Die Design Standards-Sapco

()

.

.

.

.

( ) 5G .

. -

- ( ) ( ) .

: .

.

.

Preface Supplier of Automotive Parts Company (SAPCO) was established in 1993 and became the pioneer in automotive parts supplying in the Iranian car-making industries. SAPCO is the greatest branches of Iran Khodro Company, the largest auto-manufacturer in Iran. It is actively involved in engineering, quality and planning aspects of auto-parts. One of the main engineering and technical sections in Sapco is "Department of Tool Engineering" which supports all of the supplying groups in the field of planning and developing the process of "Tool Manufacturing" as the foundation of supplying of parts. The main target for Department of Tool Engineering is to manage the procedures in which the tools have been manufactured with suitable standards and target price. Therefore, the Metal Stamping Dies team has been persuaded to publish a reference standard to lead the process of manufacturing contracts reach the above factors. Using "Die Design Standard of Sapco" helps to reach an optimized result for the designing and manufacturing the dies with size G5 (less than 700mm length) and Progressive type. This reference is useful for the designers and manufacturers of metal stamping dies, students of technical universities and other groups involved in this industry. In order to use this standard book, it is better to seek the needed subject in the content which is ordered based on the steps needed from design to manufacturing and general elements such as die shoes and guides to principal part such as punch and dies steel blocks, etc. Preparing this standard book would not be possible without the helps of our colleagues in the Metal Stamping Dies group, whom special thanks should go to Mr. Mohammad Tajedin the head of stamping dies department as the technical supervisor, Mr. Soroush Chehrenegar as author, translator, editor and illustrator, Mr. Hossein Nouri, Mr. Javad Sadeghi, Mr. Mehrdad Olfatian, Mr. Mostafa Naghdi and Mr. Mehdi Parto as the illustrators and authors team. In addition, we will appreciate any criticism and suggestion about this book to improve it in the next edition. Metal Stamping Dies department of SAPCO Nov. 2005

Process sheetDie Lay OutStrip layoutFinal version of assembly drawingPart detail drawing3D CAD Data specificationsMeasurement report of finished partInstruction of die installation and setupClamping methodsTransportationFeeder specifications for progressive dieDie shoes and guiding systemsPunch and diePunch, die, clearance and gapsCritical points on the diePiercing on the inclined surfaceBlank holder and strip guidePunch holderMethods of locatingPilot pin in progressive toolControlling the feed by side cutterScrap cutterStrip pusherPart box, Scrap box and chuteStop blocksStock BlockBottoming markerCam unitsCam padSprings and its positioningStandard boltsStandard pinsTypes of flangeFlange in cornersSpring back in bendingBead designAir vent systemsCoordinate holeSurface roughness in the die elementsCalculationsDie PaintingIdentification plaques of dieAppendix AAppendix B1Appendix B2Appendix CAppendix DAppendix E

Content1357891112131518

4644423938343332312219

6665646261565554535049

8382797875747372706968

89868584

Date: Nov.2005Supplying Automotive Parts Co.

(SAPCO)

DIE DESIGN STANDARDCreated by:

Department of Die and Tool

Page 1 of 81

Title: Process sheet

The process of die design for each part begins with sketching of the processes of the part, which will be brought separately in the compartments of a table, called process sheet. Each one of the processes generally includes one of the principal operations such as cutting, forming, drawing or trimming. The process sheet should contain the processes, which form a flat sheet metal to a fully formed part. Following requirements and information should be included in the process sheet: Tool number, arranging from 1 to n (n is the last tool number). Operation number shows the order of operations added to a "OP", e.g. OP05, OP10, OP20, OP30, As a rule, it should be named the first operation to "OP10" for "Draw" operation. However, If a blanking operation needs before to the OP10, it will add an "OP05" e.g. for a blank operation. In the case of needs to any other operations between the regular operations, it should be used a median operation name for them. For example: Op05, Op10, Op15, Op20, Op25, Op30, Op40, etc. Operation name is the name of an operation in which one of the principal operations such as Draw, form, Trim, Re-strike, etc. is to be done on the panel. Tool size is general dimensions of tool (width, length, and height), used for choosing of appropriate press and to estimation of total weight of the tool. Tonnage of press (or press force) is amount of minimum required force to apply operation easily, used for choosing appropriate press. Die specifications specify whether die should produce right hand or left hand part or both. Part number is an identifier for the technical number of parts. Thickness is the thickness of raw sheet metal. Approver Identifications with its date should contain signature of drafter, checker or approver with printing date. Page number specifies the number of sheets attached. Material specifies the raw sheet metal material used in the operations. Blank areas are used to sketching operation processes. Direction of feeding and pressing should be shown. (See a sample of process sheet in the next page)


(SAPCO)



Page 2 of 81

Blk./Pie.

0510

Flg. up20

Sep.

70x45x30D

im.(cm

)D

im.(cm

)

Dim

.(cm)

Dim

.(cm)

Dim

.(cm)

Die m

aterial: SP

KRD

ie material: S

PKD

ie material: S

PKR

70x40x3070x40x30

XX

XX

XXX

XXX

Date:

Date:

130

ALN L

R&

L Spec.R

Die

No.

ToolO

p. Nam

eO

p.N

o.Tool

(ton)P

ress

ALN L

R&

L Spec.R

Die

No.

Op.

No.

ToolO

p. Nam

eO

p.N

o.Tool

(ton)P

ress

ALN L

R&L Spec.R

Die

ToolN

o.O

p. Nam

eN

o.O

p.Tool

Press

(ton)

ALN

R&

L Die

Spec.

RL

ToolN

o.

R&

L

ToolO

p. Nam

eP

ress(ton)

ALN

Die

Spec.

RL

Part N

ame:

Part N

o:D

rawn:

Thickness:C

hecked:S

ht.No.

ToolN

o.N

o.O

p.O

p. Nam

eTool

Dim

.(cm)

Press

(ton)D

ieS

pec.R

LA

LNR

&L

No.

ToolO

p. Nam

eO

p.N

o.Tool

(ton)P

ress

Blank

Pierce

Feed

Press

Press

FeedFeed

Flange up

Separate

SAP

CO

-Departm

ent of Die and tool

Material:

Operation S

heet(S

heet Metal Tools)

Num

ber: D

ate: A

ttach.:

....................................

XX

XX

XXX

XXX

XX

XXX

X2 m

mX

XX

XXX

XX

X.X

X.X

X1 of 1

XX

XX

XXX

XX

.XX

.XX

297

6060

60


(SAPCO)



Page 3 of 81

Title: Die Lay Out

In order to preview the general concepts of die design, detailed die layout drawing of the processes should be prepared completely before die design. See the sample of die layout drawing in the index A. Each die layout drawing should include following information: Title Block should contain general information such as part name, part number, tool name, tool operation number, material and thickness of sheet metal, toolmaker name and its logo, signature of drafter, checker and approver with printing appropriated date. Scale, sheet number and other needed information should be added too. Title block should be placed on the right hand lower corner. Operations side Boxes, should be ordered upward vertically above the title block which contains concept sketches brought from the process sheet. Following information should be included in the side boxes: a) Operation sketch showing the operation in which one of the principal operations,

such as drawing, trimming, flanging, piercing, cam pierce or other operations will be applied. In addition, illustration of press direction and feeding the panel should be shown.

b)In order to obtain the best result in the forming of the part during the stroke of tool, suitable rotation angle of punch and die surfaces should be defined based on the rotation angle of CAD data during die face design, if needed. In other words, the draft angles should be considered regarding to the ease of ejection of panel in direction of press.

c) Operation name according to the assumed operations should be notified. d)Operation number according to the order number of the operations should be

notified. e) Press tonnage according to the estimated force for the assumed operations should be

shown in the appropriate box. Modifications table shows the modifications generated and announced by the client. Notes area should be added if there is any important notification to toolmaker. Line type table shows the type of the used border lines of each one of the operations with a specific pattern separately.

Procedure of loading and unloading the panel from die, whether it is manual or automatic, should be specified. Plan view of panel is a single plan of panel showing the operations from the first to the final. Each one of the operations should be defined using a specific patterned line in a legend table. Following items should be specified on the plan view:


(SAPCO)



Page 4 of 81

Sectional views show the detail of operations of specific paths in which the loaded panel on the punch and die is being illustrated. Scrap cutter locations surrounding the punch should be indicated. Overlaps shows the previous trimmed edges which are extended to the current trim operation. Gooseneck shows the overlapped area of the flange punches. Bottom markers in the appropriate locations should be indicated.


(SAPCO)



Page 5 of 81

Title: Strip layout

If the die to be made is progressive, instead of plan view of panel in the die layout, the layout of strip should be drawn. In order to optimize the usage of material on the strip or blank and decrease the waste material, the layout of blanks should have the minimum waste material. See the following examples:

Ok!

Not Ok!

Ok!

Not Ok!

Ok!

Not Ok!

In the above strip layouts the "e" is (1.25t) in which "t" is the material thickness and should not be less than 2mm. In order to avoid twisting of strip, the blanking and trimming large holes should be laid out preferably in the end of the strip. If such operation has been laid out in the first stage, it causes the twisting of the strip in the entrance of strip guide and therefore the strip cannot feed easily.


(SAPCO)



Page 6 of 81

In order to avoid tearing of strip on the areas in which the strip is weak, using a bead or any embossed shape in the previous stages should be applied. For the high rate of production, the distance between the die holes should be at least 15mm if applicable. If it is not applicable, idle stages should be used when the die will be weak against the shearing and forming forces.

Not Ok!

Die Strip

These distances shouldbe Min 15mm.

Weak

Weak

Die

Idle Stage Idle Stage

Strip

Narrow cutting operations or cutting around weak areas should be done in separate stages.

Narrow cutting(is cut in two stages)


(SAPCO)



Page 7 of 81

Title: Final version of assembly drawing

Final version of assembly drawing is a structural drawing shows the functional relations between the parts of die. Assembly drawing of each die should be prepared in the shut or closed die. (See sample in the index B) Each assembly drawing should contain following items: Sectional and sub-sectional views in the condition of shut (closed die), plans on upper and lower die, Strip layout which shows the operations and the order of stages, strip width, feed direction, if the die is progressive. Diagrams shows the specifications of the used springs which specifies the rates of strength under specific pressures, applied cam units etc. Part list includes specifications of components of die. It should generally contain following information:

a) Number (No.) shows the order of component b) Part name is description of the component c) Material is the material used to manufacture the component d) Finished size is general size of the component e) Item No. is the quantity of each item f) Standard No is the material standard number of the component g) Hardness is the condition of hardness of the part Title block should contain general information such as part name, part number, tool name, tool operation number, material and thickness of considered sheet metal, Scale, sheet number, toolmaker name and its logo, signature of drafter, checker and approver with printing appropriate date and other needed information.

There are two methods for laying out of upper and lower plans, sections and views of die. See these two methods in the samples of final version of assembly drawing in the index B1 and B2.


(SAPCO)



Page 8 of 81

Title: Part detail drawing

In order to manufacture the parts of each die, a set of detail drawings of its components should be prepared. Each one of the parts of die should have separate detail drawing in an ISO standard format. The format of each drawing includes drawing frame with title block in a standard size of A4, A3 or larger size if required. Other applications of engineering drafting standards such as dimensioning, tolerances, surface finishing, etc. should be added on the part drawing, if applicable. A single sheet drawing of related or similar parts could be prepared if the ease of usage of the drawing does not affect with the complexity of drawing.


(SAPCO)



Page 9 of 81

Title: 3D CAD Data specifications

In order to maintain and repair the die and its components during the production, 3D Cad data of the die with the 2D drawings should be included, if applicable. In the draw dies, the CAD data of the die, punch or blank holder (generally is a surface 3D model) should be prepared with location of the coordinate hole axis as a reference for CNC machining purposes on the lower and upper shoes or the blank holder. Direction and location of X, Y, and Z-axes should be defined.

Draw Die with Blank Holder


(SAPCO)



Page 10 of 81

Die face CAD data

In the blank dies, the profile of die, punch or pad, which generally is a 2D curve, should be prepared with the location of the coordinate holes axis on the lower and upper shoes or pad as a reference for machining purposes. Direction of X, Y, and Z-axes should be defined.


(SAPCO)



Page 11 of 81

Title: Measurement report of the finished part

In order to approval of die, Measurement report of the part should be prepared by toolmaker. The following table is a sample of a measurement report and the required information.

Client:

Part Description:

Project:

Date:

Part Number:

Quantity:

Dim. MeasuringDim. Measurement Dim. DifferenceEquipmentNumber Result Nominal ToleranceUpper

ToleranceLower Error Comments

Measurer's

L

D

R

VC

PP

PP

3

2

1

4

5

6

...

n

Measuring Equipment:

Metrology Department: The Technician: Measurement Date: Issue Date:

Measurement Report

Page ... of ...

CMM - Coordinate Measuring Machine; CF - Checking Fixture; VC - Vernier Caliper; MC - Micrometer; MI - Microscope; TM - Thickness Measurer; PP - Profile Projector; PR - Protractor

81.52

24.95

5.55

81

25

5

0.52

0.05

0.55

+0.2

+0.25

+0.1

0.32

0.45-0.1

-0.25

-0.2

Dim. Element:L - length; D - Degree; R - Radius


(SAPCO)



Page 12 of 81

Title: Instruction of die installation and setup

In order to define and set the specifications needed for the instruction of die installation, following items should be considered: 1-Die layout:

a) Work area or contents of work that is trimming area, flanging area, etc. b) Orientation of pressing c) Working directions which are loading and unloading direction and front side of

the die. 2-Size of die that is Front/Back Right/Left Height (Die Shut Height) 3-Material of die components that is body of die, cutting edges, bend edges 4-Production system

a) Full Automation (loading and unloading with vacuum jaws) b) Semi-automation (loading with hand unloading with vacuum jaws) c) Transferring line d) Automated feeding with coil of material at the start and chute at the end e) Loading manually (loading and unloading with hand)

5-Press specifications

a) Loading/Unloading system b) Locating and positioning systems on the bolster c) U-slots for fixing and locating the die d) Cushion pin locations (pitch) e) Location of scrap holes f) Bolster and Ram size g) Press Shut height and open height

6- Press specifications in the die maker or producer site a) If user specifications such as bolster size, ram size, shut height, cushion pin pitch,

blank holder open entry is possible for tryout within the die maker site b) If user's specification can be changed for tryout within the die maker site c) If there is any requirement for specific die structure 7-Data and documents of coordinated components of die and production 8-User's standards and specifications


(SAPCO)



Page 13 of 81

Title: Clamping methods

In order to clamp the die in a fixed and stable position following methods should be used: 1- Using fastening bolt to clamp the die shoe,

Press bolster T slotClamping Bolt

Die Shoe

Press bolster

2- Using clamp with a series of riser blocks,

A series of riser blocks

Press Bolster

Die Shoe


(SAPCO)



Page 14 of 81

Press bolster

riser

Die Shoe

3- Using clamp with an adjustable riser,

Adjustable riser

Die Shoe

Press bolster


(SAPCO)



Page 15 of 81

Title: Transportation

In order to transport the die in a safe condition, hooks and fastening strips should be made. Minimum four transporting hooks and four transporting strips should be used in each die. Transporting strips and hooks should not be installed in same sides of die shoes. The transportation hooks should be installed in the longer side of the die shoe.

A - A

Min. 8mm

Min

3m

m

For the die shoes smaller than 300x300mm size, it is permissible to use two strips only. For transportation, using following types of hooks are allowed. (Refer to fibro standard number 213.11, 213.12 and 213.13)


(SAPCO)



Page 16 of 81

A CB D

o

Transportation hooks should be used with the cables to move or turn over the die.

Installation and positioning cables on the transportation hooks

Relief space under hooks should be provided so that the cable can easily pass through the space between the press bolster and the hook. A relief of Min 20 mm is required.

Less than 20mm (Not Good) Over 20mm (Good)

If transportation cable goes over the corners of die, a 5x5mm chamfer should be provided on such area.


(SAPCO)



Page 17 of 81

Not good!

Countermeasure for slip on angular part of die

Good! Good!

In order to avoid dangers involved in the transportation of dies, the eccentricity and unbalancing during the transportation should be considered. The balancing of die and its weight should be considered so that die can be lifted on a horizontal level. In figure A and B, balanced conditions are shown.

If the above requirements cannot be obtained, following alternative should be provided.


(SAPCO)



Page 18 of 81

Title: Feeder specifications for progressive die

Feeder should be a separate accessory and feed the roll automatically into position in which stamping will occur. 1-Feeder should be used in a progressive die When:

a) The high rate of production is the most important factor in production plan b) The part precision leads the production process to provide precise feeding instead

of manual feeding 2-Regarding the kind of duties, feeders should be selected:

a) Roll feeder with regulated drive, feeding of strip into press, adjustable feeding stroke with regulated drive, central lubrication, automatic roll release, End of strip monitoring.

b) Roll feeder with fixed drive, fixed drive, change of stroke via exchangeable rolls central lubrication, automatic roll release

c) Roll feeder for narrow strip, adjustable fixed feeding stroke, automatic roll release, end of strip monitoring

d) Pneumatic gripper feeder for wide strip, adjustable feeding stroke, automatic roll release, end of strip monitoring

3-High precision electrical feeders should be used, if the result of division of the part

precision (that is the minimum tolerance value in the part drawing) in to the number of stages gives a micron value. In other words, the high precision electrical feeders should be used for micron precisions.

4-Medium precision mechanical feeders should be used, if the result of division of the

part precision (that is the minimum tolerance value in the part drawing) in to the number of stages gives an approximated 0.03mm or more. In other words, the Medium precision mechanical feeders should be used for over hundredth precisions.

5-Scrap collector system

a) Roll scrap, which should be rolled in a coil b)Scrap breaker, which should be used when the scrap is better to break to small

scraps


(SAPCO)



Page 19 of 81

Title: Die shoes and guiding systems

All of the components of die should be fastened on the die shoes as a precise basement. 1. Die shoes should be made of ST52 and have ground surfaces.

2. All of the die shoes should have 4 sets of guiding post and bush. 3. FIBRO Standard parts should be considered as the principal standard. Other similar

standards are acceptable. 4. Surface roughness of guide posts and guide bush should be in condition. 5. Guide posts or guide bushes should have lubricating grooves. 6. The length of the guide post should be long enough to enter the guide bush, before

contact between the blank holder and part.


(SAPCO)



Page 20 of 81

7. In order to locate the guide post in a fixed position, clamping rings with fastening bolts should be used.

8. When the die is shut, the guide post should be lower than the upper die shoe

(minimum 3mm).

9. Blank holders with length more the 500mm, should have both guide posts and spool

retainer.

Over500mm

Pad

Ball bearing

Shoe

Guide Post

O20 H7 r4


(SAPCO)



Page 21 of 81

10.Progressive dies with more than four stages should have ball bearing guide bushes.

11.In order to prevent misassemble upper and lower shoes, guide posts and heel guides should be fool proof.

12.Die shoes with more than 800mm length, should have both guide posts and heel guides with wear plate, if needed.

13.Possibility of lubrication for all wearing surfaces of the guides should be considered. Wear plates should have either graphite inserts or lubricating grooves.


(SAPCO)



Page 22 of 81

Title: Punch and die

1-The die and punch should be made of suitable material and hardness (refer to the following table). In addition, there should not be any welding, crack or porosity on their main surfaces and edges. If the cracks, porosities or other material failures are far enough from the main edges or functional surfaces, they should be repaired using welding techniques.

Production RateThicknessof sheet

materials (mm) TrimPunch

Trim Die

Flange &Bend Punch

Over 1,000,000(High production rate)

Flange &Bend Die

Draw, Form & Restrike Punch

Draw, Form & Restrike Die

500,000 to 1,000,000(Medium production rate)

t


(SAPCO)



Page 23 of 81

Sec A-A

Back up Key

Pocket for key

Back up Key

Back up Key

Punch

Die Shoe

25

257

4-Punches made of EDM wire machining, should be fixed in the punch holder. In the large sections of punch (more than 100x100mm), a back up key should be used to eliminate thrust forces.

Punch Holder

Bumper

Punch

SEC. A-A

A

Dowel pinBolt

A

Max100

Max

100

5-According to the profile of the die hole, for the parts with the thickness lower than 3mm, the following distances should be considered. For the thicknesses more than 3mm, the distances should be increased.

Min 30mm

min

30m

m

min

35m

m

Min 35mm

min

45m

m

min 45mm

6-The punches with thin wall should be held in a punch holder: A: With one or more dowel pins:

A

Punch

A

SEC. A-A

Bumper

Punch Holder

Punch

Punch Holder

B

SEC. B-B


(SAPCO)



Page 24 of 81

B: Make a step using EDM wire machining in a same time with punch and then weld them to each other using brass weld:

C: Other type of punches (e.g. standard punch or all types of punches with stepped tail) should be gripped in a punch holder.

7-In order to avoid breaking of die steel blocks and ensure of fixed positioning of die elements, following spaces should be made.

min

5mm

1520

min20mm

a

6-8 mm for Low rate production8-12 mm for high rate productionm

in5m

m For lower than 3mm thickness strip

For g

rindi

ng

min12mm

min 1mm

8-Scrap hole of the trimming dies should be tapered. Right angle scrap hole is allowable but tapered one is preferable. Die shearing walls should have an appropriate height according to the part thickness. The following values are allowed for the parts with the thickness lower than 3mm. For the thicknesses more than 3mm, the distances should be increased.

1-3

a

90Very good.


(SAPCO)



Page 25 of 81

90

Good.

a

Max2mm

(a= 8mm for less than 200,000 stroke and 12mm for more than 200,000 stroke)

9-For small dies, a tapered hole of 15'-20' is enough. The right angle scrap hole is not required.

15'-20'

10- In order to grind the faces of the die freely parallel to each other and with the die hole axis perpendicular to the shoe faces, die should be inserted in a pocket (die holder) and then fastened to the die shoe. In such condition, guide posts will not get accident with grinder during grinding. In addition, as there is not enough space to grind the die block seat on the die shoe, the die should not fasten to the die shoe directly.

OK

//

Work order:1- Assemble die (without the die hole) in die holder.2- Machining of bottom face of die holder parallel with

//3- Manufacturing the die hole with the assembled

4- Grinding the die face with die holder simultaneously.

to top face of die .

die holder.

Accessible

Lower shoe

Die holderDie

min 5


(SAPCO)



Page 26 of 81

Not OK!

//

Die Lower shoe

The guide posts do not allow grinding of die.

11- In the case of using small dies, using button die inserted in the die steel block is essential.

Inserted button dieDieDie holder

12- There should not be any gap and space between the sectional steel blocks. The split line of the steel blocks should be perpendicular to the die face.

90

Split lineSectionalSectional

Not Ok!

=90

Split lineSectional Sectional


(SAPCO)



Page 27 of 81

13- The splitting line of the sectional steel blocks should not be positioned at the corners of the parts. (See index C). 14- In the weak and breakable areas, separate inserted steel blocks should be used.

block dieSeparate inserted

15- It should not be used shim or any other filler between the steel blocks of punch (or die) and back up keys.

Adjusting Shim Die

Back up key

16- Cutting dies should be made of SPKR or other similar material and 602HRC hardness. (Refer to the material table) 17- The dies which are affected by thrust forces, together with screw and dowel pin, back up keys should be used as well. (See index C) 18- The distance between the die face and the head of the screws (or dowel pins), should be at least 5mm.


(SAPCO)



Page 28 of 81

19- Distances between screws and dowel pins from the cutting edges should not be less than 12mm.

Min12mm Min12mm

20- All of the sectional steel blocks of die should have at least two screws and two dowel pins. The material number of the each one of the steel blocks should be marked apparently on their top surfaces.

Sectional Punch(or Die)

Bolts

Pins

S01

S02

S03

S04

The number of each steel block should be marked.(For example: S01=SPK No.1)

21- When using a button die with a specific profile (non-circular form), a lock pin should be used to prevent rotation of button die.

(a) Locked by pin (b) Locked by key

KeyLock pin


(SAPCO)



Page 29 of 81

22- Button dies for adjacent holes should be positioned as shown in the following figures.

Solid button die

Lock pin

Button dies

Partial cut of button die

Lock pin

Button dies

23- The distance between the button die and the nearest edge of the die is related to the thickness of material. See following figures:

diameter of button die.

xare standards If: t>1.5=> X=8mm

If: t X=6mm

Double dotted lines

24- Following notifications should be considered when using button die holder: a) Use button die holder for mass production (over 100,000 strokes). b) Use button die holder for thick material (t >0.5mm). c) Button blocks should have hardened backing plates when FPM (force per mm)

of work is 0.5 or greater, regardless of production rate. d) Standard button blocks are preferable to use, if required. e) The last choice is homemade button blocks.

Back up plate 6mm

25- In order to chute scraps, following notifications should be considered: a) Scrap chute angle for piercing is Min 25. b) Sheet metal thickness for scrap chutes is 2.5mm. c) Scrap chutes width should be at least 15mm wider than the maximum scrap

dimension. d) The diameter of scrap holes under the button die and its retainer shown in

the following figures. e) The diameter of scrap hole should conform with the standard of drill sizes.

(See the figures in the next page)


(SAPCO)



Page 30 of 81

Min2

Button relief hole+2mm

Button relief hole+min4mm

F

F+2

F+4

F+6Min25

Urethane

Min25


(SAPCO)



Page 31 of 81

Title: Punch, die, clearance and gaps

The clearance between trimming punch and die should be according to the following table. The thickness and material of part should be considered as well. The materials of part are categorized to the three following divisions:

a) 1100 and 5052 aluminum alloys, all tempers b) 2024 and 6061aluminum alloys; brass, all tempers; cold rolled steel, dead soft;

stainless steel soft c) Cold rolled steel, half hard; stainless steel, half hard and full hard; all of the

common used steels in the automotive industries such as ST12, ST13, ST 14, and ST37 and

die

punch

die

0.5 mm

0.7 mm

0.8 mm0.8 mm

1 mm

1.2 mm

1.5 mm

1.75 mm

2.5 mm

3 mm

3.5 mm

4mm

4.5mm

5 mm

2 mm

0.011 mm

0.014mm0.6 mm

0.114 mm

0.098 mm

0.082 mm

0.068 mm

0.053 mm

0.045mm

0.038 mm

0.03 mm

0.025 mm

0.019 mm

0.016 mm

6 mm 0.18mm

0.148 mm

0131mm

group1

thickness clearance

group2 group3

%2.25

%2.3

%2.35

%2.4

%2.45

%2.5

%2.55

%2.6

%2.65

%2.7

%2.75

%2.8

%2.85

%2.9

%2.95

%3

%3

%3.05

%3.1

%3.15

%3.2

%3.25

%3.3

%3.35

%3.4

%3.45

%3.5

%3.55

%3.6

%3.65

%3.7

%3.75

%3.75

%3.8

%3.85

%3.9

%3.95

%4

%4.05

%4.1

%4.15

%4.2

%4.25

%4.3

%4.35

%4.4

%4.45

%4.5

0.015mm

0.018mm

0.022 mm

0.025 mm

0.032 mm

0.039 mm

0.05 mm

0.059 mm

0.068 mm

0.086 mm

0.105 mm

0.124 mm

0.144 mm

0.164 mm

0.185 mm

0.225 mm

0.023 mm

0.083 mm

0.174 mm

0.151 mm

0.128 mm

0.105 mm

0.072 mm

0.061 mm

0.048 mm

0.04 mm

0.031 mm

0.027 mm

0.019 mm

0.198 mm

0.225 mm

0.27 mm

metal thickness% thickness%

metal metal thickness%clearance

The clearance (gap) between bending punch and die should be (0.9-1.2 Metal thickness). For materials with less hardness ~0.9 and for materials with more hardness ~1.2 should be applied. The clearance (gap) between draw punch and die for soft materials should be (1.1 Metal thickness) and (1.2 Metal thickness) for hard materials.


(SAPCO)



Page 32 of 81

Title: Critical points on the die

In order to strengthen the die against to the working forces, the critical areas and the retaining walls that may include possibility of breakage or crack should be designed with enough wall thickness. In the case of using button die, the minimum distance between the die and die holder should not be smaller than 3mm (See fig. A). If the hole is larger than 12, the thickness should be increased accordingly (See fig. B).

Min

30

Min

30

4Min 3

4

Min 4Max o12

A B

If the round holes are close to each other, following dimensions should be applied:

(Max) O4 2.2(min) 4(min) O4~O10

Min

30

Min

30


(SAPCO)



Page 33 of 81

Title: Piercing on the inclined surface

In order to pierce the hole in an inclined surface, without changes in diameter, piercing direction of datum hole should not be over 7 against pierced surface.

OD0.8t

d1 x7e.g.:

D=O15X=Tan7 x 0.8 = 0.098d1 =Cos7 x 15 + 0.098 = 14.986Die of actual piercingd1 = 15.2

+0.20

If small pierces are on the inclined surface, following dimensions should be included:

Max10

(a)

d1 O5O51

Max20

(b) (c)

Max30

shear on edgeMax.20 if d >O51 >Max.30 if d1 O10

shear on edge

Max15

Flat edge if inclinedangle up to 15

* common in (b) and (c)

=

(d)

d1>10

2S

S

d2d2 d2

* Dimension d2 should be greater than scrap size. If inclined angle is over 7 and accuracy is required, an allowable increase should be provided on hole size. Necessity of allowance should be decided by examining the function of the hole. In order to pierce holes to a full circle, pierce punch and die should be oval which includes higher cost.


(SAPCO)



Page 34 of 81

Title: Blank holder and strip guide

In order to obtain the best result of quality of the part, fixed location for the blank or stabilized movement for the strip should be provided. Blank holder and strip guide is used to provide fixed and stable location and movement of part over the die. The cutting edges of the punch should be inside the blank holder when the die is open, minimum 3mm. (a) Punch and blank holder should have appropriate clearance between each other.(b) Appropriate fillet or chamfer should be made in the corners of the blank holder hole through which the punch is passed (a). If the diameter of the punch is less than 30mm, the blank holder should be hardened or a hardened bush should be inserted on it. Blank holder should be made of VCN200, MS60, or other similar materials with the same properties and hardness.


(SAPCO)



Page 35 of 81

For each one of spring located in blank holder, a spool retainer should be used. The length of bearing of spool retainer in punch holder or in upper shoe should not be less than 15mm. Spool retainer limits the travel of the pad or blank holder.

Strip guide and blank holder should be used for all progressive dies.

In order to transport large blank holder, transporting hook is required.


(SAPCO)



Page 36 of 81

The methods of fastening strip guide to the die are showing bellow. In order to fix the strip guide, dowel pins should be used also.

bolt

Very Good!

In order to lead the strip into the guides, its entrance should have suitable lead angle:

A

Sec.A-A10

30

A

Lead angle specifications Lead angle

If the strip guide is out of the shoes, it should be made either safety bumpers or a hinged type guide to prevent possibly collision or damages on it.

Strip guide with safety bumpers


(SAPCO)



Page 37 of 81

Hinged type strip guide


(SAPCO)



Page 38 of 81

Title: Punch holder

Standard punches should have punch holder.

Punch

Punch Holder

Bumper

The punch bumper plate is required for punches with a diameter less than 30mm.

Punch

Punch Holder

Bumper plate


(SAPCO)



Page 39 of 81

Title: Methods of locating

As a rule, in order to locate the part (panel) on the die face in single operation dies, die face area should be greater than blank size to place the locators. According to the geometry of part, following methods of location may be used: Shape locators: When using shape of the part as a locator, following restrictions should be considered:

10-30

Max120

Block locators are required when the shape locator cannot prevent small gaps.

Dower Pins

R

5mm

blocksGauge

Dowel pin required after tryout Block locators to prevent rotation

In the parts with a shallow shape (small depth), scrap cutters holds part of locators also, however, the block locators are required to prevent rotation of part.

Relief for upper edge engagement


(SAPCO)



Page 40 of 81

Pin locators In trim dies because of insufficient area on the shape of the die, pin locators should be used on panel holes for diameters more than 20.

10

OverO2030

R5

If the size of hole is 8- 20mm, a pin locator should be used in addition to the shape of the part. If the shape of the part with the pin is not sufficient to locate, bounding locators, which prevent the rotation of part, should be used too.

13-20

8

3-5

O5-O20 Pilot pin locators This pin should be applied to a hole with diameter less than 8mm. It serves as a final locator after utilizing side locators. The gap between side locators and panel is indicated on the right drawing. Locating hole are required as outside the panel as possible.

Pad knockout stroke +2for general engagementD - 0.2

20-30

D

R gap

0.5

-1


(SAPCO)



Page 41 of 81

Notifications on the method of locating part using holes To use a hole as a locating feature, following important hints should be considered: 1- A hole with stable accuracy of position on piercing operation 2- A hole with no deformation through all operation 3- Diameter of hole is 0.2 mm less than pin diameter. For example if diameter of hole

is equal 20, location pin diameter should be 19.8 5- The diameter of pin should be indicated on the drawing Stay locators Stay is required for small and unstable location areas. The panel should be kept balanced. It should be made with removable structure. Safeties on delivery & storage should be considered. For locating & stability, touching area should be as small as possible.

Location Stay


(SAPCO)



Page 42 of 81

Title: Pilot pin in progressive tool

In order to bring the strip in its exact location in progressive die, pilot pins should be used. The clearance between the pilot pin and its hole should be 0.02-0.05mm or H7/h6 fitting. All pilot pins should have a ground surface with surface roughness of

. All pilot pins should be hardened to 502 HRC. The cylindrical part of the pilot pin should be (1.5t) which "t" is the thickness of material.

1.5tSee Det. X

H7/h6

Pilot Pin Sheet material

Punch holder

Clearance=0.03~0.05mm

According to the condition in which there is a hole or not in the part, one of the following methods of using pilot pin should be applied: a) Direct pilot pins: In this case, there is at least one hole on the part to use pilot pin directly.

Pilot pins

b) Indirect pilot pins: In this case, there is no hole on the part. Therefore, it should be made a hole out of the main area of the part (on the waste area of the strip) for using pilot pin.


(SAPCO)



Page 43 of 81

Types of pilot pins: One is the pilot pins which installed in the punch face directly (a) and the second is installed on the punch holder (b).

Press fit

Det.A Punch Punch

Screw retainer

See det.A K=1

.5t

(a)

Spring loaded

(b)

The clearance between pilot pin and its die hole should be %5 of the diameter of pilot pin.

Punch holder

O10

O10.5


(SAPCO)



Page 44 of 81

Title: Controlling the feed by side cutter

In order to control the feeding strip in the progressive dies, using side cutter is essential. According to the part accuracy and product tolerances, one or two side cutter(s) should be used.

Pitch

Final Part

Stage 1Stage 2Stage 3

Scale x2 In order to avoid the remaining waste material at the end of the strip, after passing the first side cutter(s), based on the part accuracy and tolerances, one side cutter or a fixed pin should be used at the final station, as well. In order to eliminate the possibility of remaining burrs after side cutter stage, the profile of side cutter should be made as shown in the following figures (B or C).

MIN

10

MIN

10

MIN

10

allow the strip pass canel easily!

but side cutter will be highThe "burr" will not remain

The "burr" will remain but allowthe strip pass the canel easily!

The "burr" will remain and do not

SIDE CUTTER

SIDE CUTTER

SIDE CUTTER

STRIP

STRIP

STRIP

30

DETAIL D

D

R

DETAIL E

1-2

mm

E

cost to make!

1-2m

m

Max

1m

m

3-10mm

side cutter sizeAccording to the


(SAPCO)



Page 45 of 81

A steel heel for each side cutter should be used, if the side cutter cutting face is flat. At least 2 bolts and 2 dowel pin should be used.

B

(Grinding support)

Grinder

(Rotate the grinding direction 90)

Remove the springs grinding!

with the side cutter punch!Grinder is geting accident

Use a supporting block to eliminate(Grinding support)

the movement of pad during grinding.

A

For the specifications of material and heat treatment of punch and die, which is used for side cutter(s), refer to the section of punch and die.


(SAPCO)



Page 46 of 81

Title: Scrap cutter

In order to cut down the scraps surrounding trimming punch, scrap cutters should be added around it. Size of scrap cutter

L

H

t < 2M12 x 50

t >2M16 x 50

O13 x 50 O16 x 60

H


(SAPCO)



Page 47 of 81

In case of sloped die face (1530), cutters should be laid out as below.

Layout of cutters in the corners of punch should be done as follow:

X

radius tangent

The cutter should be placed as close as to radius tangent of drawing.

Place of cutter should not get out of trim line .

Gravity of scrap should be outside of this line .

The strength of cutting steels should be considered.

cutterScrap

Avoid placing a cutter at which extremely long cutter is required.

good goodnot good

A punch and the edge of scrap cutters should not face each other.

2

2

h

PAD

UPPER STEEL

VIEW A

SCRAP CUTTERLOWER STEEL

Entrance of cutting edgematerial

thicknessentrance ofcutting edge

t


(SAPCO)



Page 48 of 81

Layout of scrap cutters should be according to part profile.

It should not be remained more than two corners on a scrap.

GoodNot good

In order to provide easy falling of scraps, the angle between the scrap cutters should be either parallel or obtuse to each other.

Q ~ 5

Parallel Line

In the complex parts, falling scraps should not be crossed or collided with each other.

Good Not good


(SAPCO)



Page 49 of 81

Title: Strip pusher

Progressive dies should be equipped with spring pusher in order to eliminate undesirable movements of the strip in the strip guide during the press action. The following three types of the pusher are allowed:

B-B

Die

Strip

Strip guide

FEED

FEED

A

A-A

A

StripStrip guide

Die

Pusher

Pusher

Die

Strip guide

Strip


(SAPCO)



Page 50 of 81

Title: Part box, Scrap box and chute

Shoes with downward outlet for blanks and scraps should have riser blocks in order to provide a space to locate part box, scrap box and their guide rails. Scraps and blanks should have separate container. The material of part box, scrap box and chute should be ST37 with 2-3mm thickness.

It should be at least 3mm distance between the lower face of the boxes and the press bolster. (see above figure)


(SAPCO)



Page 51 of 81

In order to have a safe stocking of die and preventing scrap chute damages (when scrap chute is larger than die shoes), it should be used hinged scrap chute. (Fig. B)

The scrap chute should be made of ST37 with 2.5mm thickness or other similar material. In order to facilitate the part exit from the final station of progressive dies, a slope of more than 25 degrees at the end of the channel should be considered.


(SAPCO)



Page 52 of 81

It could be provided a sloped scrap chute in the die steel without using any chute directly, if applicable.

Very good

Good

Min25

Good

Min25

If in the final station discharging of the part cannot be easily done, a vibrator could be used.


(SAPCO)



Page 53 of 81

Title: Stop blocks

In order to terminate the shutting travel of die, stop blocks should be used between the upper and lower shoes. It provides a specific distance between the die and punch. When the contact surfaces of stop blocks reach each other, it means the press travel is adjusted. This could be controlled using spotting paint. Minimum four stop blocks is needed for each die. The bearing surface of the stop blocks should be parallel to each other. Stop blocks in all dies should have the same thickness. Stop blocks should be made of CK45 (1.1191). Following types of stop blocks are applicable:

stop block

A A

Section A-ASection B-B

Very good GoodGood

stop block

stop block

holder bolt


(SAPCO)



Page 54 of 81

Title: Stock Block

In order to store dies in a safe condition, stock blocks (or storing blocks) should be made. Stock blocks should be made as much as the quantity of stop block sets (at least four). They will be positioned between the upper and lower stop blocks to provide a suitable distance between punch and die during stocking. At this time, the upper and lower shoes should be fastened to each other using fastening strips. The height of stock blocks should be long enough to prevent contact between the punch and die. The guide posts should be entered in bushes Min 30mm during storing. Stock blocks should be made of CK45 (1.1191)

stock block

Min

30m

m

30m

mM

in

stock block

Following types of stock blocks are permissible:

Type A Type B Type C

Needs M6 bolt for connection cable or chain

(Very good) (good) (good)


(SAPCO)



Page 55 of 81

Title: Bottoming marker

Bottoming marker should be used for forming dies, such as Draw and Restrike in order to check whether the forming process is completed or not. Insert bottoming markers on a horizontal flat face of die at right angle to the part surface as much as possible. The place on the part in which the markers is marking on, should have the least material flow. According to the size of the part, one or two markers are required to check the formation of different areas of the part. The hardness of bottom marker should be 60~64 HRC.

0.3(

t>0.

8)

marker

Detail AA

shim

Panel

See detail A

0.2(

0.61.4 R= 5if t


(SAPCO)



Page 67 of 81

In order to flange the part with a complex form, the form of the punch should be similar to the part. Such flanging operations are called spank flange. (See following figures) When spring back is expected, parting line should be inside of tangent radius even if R5

Pad

Punch

Die

Pad

Die

Punch

R< 5

2mm from tangent if R>5

Punch

Pad

Die

Pad

Punch

R


(SAPCO)



Page 68 of 81

Title: Flange in corners

As the bend die would make much abrasion on the corners, the following condition should be considered on the sectional die: 1- Stretch flange, with over 15% elongation, and hard facing treatment or welding treatment:

l

Trim line

Bend linePercentage of shrinkage = L - ll

L

2- Shrink flange, with over 15% shrinkage, steel insert in corner area:

ll - LPercentage of shrinkage =

Bend line

Trim lineLl

Insert block is not necessary if flange length is less than 10mm. (following case)

R

With large radius (>30) below 5mmcorner notched


(SAPCO)



Page 69 of 81

Title: Spring back in bending

In the bending operation, after removing the pressure, the part tends to recover itself elastically and its bend radius becomes larger. Under certain conditions, it is possible for the final bend angle to be smaller than the original angle (negative spring back).

Before ending pressureSpringback =

Following methods are used to reduce or eliminate spring back in bending operations, if applicable:

W

< 90

< 90

90 90

P(counter)

(a) (b) (c) (d)

In the compensation method (a) the metal is bent more than the final angle, therefore, it springs back to the desired value. In some cases, some trial and error is required to choose the suitable bending angle. The following design (left hand figure) can create the bend but it is hard to achieve the necessary over-bend, which must be created to allow the metal to return to 90 degrees. The design (right hand figure) works best when the metal is bent over a radius that is equal to or less than metal thickness. This design achieves the over-bend by coining the radius at a point slightly above the lower tangent point of the bend radius. By vertically shimming the forming section up and down, the gap, as well as the amount of coining, can be adjusted.

Lower diesection

Pressure pad

Bendingpunch

punchBending

Pressure pad

sectionLower die

Adjusting shim

True Bend Radius

Radius equalsinside bend radiusplus metal thickness

Very Good!


(SAPCO)



Page 70 of 81

Title: Bead design

In order to control the flow of the material between punch and die, beads or binder should be added to the die face and in the opposite side on the punch.

Die

Punch

Blank holder

Sheet material Bead

Both Round and square beads can be used. The beads are either unitary or inserts types.

CC

15 minW

AB

H

R1

R1

R1

R2

H=W/2A=R1+C+R2+W/2B=R3+R4+C+W: Dimension CR1=1~2 C=8R1?2.5 C=6e.g. R1=2, R2=8, W=10, R3=R4=3A=2+8+8+5=23mmB=3+3+6+10=22mm

Dimensions needed for insert beads are as following:

26

12

25

10

(Refernce)RHW

H

W

R

H

w

84

1.5

R

Positioning of bolts on the bead is as follows:


(SAPCO)



Page 71 of 81

Trapezoidal beads

87 7R3

R0.5 R1.5

R0.5 R0.54

maintain plan

(13) (13)

57 7R3

3

7

in 7mm

match the inclined surface in certain.

General To improve yeilding

Step bead

AC

3

Unitary bead

Min. 7mm For Dimension C.

eg. R1=5, R2 =3

A=5+3+7=15mm1R

R2

A= R1+ R2+C

When trim line is located on the step bead, following method is preferable:

MIN 4mm

R

When trim line is located on die face:

Trim line

D=5mm

D


(SAPCO)



Page 72 of 81

Title: Air vent systems

On any locations on the die face, which may have the possibility of air trap, for example space between the draw punch and die, or guiding posts and bushes, air vent holes or grooves should be made. Depend on the expanse of the punch and die face in the draw tools, several holes may needed.

Blank

Punch

Die

holder

Air vent groove should be made on the top face of the upper shoe where the press ram may cause air trap.

Air vent groove

Air vent groove

(Top View)

Press upper ram

Upper shoe

Upper shoe


(SAPCO)



Page 73 of 81

Title: Coordinate hole

All of the die shoes should have coordinate holes in order to establish X and Y machining references.

A A

Using precise pins inserted in these holes will make unique reference for the machining of steel blocks and other elements of die, which fastened on the shoes.


(SAPCO)



Page 74 of 81

Title: Surface roughness in the die elements

Each one of the elements of die should have a smoothed surface related to their function. Following table shows the suitable surface roughness needed in each die.

50 100

2512.5

3.2 6.3

1.60.4 Surfaces for shape, trim edge,

Connecting surfaces of steel

Finished surface not connected to other parts

Roughly finished surface with less importance

Natural surfaces of casting and steel

Triangular Arithmetical MeanSurface roughness

indication Roughness (Ra) Application

bend edge and sliding

(finished by grinder)

Some examples of usage of the surface roughness marks are shown in the following drawing.

Die

Lower shoe

Guide post

(or die holder)


(SAPCO)



Page 75 of 81

Title: Calculations

1- Holding pressure in Draw dies (using soft steel panels):

PH = B L Pn PH: holding pressure (kg) B: average width of blank holder (mm) L: average periphery length of blank holder (mm) Pn: required pressure for unit of area (kg/mm2) The classification of the Pn is defined in the following table:

Rear fender, Wheel house outer,

Tail gate inner, Door inner, Tail

Front panel, Door outer,

Example

Mainly drawing

Drawing and bulging

Mainly bulging

Purpose

gate outer, Wheel house inner

Front pillar

Hood outer, Roof

0.13

0.22

0.29

Pn

2- Stripping pressure in Trim dies: Stripping pressure varies according to metal thickness and shape, but generally stays within 4~20% of trimming pressure. Extremely high stripping pressure would be required if clearance is below 10% of thickness. In the case of soft steel panels, stripping pressure can be described as below:

Simple shape

Over 4.6 mm

Within 2~4.5 mm

Below 2 mm

Metal thickness

Ps = P(0.10~0.12)

Stripping pressure (Ps)Shape of panel

Complex shape

Simple shape

Complex shape Ps = P0.08 or =27.00Lt

Ps = P0.06 or =19.60Lt

Ps = P0.07 or =24.50Lt

Ps = P0.05 or =17.20Lt

-

Ps: Stripping pressure (N/mm2)

P: Trimming pressure (N/mm2) L: Cutting length (mm) t: Metal thickness (mm) Above calculation describes stripping pressure on the starting point of operation. 3- Calculation of pad pressure Pad pressure depends on the thickness or shape of the panel, but is generally require 15~30% of bend pressure.

P = PB(0.15~2) or = 3.5~4

P = PB0.3 or =6Lt

Inner panel

Outer panel

Panel type Pad pressure


(SAPCO)



Page 76 of 81

P: Stripping pressure (N) PB: Trimming pressure (N) L: Cutting length (mm) t: Metal thickness (mm) "P" is the load at the beginning point of pad operation. 4- Calculation of ejection pressure and pad: a) The ejection pressure of an external pad:

Outer Pad

Die

Punch

5% shearing pressure

3% shearing pressureLarge die

Small die

Size Ejection pressure

b) The ejection pressure of an internal pad:

Pad

Die

Punch10% shearing pressure

5% shearing pressure

Ejection pressure

Large die

Size

Inner

Small dieWith a thick and hard material

5-calculation of draw pressure:

Fn FnFz

d1

dnD

s

Fz = (d1+S) SRm1.2 [(B - 1) x(Bmax - 1)]

Fz: deep drawing pressured1: punch diameterS: material thicknessRm: tensile strengthB: Draw ratio: B=D/d1Bmax: Max draw ratioD: blank diameter

(In general, the approximate value of draw pressure is 0.7shear pressure.) 6- Holding pressure in Draw dies:


(SAPCO)



Page 77 of 81

Fn = / 4(D P)2nd-2

dn = 2(R+S) + d

Fn: Pad forceD: Blank diameterdn: Diameter of effective area of padP: Pad pressure

Steel P = 2.5 N/mm2copper P = 2-4 N/mm2Aluminum P = 1.2- 1.5 N/mm2

a. In general, the approximate value of draw pressure is (1.3shear pressure). b. The radius of punch and die edges in draw dies is minimum (4t) in which the "t" is

the thickness of material. c. The maximum height of draw is (0.7diameter of draw punch)

6- Bending pressure in Bend dies:

Simple bend(straight bend line)

Curved bend(Curved bend line)

Restriked bend

F' = 0.2 F

F' = 0.3 F

F' = 0.5 F

Type of bend Figure Bending force

(In these calculations, F' is Bending force, and F is shearing force.) 7- Pad pressure in bending die:

Pad pressure

F'' = 0.4 F' + weight of padF'' = 0.4 F' - weight of pad

Type of bend diePad in topPad in bellow

(In these calculations, F' is Bending force, and F'' is pad pressure.)


(SAPCO)



Page 78 of 81

Title: Die Painting

Elements of progressive and G5 dies should be painted using the standard table of colors, as follows:

Blue

Blue

yellow

Painting Colors

Scrap box and part box

Scrap chuter

Safety cover

Position of Painting

1

2

4

NO

Transportation strip white3

Standard code

RAL5024

RAL5024RAL9016

RAL1018

Note: Other elements of die should be remained without coating of paint.


(SAPCO)



Page 79 of 81

Title: Identification plaques of die

In order to identify the specifications of each die, a specific plaque should be provided for each one of the following specifications. All plaques should be riveted to the die with 5mm distance from the edges of the die. 1- General specifications plaque should be attached to all dies and it implies that the die is the possession of SAPCO.

Size X

Weight

Part Name

Tool Maker

Tool Type

Tool Code

Part No.

Mfg. Date

(kg)

(mm) X

Supplying Automotive Parts Co.

2- The contents of the general specifications plaque should be filled as follows:

Size X

Weight

Part Name

Tool Maker

Tool Type

Tool Code

Part No.

Mfg. Date

(kg)

(mm) X


9609906580

1203121427

FRT RH DOOR INNER FRAME STIFFENER

SEPEHR

Pierce OP30

2200 1300 850

06/2004

4000+3000

3- If there is not enough space to attach the general specifications plaque, a simple plaque as shown in the following picture, should be attached:

Tool Code

Part No.



(SAPCO)



Page 80 of 81

4- If the tool is progressive type, the following plaque should be attached on it:

Pitch (mm)

Press Type

Thickness

Strip Width

Feed Type

Progressive Tool

5- In order to specify the direction of feed (loading the part) following plaque is needed.

6- In order to specify the front side of the die, following plaque should be attached:

7- If the die is equipped with Nitrogen gas spring, following plaque should be attached:

THIS DIE IS EQUIPPED WITH HIGH PRESSURE NITROGEN GAS SPRING.MAX CHARGING PRESSURE BAR/ PSI. GAS SPRING MUST BE

PROTECTED AGAINST SIDE LOAD, HIGH TEMPERATURE, GRINDING DUSTAND WELDING PARTICLES. GAS SPRING ARE TO BE REMOVED IN THE DIE

ONLY IN LOAD FREE POSITION.

WARNING!


(SAPCO)



Page 81 of 81

8- If the die is to be applied with air pin, the layout of the press bolster and other needed information should be attached as shown in the following plaque:

PRESS SPECIFICATIONS

CUSHION HEIGHT ABOVE BOLSTER(mm)

CUSHION Stroke(mm)

PRESS TYPE

CUSHION PRESSURE(Ton)

2

4

1

3

5 3 42

9- The locations of each one of the mentioned plaques on the die is shown as followed:

A- General specifications plaque B- Progressive die C- Front side of the die D- Nitrogen gas spring E- Layout of the press bolster F- Direction of feed

Die and Tool Department of SAPCO

D 1

D 2

D 3

D 4

D 5

D 6

D 7

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

D 16

D 17

D 18

INDEX D - Die design check list for progressive and G5 dies

PART NAME :

REMARK :

SIGNATURE :

PROJECT NAME:

PART NO:

DRAWING NO:

Sapco.

Controling visual aspects of part (burrs, tears, creases and deformations)

Controling of 1/3 of radius and cut band area and 2/3 of break in the trimed edges of blanck or parts

Using Cam unit mechanism according to Sankyo standard

Scraps and parts should have separate boxes.(If possible)

Scrap and part boxes should have guiding rails.

In oder to facilitate the egression of part in the final station of progressive dies, a slope of more than 25 degrees at the strip guide should be considered.

Loading and unloading of the panel should not be affected by the use of CAM units.

The possibility of damages of CAM units in their actions should be controled.

Pre Buy Off

When the die is closed, the guide post should be lower than the upper die set (min 3 mm)

The length of the guide post should be long enough to enter the guide bush, before the conact between the blank holder and part.

The bearing surfaces of the stop blocks and stock blocks should be parallel to each other and their diameter should be same.

The head of punch and blank holder should be controled by die spot operation against the die surface in order to control bedding out of the die main faces.

Dies with downward outlet for parts and scraps, should have riser.

The genral dimensions of die should be appropriated with press bolster sizes .

The ballancing condition of pads and ejectors, in the start and end of gripping action, should be controled in all of the stages in progressive dies.

For any locations in die, which may have the possibility of air trap, for example " space between the draw punch and die" or " guide posts and bushes", suitable air vent holes or grooves should be considered in the design.

In flange dies, the flanged edges of part should pass through the die entry.

Buy Off Comments

Die Check List ( progressive & G5)

DIE & OP NO:

SUPPLIER:

NAME:

DATE:

ITEM (PROGRESSIVE & G5)RowTest

Controling of spotting of heel guide with length of more than 800mm

Page 1 of 3

Pre Buy Off Buy Off Comments ITEM (PROGRESSIVE & G5)RowTest

S 19

S 20

S 21

S 22

S 23

S 24

S 25

S 26

S 27

S 28

S 29

S 30

S 31

S 32

S 33

S 34

S 35

S 36

S 37

S 38

S 39

S 40

S 41

S 42

There should not be any gap and space between the inserted steel blocks and their splitting line should be perpendicular to the part profile.Cutting dies should be made of SPKR or other kind of steels with the same mechanical properties and minimum 60HRC hardness.

Guide posts and heel guides should be fool proof.

The use of punch holder is required for each one of te die with small punches.

Punches which are made by wire cut operation should be inserted in the punch holder with sliding fit tolerance.

Surface roughness for punch, die and blank holder, should be in condition.

The length of bearing of spool retainer in punch holder or in upper shoe, should not be less than 15mm.

Using spool retainer and a set of guide post and bush is essential when the blank holder size is more than 500mm.

Larger punches and dies should be made sectional.

In order to avoid waste material at the end of the strip after passing the first side cutter, based on the part accuracy and tolerances, one or more side cutters or fixed pin should be used at the final stations.

The splitting line of the inserted steel blocks should not be positioned at the corners of the parts.

Progressive dies with more than 4 stages should have guide posts with ball bearing bushes.

Shearing walls should have appropriate height according to the part thickness and production rate.

Guide posts or guide bushes should have lubrication grooves.

The punch bumper plate is required for punches with a diameter less than 30mm.

Distances between screws and dowel pins from the cutting edges should not be less than 12mm

The minimum quantity of stop block for each die is 4.

The dies and punches should be made of suitable material and hardness. Also, there should not be any welding, cracks or voids on their surfaces.

The distance between trimming edges of die and outer contour, should be at least 30mm.

Punch and blank holder should have appropriate clearance between each other.

The minimum distance between the die face and the head of screw or dowel pin, should be minimum 5mm.

For dies which are affected by thrust forces, together with screw and dowel pin, back up keys should be used as well.

Appropriate fillet or chamfer should be included to the corners of the blank holder holes, through which the punch is passed.

Blank holder should be made of VCN200 or MS60 or other similar steels with the same properties and hardness.

Page 2 of 3

Pre Buy Off Buy Off Comments ITEM (PROGRESSIVE & G5)RowTest

S 43

S 44

S 45

S 46

S 47

S 48

S 49

S 50

S 51

S 52

S 53

S 54

S 55

S 56

S 57

S 58

S 59

S 60

S 61

S 62

S 63

S 64

S 65

S 66

S 67

Minimum thickness of bushes in the spool retainer should not be less than 3mm.

Shim and other kind of fillers should not be used to fill back up keys gaps.

Spare part list should be included according to standard & contract.

Using a fastening cable or chain, in order to fasten storing block to the lower shoe.

Using part list in order to cotrol the size & material of the dies elements (such as punch, die, pad,)

Using center line marks or groove in each die.

Using shank hole (threaded) in upper shoe in order to fasten the upper die to press ram.

Strip pusher should be used as much as required along the strip guide.

Dies with more than 800mm in length, should have heel guides with the appropriate wear plates in addition to guide posts.

For each one of the dies, an identification plaque including operation name, part name,part number, left/right hand of part and tool weight should be prepared.(refer to standard)

In order to specify the feed direction, a separate plaque should be prepared.

The seats of spring should be machined and a guide pin should be prapered.

When the die is open, the cutting edges of the punch should be inside the blank holder(minimum3mm)

The ease of maintenace should be considered.Also, the main elements of die should be replaceable easily.

Transportation hook for large blank holder is required.

Stock blocks should be included in the dies.

All of the dies should have coordinate holes for machining references. 0,0 refernce point should be marked.

For transportation, hooks and fastening strips should be made.

In order to fasten the die on the press bolster, using U slots or clamping area is needed.

The clearance between guide post and guide bush in trim dies should be 0.25 of the clearance between punch and die.

Possibility of sharpening in edges of punch and die (in the shearing dies).

Using springs of Fibro standards or similar

Using Daton (punch-die) sets for regular shape holes.

All of the sharp edges and corners of shoes, dies and blank holders should have 45 chamfer

A heel in semi-cutting punches should be used, e.g. side cutters. (heels should be fastened to the die set with 2 bolts & 2 pins)

Page 3 of 3

INDEX E - Technical Requirements

Technical Requirements Progressive and sheet metal tools

Supplying Automotive Parts

Co.

Documentation

1. Operation sheet of part processes is required. 2. Die lay out or strip lay out for each die should be included. 3. The final version of assembly drawing of die is required. 4. The 3D CAD data of die should be included. 5. Part list of die elements should be prepared. 6. Spare part list should be included. 7. Material certificate of die components is required. 8. The heat treatment report for the steel blocks is required. 9. CMM report of finished parts should be included, if required. 10. Maintenance plan. 11. Standard parts certificates. 12. Instruction of die installation and setup. 13. The feeder specification sheet for progressive dies is required, if applicable.

Strip, strip lay out and strip guide 14. Minimum waste material on strip lay out should be obtained. 15. Strip guide entrance should have a tapered entry. 16. In order to ensure safe leading of strip, strip guide should be start before the side

cutter location and it might be extended out of the die. 17. In order to avoid twisting of strip, the blanking and trimming large holes should be

laid out preferably in the end of the strip. 18. Strip guide and spring blank holder should be used for all progressive dies. 19. In order to avoid tearing of strip in the positions in which the strip is thin, using a

bead in the previous stations should be considered. 20. An adjustable location and positioning of panel or strip should be considered. 21. All holes which their locations are related to each other and specific tolerance is

included in them, should be punched in a single operation, if possible. 22. Idle stations should be used when die will be weak against the shearing and forming

forces. 23. Narrow cutting operations should be done in separate stages. 24. In order to avoid deformation of holes and trimmed edges, the correct sequence of

piercing, trimming, forming and bending operation should be considered. 25. Working operations in a progressive die should be combined as a single operation

and additional stages should be avoided, if possible. 26. Idle stations should not have breathing effect.

Punch, die and blank holder 27. Larger punches and dies should be made in sectional form. 28. Those punches which are made by wire cut operation should be inserted in the punch

holder. 29. Surface roughness for punch, die and blank holder, should be in condition. 30. When the die is open, the cutting edges of the punch should be inside the blank

holder (minimum 3mm).

31. The head of punch and blank holder should be made of the exact shape of the part. In other words, the head of punch and blank holder should be finished by spotting operation against the die surface.

32. The dies and punches of the tools should be made of suitable material with the required hardness. Also, there should not be any welding, cracks or voids on their surfaces.

33. In order to avoid the wrong installation of removable punches (ball lock type), the punch shanks should have various diameters and stepped forms.

34. The clearance between trimming punch and die, also between bend and draw punch and die, should be according to the related standards, thickness and material of part.

35. Punch and blank holder should have appropriate clearance between each other. 36. Appropriate fillet or chamfer should be included to the corners of the blank holder

holes, through which, the punch is passed. 37. A tapered scrap hole in the end of the shearing wall of the die is preferable. 38. There should not be any gap and space between the inserted steel blocks and their

splitting line should be perpendicular to the part profile. 39. Cutting dies should be made of SPKR or other kind of steels with the same

mechanical properties and minimum 60HRC hardness. 40. For dies which are affected by thrust forces, together with screw and dowel pin, back

up keys should be used as well. 41. Die shearing walls should have an appropriate height according to the part thickness

and production rate. 42. Transporting hook for large blank holder is required. 43. The splitting line of the inserted steel blocks should not be positioned at the corners

of the parts. 44. In the weak and breakable areas, inserted steel blocks should be used. 45. Blank holder should be made of VCN200, MS60, or other similar steels with the

same properties and hardness. 46. In order to locate the guide pins on the die face, in single operation dies, die face area

should be greater than blank size. 47. In order to adjust the inserted steel blocks and back up keys, the use of shim is not

allowed. 48. The minimum distance between the die face and the head of screw (or dowel pin),

should be minimum 5mm. 49. The distance between trimming edges of die and outer contour, should be at least

30mm.

Punch holder, bumper plate, pilot pin and spool retainer 50. The use of punch holder is required for each one of the dies with small punches. 51. The punch bumper plate is required for punches with a diameter less than 30mm. 52. The punch bumper plate should be made of SPK or similar materials with the

required hardness. 53. For each spring located in blank holder, a spool retainer should be added. 54. The length of bearing of spool retainer in punch holder or in upper shoe, should not

be less than 15mm. 55. The minimum thickness of spool retainer bushes should not be less than 3mm. 56. The maximum difference between the pilot pin diameter and punch diameter should

not be more than 0.05mm. 57. Pilot pins should be in exact and equal distances from the center lines of the die. 58. Pilot pins should be aligned with the center line.

Side cutter

59. In order to control the feed in progressive dies, using the side cutter is essential. 60. One or more side cutters should be used according to the part accuracy and

tolerances. 61. In order to avoid the remaining waste material at the end of the strip after passing the

first side cutter, based on the part accuracy and tolerances, one or more side cutters or fixed pin should be used at the end of the final stations.

62. A steel heel for each side cutter should be used.

Guiding units

63. When the die is closed, the guide post should be lower than the upper die set (minimum 3mm).

64. All of the dies should have 4 sets of guiding post and bush. 65. Dies with more than 800mm in length, should have heel guides with the appropriate

wear plates in addition to guide posts. 66. Progressive dies with more than 4 stages should have ball bearing guide bushes. 67. Guide posts and heel guides should be fool proof. 68. Surface roughness of guide posts should be in condition 69. Guide posts or guide bushes should have lubricating grooves. 70. Using spool retainer and a set of guide post and bush is essential and when the blank

holder size is lager than 500mm, heel guides should be used. 71. The length of the guide post should be long enough to enter the guide bush, before

the contact between the blank holder and part.

Stop block and stock block 72. Minimum bearing strength for each stop block should be 10,000 PSI. 73. The minimum

Documents

Die Design Standards-Sapco