STEP BY STEP TROUBLESHOOTING OF DIES “IN PRESS”

1_ Identify Part Problems:

Identifying part problems is usually fairly easy. These can include splitting, cracking, nonconforming part
geometry, wrinkling, loose metal, undertrained parts, excessive burrs, scratches, dents, slug depressions,
and core marks. The person inspecting the part needs to have a clear understanding of each type of
failure and be able to communicate it clearly to the person responsible for correcting the problem. Is it a
fault of the die or an outside source?
2_ Verify that the die is set up properly:
Very often stampers make major changes to a die, only to find out the die was not set up correctly in the
first place. Here a few basic things to check:
A_ Verify the die shut hight, stop block lead readings, and press tonnage readings.
If you are using bottom makers, verify that they are visible and to the correct depth in the part and/or
scrap.
B_ Make sure the die is tight against the positive location stops and is parallel to the coil.
C_ Verify that the lubricant application method is correct, ensure the die and metal are getting lubricated
as necessary, and make sure all sprayers and rollers are working properly.
D_ Check the thickness, width, and metal mechanical properties of the incoming coil.
E_ Verify the pilot and feed release timing progressive dies.
F_ Make sure the feed distance (pitch) is set correctly.
G_ Ensure that pressure systems, such as nitrogen systems, press cushions, and hydraulic pressure
systems, are charged to the correct operation pressure.
H_ Verify that the die is flush with the bolster plate and ram. Make sure there is no debris underneath the
die shoe, castings, or plates.
I_ Check all remaining press parameters, such as counterbalances and clutch pressure.
J_ Make sure all locators and gauges are in their correct positions and that the blank is being properly
located.
K_ Verify that there are no pieces of loose scrap, slugs or obstructions in the die.
L_ Ensure the coil material is being adequately straightened, leveled, and flattened before entering the
die. Periodic adjustments in the straightening equipment might be needed during production.
M_ Make sure scrap and slugs falling from the die are being carried away properly and that all slugs
shuts and shakers are functioning correctly.
N_ Verify that all bolts securing the die in the press are tight.

The key is to eliminate systematically, one by one, all of the controlling variables. Only then can
you say “based on the data presented or discovered, it is my opinion that…this is what’s
causing the problem…