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2018 Tooling by Design - Curling Dies: Details Matter | MetalForming Magazine

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CURLING DIES: DETAILS MATTER

By: Peter Ulintz

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Thursday, November 1, 2018

Curling is a metalforming process used to form two

edges into a hollow ring, which may be used to crimp a
wire in an electrical terminal. Another type of curl forms
one edge of the sheetmetal onto a flat plate, such as a
door hinge.

Curling dies work remarkably well when the tool design

(and build) and part material favor the process. One
such product type are electrical terminal connectors
(Fig. 1). Most electrical connectors, typically produced
in progressive dies from ductile copper alloys, exhibit
minimal springback, ideal properties for curling
operations.

Fig. 2 illustrates the forming sequence to process a

terminal part from flat sheetmetal into a cylindrical
shape. The first form station begins the curl—or nip—
Fig. 1—Electrical terminals with curled ends.
process on both ends, usually 75 to 88 deg.

The second form station forms the center into a V

shape. The objective is to form as steep a V as the first
form and punch width. Forming with a radius slightly
less than half of the inside diameter will allow for easier
nesting into the last form station, and generate a round Fig. 2—Forming a curl on an electrical terminal.
part.

The third station is the final curling station. It completes

the forming of a cylindrical tube without the benefit of an
arbor in the inside diameter. Fig. 3 illustrates the closing
sequence of the curling station from initial punch Fig. 3—Die-closing sequence for last curl station.
contact on the preformed shape to the final sizing of the
outside diameter.

The outside diameter sizing is effective only if the ends

butt together and force the material outward into the
round circle that the closed die forms at the bottom of
the press stroke.

The length of the flat blank is critical for success. Any

inaccuracy in the calculation gets multiplied by a factor
of four for 360 deg. of bending. If the precut blank is too
long, the form tool will not close properly on the part and Fig. 4—Forming a curl on a hinge plate.
distortion of the cylinder will result at the bottom of the
press stroke. If the blank is too short, the ends will not fill the entire circle in the tooling, and no outward push will
occur. This means the part will not be round and a gap may result between the ends.

With proper blank development, roundness and accuracy of the part can be reasonably controlled with this process. If
the inside diameter requires greater accuracy, a round pin on a cam could be inserted into the part prior to closure in
the last form station. An air cylinder could suffice for insertion of an arbor and withdrawal after completion.

Another type of curl found on hinge plates features a similar number and type of forming steps to the electrical
connector, but has a different tooling design because the curl is formed from one side only (Fig. 4).

Regardless of the curling process employed, close attention to details during die construction, including surface-finish
requirements, and the blank development are essential for success. MF

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7.12.2018 Tooling by Design - Curling Dies: Details Matter | MetalForming Magazine

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