, rising and lowering
the die.
For semi steel die sets, the punch shank is cast integrally with the body of
the top plate and it is then machined. To supplement their holding power of
the shank, cap screws are often inserted upward to engage tapped in the
press ram.
SHANK
BOTTOM PLATE:
The bottom plate is the lower working member of the die sets. Usually the
bottom plate is made thicker than the top plate to compensate the weakening
effect of the slug and blank holes, which must be machined through it.
Generally it is made up of MS.
GUIDE PILLAR:
Guide pillars are precision-ground pins which are press fitted into
accurately bored holes in the bottom plate. They aligns punch & die
components with the high degree of accuracy.
Guide pillars are used for precision die sets are chromium plated to
provide high degree of accuracy of resistance to wear. The addition of
chromium reduces wear up to 50%.
They are specified at least ¼ inch shorter than the shut height.
In initial engagement the jamming of top plate and bottom plate is problem
to avoid this kind of problem non sticking pillars are used. Sticking occurs until
the bushings have engaged the pillars sufficiently for complete alignment.
GUIDE BUSHINGS:
Guide bushings are engaged with the guide pillars for aligning the top
plate with the bottom plate. Most bushings are made up of tool steel they are
also available in bronze.
1. Plain bushing are simple sleeves, pressed into the top plate.
2. Shouldered bushings are turned down at one end and they are
Pressed into the top plate against the shoulder thus formed.
Some die sets are provided with ball bearing. Guide pillars are pressed
into the top plate and thy engage linear ball bearings.
Lubrication is provided by cup greasing and this is sufficient for entire run.
Ball bearings should take more place than conventional guiding and they
reduce die space a small extend.
PILLAR ARRANGEMENT:
Ways of positioning the pillars in a die set.
A. Two pillars are applied at the back of the die sets. This is most
commonly used two pillar arrangement.
B. Pillars are applied at the sides force feeding strip from front to back.
C. The pillars are arranged diagonally.
D. Four pillars are used the foregoing are standard pillar arrangement as
listed in die set catalogue.
Most tools are provided with two guide pillars applied at the back of the
die set because this type gives maximum visibility and accessibility since it is
open on three sides.
There are three most distinct types of back pillar die sets.
2. Long: This type is used for dies, which are long and narrow.
3. Reverse: This type is used for dies, which are relatively longer in
measurement from front to back than their measurement from side to
side.
A and center pillar style as shone in fig B are available in diameters ranging
from 4 to 48 inches.
FOOL PROOFING:
Center pillar and diagonal pillar die set are provided with different diameter
pillars, dimension A and B Thus, the top plate cannot be reversed on the
bottom plate.
RECOMMENDED THICKNESS:
The thickness is illustrated in this example.
E.g. If the die set area for a particular die measures 30 by 20 inches and the
force in tons is less than 30, the values of 1 x 3/4 th inches for C and 2 inches
for D would be selected. However, if the force is in tons were 60, we would
use the values opposite pressure in tons of 50-70,and the value for C would
be 2½ inches and for D3 inches.
CHAPTER -19
COMPOUND TOOL
Compound Tool:
A common characteristic of compound dies is the inverted construction.
The blanking die is on the upper die shoe and blanking die on the lower half.
The pierced slugs pass through the lower die shoe.
Inverted Die:
In this type of die the arrangement of die and punch is reversed and the
punch is mounted on the die shoe with the knockout pins and the combined
pressure pad and the stripper. This type of die is known as inverted die.
The inverted die has the advantages that the cutting edges are kept clear
of chips by the operation of the stripper and ejector.
Fig depicts the shedder relationships at the bottom of the press stroke
Therefore A = E +T
D=E+T+A+ 2½ T minimum
In this fig E, the transfer pins are assembled by pinning them in the pin
plate.
In view A the pin plate and knockout rod are also fitted together and secured
by pining. This method is for light duty, where the knockout forces are evenly
distributed and balanced in relation to the shedder counter. The knockout
assembly shown in view B is stringer, since knockout rod is welded to pin
plate.
In this fig the knockout shaft is threaded in the shedder and secured by a
lock nut. Two lock nut are jam tightened on the shaft, stopping the shedder
travel.
In fig I the stripper strips either the work piece or the stock material from the
punch. A spider type bridge plate 02 is shown. It operates within a suitably
countered recess, which is milled in the punch holder. In this case the transfer
pin is a threaded stud secured with lock nuts to maintain the spacing between
the stripper 04 and spider.
H= 2W minimum
For light gauge materials two or more shedding pins should be installed in
the shedder. The springs must be strong. If they are, or if the shedding pin
location are not balanced the blank may be pushed through the stock strip L
CHAPTER -20
PROGRESSIVE TOOL
PROGRESSIVE TOOL:
In a progressive tool strip is moved in stages from station to station.
Different operations are performed on it at each station except idle stage. A
complete strip is removed at the final stage. Progressive tool may be
considered as series of tools placed side by side with the strip passing
through each successively. Before designing the tool the piece part may be
studied carefully. This is to plan the operation to be carried out in different
stations. For this process strip lay out is made.
1. Feed direction.
2. Pitch maintained.
3. Position of stopper.
4. Width of the strip.
5. Scrap bridge.
The method employed in laying out the strip influences the economic
success. The strip lay out is such that maximum area of strip is utilized for the
production of the stamping.
The tool shown in figure the finish part is produced through three stations.
The strip is stopped at the first station by the auxiliary stopper, and 2 holes are
pierced.
In second station the pilot enters into the holes. In third station the piece
part is blanked and pierced component is obtained.
The solid margin around the die is 1.2 times the sheet thickness.
Margin between 2 blanks, strip edges should be adequate.
The shank should be loaded at the centre of the press.
Scrap disposal should be provided.
For precision pilots must be provided.
The tonnage, table area, ram face area must bead equate.
PILOTS:
The blanking punch is fitted with pilot for
accurate centralization of the piercing hole.
Pilots can be spring loaded with a grub
screw for adjusting the spring compression.
Generally the trigger stopper of blanking tool
with pilots is adjusted in such away that the
strip is fed about 0.1mm more than the pitch.
This allows the strip to move freely towards
left as the pilot centralizes the pierced holes.
SCRAP DISPOSAL:
In progressive tools the scrap is spread in a wider area. The shank must be
placed in such a way that all the scrap falling through the die has got clear
passage through the press table.
In this tool the strip fed is stopped by auxiliary stopper in first stage. In
second stage a hole is pierced. IN next stage piloting is done, and in fourth
stage the punch blank the strip & piece part is obtained. In this tool the
punches should be spaced widely to provide healthy margin.
STAGE STOPS:
When a new strip is taken, the first stage stop is pushed against the spring
end is held against the stage stop to pierce one central hole in the strip. In
second stage the strip is fed to second stage stop, which too must be held,
pressed against the spring during the second stage feeding. Stage stopper
stops the strip at each station of the tool.
PILOTING WORK PIECE WITHOUT HOLES:
If the work piece has got no holes additional pilot holes can be provided to
utilize the strip area. The additional holes are also provided in the case where
the accuracy requirements are high, or the holes are very smaller in diameter.
In such cases the pilots are provided on the scrap bridge or where the
adequate space is available accept blanking area.
BLANKING AREA
PIERCING
PILOTING
Figure shows progressive tool for a pointer. Blanking punch for this
component is rather difficult. It is more convenient to sacrifice the strip
material and make sturdy punches and dies. The utilizes less than 1/3 rd of
the raw material but runs trouble free.
The side cutting stop controls the pitch during feeding. The side cutting
stop uses two punches that sheared the strip width accurately. The width of
the side cutting stop is equal to the pitch. The side cutting punches have a
step. The non-cutting rear side of the punch is made longer than the cutting
side so that it engages with the die cut out before the punch commences
cutting.
SIDE CUTTER
PRIMARY STRIP
SECONDARY
STRIP
CHAPTER -21
SHAVING
SHAVING:
SHAVING CLEARANCE:
The cutting clearance in shaving operation may be practically non-existent.
It is common practice to use close fit between punch and die with minimum
clearance possible. However in the case of larger shaving allowance a cutting
clearance of 5% of shaving allowance will be acceptable.
Tmax =60N/mm².
Shaving allowance of M.S.
In single stage A =C+0.04s.
C = 0.005 x 2 x√360/10.
=0.06/side.
A =0.06 x 0.04 x2
=0.14/side.
CHAPTER -22
BENDING
PRINCIPLES OF BENDING:
The principle of bending involves.
Neutral Plane:
The neutral plane is theoretical plane originated by inherent bending
stresses. The Neutral plane accurs at a distance of 0.33 to 0.5 S, from the
inner surface.
Bend Angle:
The bend angle is the angle included between the two extreme positions of
the bend radius. It originates at the bend axis.
BEND ELEMENTS:
T
- 0.5
3T
0.3
BEND AXIS
T
90°
BEND LINES
90
OUTER SURFACE °
R
INNER SURFACE
LENGTH:
Formula for Calculating:
Where,
Lo = Original Length
Ri = Internal radius
ξ = correction factor [to be chosen from graph]
Note; If the value of (ri/s) exceeds r in the graph length of the strip should be
calculated by using center fibre formula.
y = SE (2 ri + S)
i.e, 2 Rmax. + S = (SE / y) – S
Rmax = (SE 2y) – (S 2)
In this case S/2 can be neglected comparing to the value of Rmax.
Therefore, Rmax = SE / 2y
• There is also a limit for bend radius on minimum side. If the bend radius compared
with the thickness of the sheet is below certain, the stress in the outside fibre
exceedes the ultimate tensile stress therefore rupture occurs.
• Rmin = C S
4. Copper 0.27
5. German Silver 0.45
6. Brass 0.4
7. Aluminium hard 0.4
8. Aluminium pure 0.7
9. Aluminium half hard 1.4
10. Gun Metal 1.2
11. Stainless Steel 0.5
12. Brass 0.3
BENDING FORCE:
FOR ‘V’ BENDING DIES
Bending Force = [ C bs² ] W
Where,
C is a constant
b = width
s = sheet thickness
W = width of the Die
The value of constant ‘C’ can be takes from the graph or can be calculated
using the formula,
C = 1 +[ (4S)/W]
[ The formula can be used up to W=20 S]
BENDING FORCE:
FOR ‘U’ BENDING DIES
Bending Force, Fb = [ C bs² ] W
But instead of W, two times the Distance of point of contact of punch and
die is considered.
Thus, W= 2(R1 + cb + R2)
Bending Force = [{ C bs² } W] [2(R1+ cb + R2)]
Where,
C= Constant
B= width of the bend
S= Sheet thickness
= Ultimate tensile stress
R1 = Die Radius
Cb = Bending clearance
R2 = Punch radius ICDP TECHNICAL TRAINING CENTER
EIGEN ENGINEERING
Over Bending
Corner Setting
Offset Punch Method
Angular Punch Relief
This is the most effective way of avoiding the spring back. This is a method
of eliminating spring back than making compensating allowances.
Using convex pad Punch side wall relif- angular straight undercut
OVER BENDING:
This causes excessive wear in the die members. If the piece part is
loaded such that burr is located on the inner surface of the formed piece part,
the burr will face towards the punch.
Since there is no drag between the work piece and the punch, burr cannot
erode the punch.
Hook Stripper:
BENDING DIES:
‘V’ Bending Dies
‘U’ Bending Dies
Multiple Bending Dies
L’ Bending Dies
HARD:
Avery stiff; springy, cold rolled strips intended for flat work, where ability to
withstand cold forming is not required.
HALF HARD:
QUARTER HARD:
SOFT:
A soft, ductile cold rolled strip suitable for fairly deep drawing operations
where surface disturbances such as stretcher strains are objectionable. Strip
of this temper is capable of being bent flat upon it self in any direction.
DEAD SOFT:
A soft ductile, cold rolled strip produced without definite control of stretcher
and fluting it is suitable for difficult draw applications where such surface
disturbances may be tolerated. It is suitable for bending flat upon itself in any
direction.
CHAPTER -23
DEEP DRAWING
DEEP DRAWING:
Drawing is a process of cold forming and flat precut metal blank into a
hollow vessel.
The volume and the thickness of the material of the metal remain
essentially constant and final shape of the component will be similar to the
contour of the punch.
The relationship between the diameters and depth of the drawn sheets
vary widely and relationship is an important factor in the design of the drawing
dies.
If the drawing ratio exceeds a certain limit the material will fail due to
excessive stresses.
Compression
Circumferential
Radial
tension
Blank Holding
Friction
Tension
Bendi
ng
METAL FLOW DURING DRAWING CYLINDRICAL
CUPS:
PUCKERING:
BLANK DEVELOPMENT:
(FOR CYLINDRCAL SHELLS)
WHY BLANK DEVELOPMENT?
The development to approximate blank size should be done to.
Determine the size of the blank to produce the shell to required depth.
Various methods have been developed to determine the size of the blank of
the draw shell.
METHODS:
Algebraic calculation.
Simple graphical method
A combination layout and mathematics.
ALGEBRAIC METHOD:
The following equations may be used to calculate the blank size for
cylindrical shells of relatively thin metal. The ratio of shell diameter to corner
radius can effect the diameter and should be taken into consideration. The
cylindrical shells can be considered as consisting of circular pipes or disc.
A= Lp + g
The center of gravity point in this method can be found out graphically or
can be calculated arithmetically.
(pD²)÷4 = L1+ L2 +L3 ……………………(2p X)
pD² = L1+ L2 +L3 ……………………(2p X)×4
D² = L1+ L2 +L3 ……………………(2p X) ×4
D = √ {(L1+ L2 +L3) 8X}
Area = length of the profile X length of the path of the center of the gravity.
CLEARANCE:
1. The clearance between the punch and the die must be greater than the
thickness of the material to be drawn.
2. Too large clearance will result in wrinkled and
3. Too small clearance will result in tearing of the component.
The formula will help to calculate the clearance for draw dies.
For deep drawing quality steel, = s + (0.07 × √ (10s)
Aluminium,………………….. = s + (0.02 × √ (10s)
The table also provides guidelines for determining the above clearance.
The nose radius and side walls of the punch should be polished with
vertical stroked especially when drawing soft materials to eliminate any cross
packets in which the metal flow and cause fracture when the is stripped from
the punch.
DRAWING FORCE:
Drawing Force can be calculated the Percentage shearing force. The
percentage depends on the draw ratio d/D or ‘m’
F = d × Su ×A
d = diameter of the cup in mm
S = thickness of the material in mm
Su = ultimate strength in N/mm²
A = constant
Values of a:
PRESS CAPACITY:
The blank holding force can be calculated by multiplying the value by blank
holding area.
CALCULATION:
The formula will help to calculate the clearance for draw dies.
For deep drawing quality steel, = s + (0.07 × √ (10s)
Aluminium, = s + (0.02 × √ (10s)
Non ferrous = s + (0.04 × √ (10s)
DRAW BEEDS:
One of the functions of the draw beed in a blank holder is to provide
additional resistance to metal flow, thus helping to control the movement of
metal into the die cavity.
AIRVENT:
An air vent should be provided in the punch and the die to eliminate air
pockets, which tend to collapse the cup when stripped from the die. On non-
cylindrical shapes two or more air vents are provided. To prevent plugging of
the air vents with the drawing compound and dirt they must be placed in such
apposition that they can be easily cleaned.
LUBRICATION:
Necessary due to the higher frictional forces between the punch &
sheet metal, die & sheet metal.
The purpose of the lubricant is to provide a film between the work piece
and the punch and the die
QUALITIES of LUBRICANTS:
The film must be strong enough to permit metal deformation without being
squeezed from the surface. Table gives various compositions for press
lubricants for stamping and drawing.
LUBRICANTS:
For Normal Draws:
Bottom of the drawn cup is torn if the D/d ratio is too large. Increasing
the number of stages or the using the steels with better drawing quality
will result in successful draw.
Tearing at the bottom corners occurs at the bottom of the shells if the
sheet thickness is not uniform, the draw clearance is less. Increasing
the draw clearance is the remedial action.
Bulges will occur if the draw clearance is more. Increasing the blank
holding pressure will help in controlling the defect.
CHAPTER -24
PRESSES
PRESSES:
PARTS OF PRESSES:
CAPACITY OF PRESS:
The rated capacity of press is the force, which the slide will exert near the
bottom of the stroke.
PRESS BED:
Press bed serves as table to which the bolster plate or the lower tool
assembly is mounted.
PRESS SLIDE
It is the reciprocating member of the press. It is guided in the press frame.
The upper tool member is called plunger slide. On a Hydraulic press it is
called as platen.
PLUNGER SLIDE
The inner slide of double action is called plunger slide. In a double action
press the punch is mounted on this slide.
BOLSTER PLATE
It is the plate secured to the press bed for locating and supporting the tool.
PITMAN
Pitman is the connecting rod, which conveys power and motion for the
main shaft to the press slide.
CLUTCH
It is the coupling used to connect or disconnect the driving machine
member to or from driven machine member in a press it connects or
disconnects the flywheel to the main shaft.
1. Positive clutches in which driven and driving members of the clutch are
inter touched in engagement. . Eddy current clutches.
2. Friction clutches
STROKE:
The stroke of the press is the reciprocating motion of the press slide. It is
the distance between terminal points of motion.
SHUT HEIGHT:
It is the distance from the top of the bed to the bottom of the slide with the
stroke down and the adjustment up.
DIE SPACE:
Die space is the area available for mounting tools in the press.
CLASSIFICATION OF PRESSES:
Presses are classified by following characteristics.
Source of power.
Number of slides.
Frame types.
Intended use.
SOURCES OF POWER:
The press is powered by one of the following sources,
1. Manual
2. Mechanical
3. Hydraulic
4. Pneumatic
1.MANUAL:
The presses are hand or foot operated through levers, screws, or gears.
2.MECHANICAL:
4.PNEUMATIC PRESSES
POWER PRESS:
The constructional feature of a power press is almost similar to the hand
press, the ram instead of driven by hand is driven by power. (Ie: mechanical
or hydraulic)
GAP PRESS:
It has a Gap like opening in the frame for feeding the sheet metal from one
side of the press.
INCLINED PRESS:
The characteristics of inclinable press is its ability to tilt back on its base,
permitting the scrap or finished products to be discharged from the gravity
without the aid of any type of handling mechanism.
ADJUSTABLE BED PRESS:
It has the mechanical arrangement for raising or lowering the table on
which the die is fitted. This enables the setting of different sizes of work and
dies on the machine.
HORN PRESS:
It has a cylindrical horn like projection from the machine frame, which
serves as the dies support. The horn may be interchanged for the different
sizes of work. The press is intended for cylindrical work pieces.
STRAIGHT SIDE PRESS:
It has two vertical rigid frames mounted on two sides of the base, which
are intended for absorbing severe load exerted by the ram. The machine is
suitable for heavy work but due to presence of side frames, the sheet metal
cannot be fed from the side.
PILLAR PRESS:
It is a hydraulic press having four pillars mounted on the base. The pillars
support and guide the ram.
POWER PRESS DRIVING MECHANISM:
1. Crank and connecting rod drive.
2. Eccentric drive.
3. Knuckle joint.
4. Cam drive.
5. Toggle leaver.
6. Screw drive.
7. Rack and Pinion drive.
8. Hydraulic drive
ECCENTRIC DRIVE:
It is used in presses for shorter length of stroke of the ram. The working is
simpler to crank and connecting rod mechanism.
CAM DRIVE:
It is used to give a specific type of movement to the ram the ram remains
idle for some period at the bottom of the stroke.
SCREW DRIVE:
PRESS SIZE:
The size of the press is designated by its maximum applying load on a
piece of blank and it is expressed in tonnes. The mechanical presses are built
having capacities ranges from 5 to 4000 tonnes.
PRESS SELECTION:
The first & foremost consideration for choosing a press is the tonnage
required for the operation of tool, similarly the table size, throat, stroke & shut
height of the press should be suit the press tool.
CHAPTER -25
TOOL FAILURE
ICDP TECHNICAL TRAINING CENTER
EIGEN ENGINEERING
TOOL FAILURE:
1. The stamping
2. The tool
3. The press
4. The operation
PRESS SELECTION:
CUTTING SPEED:
The temperatures reached during high-speed cutting processes do not
impair the hardness of the cutting edges.
DIE SETTING:
The proper setting of the tool in press is of utmost importance. If the
alignment is not correct, excess friction and certain dangerous lateral stress
are produced which causes premature wear of the tool member.
SHARPENING OF PUNCHES:
The punches are subjected to wear three times as fast as the die plates.
The stock clings to punch slides like press fit.
1. Do not employ the same kind of tool steel for cutting members, punch
and die plates.
2. Make the punch longer than strictly necessary and sharpen them more
frequently than the corresponding die-plates.
After sharpening a die plate or a punch, remove the feather with a fine
oilstone. It is surprising what a favorable influence this little precaution has on
the useful duration of the dies. A fringe benefit of this consists of improved
surface finish of the cut surfaces.
BREAKAGE OF DIE-PLATES:
During the operation of the operation of the tool the following details may
be directly or indirectly cause the die plate failures.
Very dull cutting edges means overloading causes spoiling and breaking of
die plates.
The cause for wear in a drawing die is the continuous friction between the
stock and the tool members.
The die ring can be polished after which its dimensions are enlarged
beyond the tolerance limits.
PRESS SELECTION:
Every press at the instant of impact deflects somewhat misaligning the
punch a little. If the deflection is too pronounced, then the misalignment
becomes too great so that uneven wear is produced and thus tool life is
greatly reduced. By reducing the drawing speed the tool life is somewhat
increased.
STOCK:
The stock should be clean, without scale, oxidation, or rust. The sheet
metal must be perfectly uniform in texture, hardness, thickness, surface finish,
etc.
STOCK LUBRICATION:
In drawing operations, lubrication creates a film between the stock and the
tool members, thus allowing the stock to slip easily between the active tool
members. In this way the friction between the working surfaces of the tool and
the stock that is being produced is reduced and the heat produced by the
operation is greatly decreased.
PRESS ROOM:
The cleaning of the tool in order to avoid accumulation of dirt, chips, and
foreign matter, which when mixed with lubricant, act as an abrasive and
considerably increase tool wear.
SLUG PULLING:
Slug pulling is the return of slugs above the die plate.
TOOL SETTING:
The tool must be located on the bolster plate or the press table that the
slugs have an absolutely pre discharge path, i.e. all the clearance holes of the
plates and die shoes, must have correctly positioned discharge holes of the
right size.
MAGNETISED PUNCHES:
Punches some times become magnetized, either while being sharpened
or punching action. This causes increase in damage of slug fitting, so always
demagnetize the punches after resharpening and whenever they have
become magnetized naturally.
PREVENTIVE METHODS:
Put a piece of heavy paper or cardboard between the die bottom and
bolster plate: and between the punch holder top and the ram bottom face.
Then in case of jamming, burn out the paper.
MAGNETISED STAMPINGS:
PREVENTION:
STAMPINGS:
Avoid the magnetic lifters for handling stock; use hook lifters instead; if
possible change the type of steel with less carbon content or alloying
elements.
TOOLS:
PRESSES:
For press construction use mild steel that is magnetically “soft” and have
low hysterias.
REMEDIES:
Demagnetizing the stampings, tools and press components.
PITCH PUNCH
PITCH 14,5
NOTCHING
NOTCHING
IDLE
0.08mm
45 DEG BEND
FORM UP
IDLE
COINING DOWN
FORM UP
90 DEG
NOTCHING
COINING
NOTCHING
FLAT
PART OFF
Component
P1
BP
P2
P1
P1 CP1
PL1
P1
Width-16mm
Stage-1
piercing
Stage-2
Sidecutting
Stage-3 Pitch-6,5mm
Piercing
Stage-4
Piercing
Stage-5
Idle
Stage-6
Forming
Stage-7
Idle
Stage-8
Bending
Stage-9
Corner Setting
Stage-10
Idle
Stage-11
Forming
Stage-12
Idle
Stage-13
PartOf
PIERCING
01 STATION
11
COMPONENT DEG
PITCH
PILOTING
02 STATION
NOTCHING
03 STATION
IDLE
04 STATION
NOTCHING
05 STATION
IDLE
06 STATION
TRIM
07 STATION
IDLE
08 STATION
PRE
FORM
09 STATION
RES
10 STATION
FINAL
FORM
11 STATION
RES
12 STATION
BLANK
Reference Books