10/30/2015

Gettooledup:NOTESTOGUIDETHEDESIGNERONPRESSTOOLDESIGN
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Gettooledup
tellmewhateveruneedtotooledup

Friday,October22,2010

AboutMe
GokulanathanT
Chennai,Tamilnadu,India

NOTESTOGUIDETHEDESIGNERONPRESSTOOLDESIGN
1.Thesenotes'aretoguidethedesigner,todesignapracticalpresstool,togetan
acceptablecomponentfromthetoolandareveryvaluablepoints,toproduceaperfect
tooldesigndrawing.
2.Thepresstooldesignershouldkeepthesepointsinmindorshouldrefertothese
notes,beforestartingafreshpresstooldesign.
3.Dependinguponthetypeofpresstool,tobedesignedfortheparticular
operation/stageofthecomponents,thedesignershallapplytherelevantpointsofthese
notes.
4.Thesenotesaregroupedunderthefollowingheadingsofthetooldesign..
A.Mostimportantpressdimensionstobeconsidered,
B.Miscellaneousnotestothedesigner,
C.Planningandlayout,
D.PunchesandDies,
E.Cuttingclearance,
F.Shearingandshear,
G.Locatingofwork,
H.Sheddersandstrippers,
J.Progressiveandautomatictools,
K.Compoundandcombinationtools,
L.Forminganddrawingtools,
M.Toolmaterialsandcraftsmanship,
N.Dietryoutandoperation.
A.MOSTIMPORTANTPRESSDIMENSIONSTOBECONSIDERED:
5.Beforestartingatooldesign,thedesignershouldknowthespecificationsofthepress
onwhichthetoolshallbeusedduringtheproductionrun.Thefollowingfactorsofthe
pressspecificationmustbeconsidered:
5.1SHUTHEIGHTWITH/WITHOUTBOLSTERANDBOLSTERPLATE
THICKNESS,
5.2ROLLFEEDHEIGHT,
5.3SHANKDIAMETERANDLENGTH,
5.4HOLEINPRESSBED/BOLSTER(WIDTHANDLENGTH),
5.5STROKELENGTHANDITSSTEPSDETAILSLIKEFIXEDORADJUSTABLE
STROKE,
5.6DOESGATEGOUPINTOTHEWAYS?GATETOPRAM,
5.7IFTHEGATEGOUPINTOTHEWAYS,CHECKTHEOPENINGBETWEEN
THEWAYS,

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MYcontents
2008(4)
2009(21)
2010(3)
October(2)
Hyperthreadinginautocad
NOTESTOGUIDETHEDESIGNER
ONPRESSTOOLDESIGN
November(1)
2011(1)
2012(2)

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5.8WHICHWAYSHOULDDIEFEED?
5.9TONNAGEOFTHEPRESS,
5.10ADDITIONALHOLESFORCLAMPINGPUNCHHOLDERTOTHETOPRAM
(GATE),
5.11TAPPEDHOLECENTERSINPRESSBOLSTERTEESLOTPOSITIONS
ANDITSSIZE,
5.12THEDISTANCEABOVETHEBOTTOMOFTHESTROKEWHERETHE
PRESSUREFIRSTOCCURS,
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Gettooledup:NOTESTOGUIDETHEDESIGNERONPRESSTOOLDESIGN

5.13ANYADDITIONALPRESSUREREQUIREDDUETOATTACHMENTSSUCH
ASTHEBLANK
HOLDER,IRONINGWRINKLESORSTRETCHINGTHEMATERIALINDRAWN
WORK,

5.14DIECUSHIONDETAILSANDITSMOUNTINGPOSITIONS.PRESSURE
TRANSFERPINSPOSITIONSINTHEBED/BOLSTER.
B.MISCELLANEOUSNOTESTOTHEDESIGNER:
6.SHOULDPARTBEMADEPROGRESSIVEORCOMPOUNDThisshouldbe
givendueconsiderationbeforeproceedingwiththedielayout.Ingeneral,precision
stampingscanbemademoreaccuratelyincompounddies.
7.LAYOUTCORRECTFORBURRSIDEmanystampingshavearightburrside,
whichthepartprintmaynotspecify.Thispointshouldbecheckedbeforestartingthe
dielayout.
8.STARTINGANDAUTOMATICSTOPSCareshouldbetakeninestablishingthe
positionofstartingstopstoavoidcuttinghalfslugsorblanks.
9.BACKINGUPPUNCHESWITHSIDESTRAINPunchescuttingononesideonly
shouldbeheeled,theheelenteringthedieforsupportbeforeanycuttingtakesplace.
Thesameconditionmayarisewithformingorshavingorbendingpunches.Shavingon
onesideonlyshouldbeavoidedandaformingpunch,whichhasallthepressureon
oneside,mustbebackedupsolidinsomemanner.Dowelsasarule,arenotsufficient.

10.INDICATECLASSOFWORKMANSHIPSomeworkingsurfacescanbeleftas
theycomefromfurnaceormachineandsomeshouldbegroundandsomelappedor
stoned.Thedesignershouldindicatewhatisrequired.
11.SELECTIONOFPROPERSTEELSTodaytherearesteelsforeverypurpose
andsomethoughtshouldbegiventowhatisexpectedofthedie,whatmaterialisbeing
punchedorformedandchoosethebestmaterialfortheparticularjob.
12.SPRINGSTRIPPERS:Makethespringstripperofamplewidthandlengthto
provideroomforadditionalspringsifnecessary.Alsomakeitthickenoughtoproperly
takecareofthestripperboltswhichsometimesloosenup.Ifsomeofthepunchesare
tobeguidedinthestripper,itmustbesupportedonguideposts/pillarsandaccurately
heldinline.Whenpunchesarenotguidedinthestripper,ampleclearancemustbe
allowedaroundallthesmallerpunchestoavoidthepossibilityoftheirbeingthrownout
ofline.Iftheyareoneortwogoodsturdypunchesinthedie,fitthestrippercloseto
thesepunches(0.001"toO.005"clearance)andallow0.010"to0.015"clearanceon
thesmallerpunches.
13.HIGHNESTSFORHANDFEDSECONDOPERATION:Ifpossible,make
locatingnests3to4timestheblankthicknesswiththetopwellroundedtoreceivethe
part.Theproperconditionherewillincreaseproduction10%to25%.
14.PROVISIONFORWEARONFORMINGTOOLS:Someformingdieswearfast
fromtheabrasionactionandusuallyprovisioncanbemadetoadjustorreplacethis
portionatlittle,ifany,addedcost.
15.STRIPPERWELLDOWELLED:Insomedies,thestripperisdependeduponto
doalotofheavyguidinganditiseasytooverlooktheimportanceoflargedowelsto
keepthestripperfromshifting.

16.INDICATEHARDNESS:Havingeachparttheproperhardnessisimportant.Frail
partsmustbedrawnbackperhapstoRockwell55Candotherpartspossiblyshouldbe
leftashighas65C."
17.CONSIDERLENGTHOFPILOTS:pilotsmustbelongenoughtoaccurately
locatethestripbeforeanypunchstartscuttingortrimmingorformingotherwisetheir
purposeisdefeated.

http://etooling.blogspot.in/2010/10/notestoguidedesigneronpresstool.html

GokulSays
Forthethingswehavetolearn
beforewecandothem,welearnby
doingthem.

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Gettooledup:NOTESTOGUIDETHEDESIGNERONPRESSTOOLDESIGN

18.STAMPTHEFEEDDISTANCEONTHEDIE:Thisdimensionshouldbeplainly
stampedonrollfeedjobstosavethesetupmanthetroubleofcheckingitup.
19.GIVEINSTRUCTIONONTHEASSEMBLYDRAWINGTOSTAMPTHE
FOLLOWINGDETAILS:Thesedetailsshouldbestampedonthetoolbolsterplate,to
assistthetoolshoppersonneltomaintainthetoolandforeasyfollowupofthe
production.
19.1TOOLORDERNUMBER
19.2COMPONENTNAMEANDDRGNUMBER,
19.3MATERIAL,STRIPWIDTH,
19.4SHEETTHICKNESSANDTOLERANCE,
19.5CLEARANCE,
19.6REQUIREDTONNAGE,
19.7DETAILSOFPRESSONWHICHTHETOOLSHALLBELOAD
19.8TOOLDESIGNDRAWINGNUMBER,
19.9SHUTHEIGHTOFTHETOOL,
19.10ROLLFEEDHEIGHT,
19.11PITCHOFSTAGEFORPROGTOOL.
20.Alwayscheckthediedrawingswithpartprintstomakecertainthatthetoolwill
producethepartcorrectly,relationofgraindirectiontoforms,shearforms,
embossments,spurredholes,blankingpressurerequiredandstrengthoffragile
projections.
21.Dimensionthedetaildrawingwithinformationintheformrequiredbythetoolmaker,
sothathehasaminimumamountoftranslationtodo,inunderstandingthetooldesign
drawing.
22.Assoonasthedesignofadieisdecideduponordermaterial/arrangetoissuethe
materialdetailstoplanning,sothattherearenounnecessarydelay.Ordertryout
materialatthesametime.
23.Alwaysconfirmtocustomers/company'sspecificationforthetypeoftool
construction,kindofsteel,diesetstandardifpossibleandstandardizedsizesofdie
sets.
24.Wheneverpossible,specifythestandardpartsaspertheinternational
nomenclature/standardsandotherpartsofthetoolshouldbereferredasperthe
standardnomenclaturefollowedinnational/internationalstandardsfortools.
25.Designalltoolpartssoastobeeasilyremovablewithminimumofdisassembly.
26.Considerinthedesign,thesafetyandtherelationofefficiencytofatigueofthe
pressoperator.

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27.Ondetaildrawingsvitallyimportantworkingdimensionsmustnotminglewithless
importantdetailslikelocationofscrews,springholes,dowelsetc.
C.PLANNINGANDLAYOUT:
28.Alwaysdetermineifamoresatisfactorydesigncanbeobtainedbytheuseofan
invertedtool.
29.Draw/Drawingtoolsareusuallyinverted.
30.Theblankusuallyfollowstheshapeofthepunch.
31.Onablankingtool,theburristowardsthepunchi.e.theclearanceshallbegivento
punchdimensioninthecaseofablankingtool.
32.Burrsfrompiercingandcontouringareonthesamesideoftheblanktakenfroma
compoundtool.
33.Inprogressivetools,theburrsofthepiercingandtheblankprofileareonthe
oppositesides.
34.Acompoundpiercingandblankingtypeoftoolisusuallytobepreferabletoa
progressivetypetoolforthesameoperation.
35.Ifthepartdrawingofablankcallsforacloseflatness,itispreferabletodesignan
invertedblankingtoolinsteadofaconventionaldesign.
http://etooling.blogspot.in/2010/10/notestoguidedesigneronpresstool.html

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Gettooledup:NOTESTOGUIDETHEDESIGNERONPRESSTOOLDESIGN

36.Oncomplicatedformsalwaysuseatemplatetocheckthepartsandthelayoutof
thepunchanddie.
37.Itisoftengoodpracticetouseashavingtoolafterablankingtooloperationon
heavystocktogetclear,sharpedgesandtoholdclosetoleranceandtogetperfect
rightangleedgethroughoutthethicknessofthe'sheet.
38.Shavingtoolsasthenameimplies,areusedtoremovethedierollorroughedges
causedbytheshearfractureorbreakthroughcharacteristicsinblankingtools.Ineffect,
theshavingtoolactionisatrimmingorsquaringupaction.Shavingtoolsaresimilarto
blankingorpiercingtools,exceptlittleornoclearanceisleftbetweenthepunchanddie.
Usuallynoshearisaddedtoeitherthepunchorthedie.Oftenitisnecessarytoshave
ablankonlyatimportantfunctionalareas.

39.Theamountofmetaltoberemovedbyashavingoperationisproportionaltothe
blankthicknessandvarieswiththestock.From8to10%ofthethicknessofmildsteel
stockisagoodaverage.Fortwoshavingallow10%andtakeoff2/3withthefirstand
1/3withsecondoperation.
40.SHAVINGDIRECTION:1'hecuttingdirectionforashavingoperationshouldbethe
sameasthecuttingdirectionofthepreviouscuttingoperationi.e.forshavingablank
profile,theburrsideoftheblankshouldfacetheshavingpunch.
41.STRIPPINGINSHAVING:Becertainthatstrippingprovisionsareadequate.The
amountofstrippingforcerequiredinshavingoperationmaybedoubleoreventriplethe
forcerequiredforequivalentblankingorpiercingtypeofcuttingoperation.
42.Whenthethicknessofthestockismorethan3mm,itispreferabletohavemore
thanonesharingoperation.TheNo.Ofshavingoperationalsodependsontheprofile
tobeshavedandthecleanlinessofthecutbandandtheneededaccuracyoftheprofile
ofcomponent.
43.CLEARANCEBEFORESHAVING:cuttingclearanceforthepriorcutting
operation(beforeshavingoperation)shouldbemadeatleastnormalorlargerthan
normalifnecessary.Mostcommonerroristousetoolittlecuttingclearanceforthose
cuttingoperation,whichprecedeshavingoperation.
44.CLEARANCEINSHAVING:Cuttingclearanceforshavingdiesmaybepractically
nonexistent.Itiscommonpracticetousefitsbetweenpunchesanddieopeningwhich
areascloseaspossiblewithoutinterference.However,incaseswheretheshave
allowanceisquitelarge,acuttingclearance(inshaving)equalto5percentoftheshave
allowancewillbegenerallyacceptable.
45.ALLOWANCEFORSHAVING:Thewidthofthescrapwebremovedbythe
shavingoperationistheshaveallowance.
AShaveallowanceforthefirstshaveorforsingleshaveoperation
A1Shaveallowanceforsecondshaveoperation
TStockmaterialthickness
Ccuttingclearanceusedforpreviouscuttingoperation(priortoshaving)

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CalorieCalculator

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ForsteelA=C+OO4TA=o.075mmmini
Al=c/2Al=o.035mmmini
ForBrass,Copper,Germansilver
A=2cA=o.075mmmini
Al=CAl=o.035mmmini.
46.RECOMMENDEDSHAVINGCLEARANCE:
Firstshavingclearance=5%offirstshavingallowance
Firstshavingallowance=A=c+o.04T
TStockthickness
CPiercingorblankingclearancein%ofsheetthicknesspriortoshaving.
Secondshavingallowance=Al=c/2

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Secondshavingclearance=5%ofsecondshavingallowance.
47.PINCHTRIMMING:Pinchtrimming(shouldbedone)canbeattempted,whenthe
sheetthicknessofthematerialislessthan1.5mm(1/16)

48.DRAWINGOFSHEETS:Indrawingofsheets,theblanksholderpressureis
normallyconsideredbetween10to20%ofthedrawingload.
49.DRAWINGPRESSURE:Tofindoutthedrawingpressureindrawtools,the
formulais:
=(Yieldpoints+ultimatetensilestrength)crosssectionalarea
2
50.DRAWINGSPEED:Drawingspeedshalldependonthematerialthatistobe
drawn.Normally30feetperminuteisconsideredforsteelmaterial.Forbrassmaterial
thedrawspeedcanbelittlemorei.e.40feetperminutedrawspeedcanbe
considered.
51.HARDENEDBACKPLATE:Whenthecompressivestressofthepunch(behind
theshoulderofpunch)onthetopbolsterplateincreasesbeyond24.5kg/mm2(35000
psi),thedesignershouldprovidea(52RC)hardenedbackplatebehindthepunch
holder.Keepaminimumof6mmthickbackplate.
52.SPRINGACTUATEDSTRIPPERS:Ifthestockorstripisthin(lessthan0.5mm),it
isgoodpracticetousemovablestrippers(springactuatedfloatingstripper)which
simultaneouslyactasablankholderthatfirmlygripthestockorstripduringcutting.This
especiallytrue,whenthecuttingcontour(profile)isirregular.
53.BACKTAPERINDIE:Forthinstriporstock,abacktaperof1/20rightfromthedie
surface,hasbeenfoundtogivegoodresults.Thecuttingangle'B'isthenlargeenough
toallowsufficientresharpeningwithoutappreciablechangeinsizeoftheblank.

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