PUNCHING TOOL

SUITABILITY FOR PUNCHDIE PRODUCTION #1

2016-05-26T04:41:00.000-07:00

When evaluating a part for die production, the most restrictive aspect to be considered is
the cost of the tooling. To build a metal stamping die is a costly process, involving many
people, many machines, and several technologies. For that reason, the demand for tooling
must first be economically justified.
The quantitative demands per given time span should be evaluated first, because a scenario
of 50,000 washers to be delivered each month requires a different treatment from
50,000 washers to be delivered each week.
A correct evaluation of the problem must be performed on the basis of:
• Availability of the appropriate press
• The equipment’s running speed
• The length of production shifts
• Scheduling for the needed time interval
For a small run with few repetitions, a single line of tooling may be chosen. However, if
the quantities are large and the time constraint exists, a multiple-part-producing tool must
be built. Such a die, generating at least two or more complete parts with each stroke of a
press, will speed up production admirably. But increasing the size of the tool necessitates
the use of a larger and more powerful press and may even require a nonstandard width of a
strip, which will certainly cost more and will have longer lead times.
With parts other than simple washers, the shut height of the press versus the height of
the part is another production-influencing factor.
The width of the opening in the press plus the width of the proposed die must definitely be
in congruence.
The possibility of reorders should be considered at this point, as they may result in an
extended production run, greater material demands, and longer occupancy of the press.
Such longer runs are usually beneficial from the economical standpoint, as they save on
die-mounting procedures and press adjustments, while also decreasing the demand for
quality control personnel involvement.
On the other hand, a problem of storage of these extra parts may arise along with the existence
of temporarily unrewarded financial investments into the purchase of material, workforce
compensation, taxes, utilities, and overhead. These all need to be taken into account since
they will only increase the final cost of the product, long before it can be sold to a customer.
To properly evaluate the situation, all applicable expenditures should be added up as follows:
1. Cost of the storage space (prorated rent or property taxes, cost of the building and
improvements)
2. Cost of all packaging and repackaging material, storage containers, protective barriers,
and insulation
3. Cost of stacking and restacking of parts, sorting them out, and discarding rusty or damaged
pieces
4. Spoilage of possible storage-sensitive material and the scrap rate
5. Cost of raw material and other production-related necessities
6. Overhead, such as electricity, cost of heating or cooling, water, and fuel applicable to
the storage of parts
7. Cost of labor, including possible overtime
8. Cost of paperwork involved with storage and subsequent handling of products
9. Interest rate at which the monies allocated to the above activities could have generated
when invested otherwise
The combined expenses 1 through 9, when added up, should be equal to or less than the
combined:
1. Cost of the removal of a die from the press
2. Cost of the installation of a die in the press (for the subsequent run)
3. Cost of the machine’s downtime during the die removal and installation
4. Cost of the press operator’s standby, if applicable
5. Cost of the press adjustments and trial runs
6. Cost of the first piece inspection and the cost of further adjustments and approvals, if
applicable
7. Cost of the extra material and supplies, which must be purchased ahead of the time
even if not immediately utilized
8. Overhead, such as cost of electricity, heating, cooling, water, and fuel
9. Cost of all subsequent billing and paperwork
10. Combined interest the finances allocated to the above causes would
have generated when invested otherwise
The length of each run and its influence on the need for sharpening and maintenance of tooling
must be evaluated for the entire production run. Should a maintenance-related interruption
be necessary, a possible split of the previously planned combined run should be considered.
A definite advantage of the die production is its unrivaled consistency in the products’
quality and dimensional stability. In absence of design and construction mistakes, the die,
once built, needs minimal amount of alterations, aside from regular sharpening.
Some dies, true, are more sensitive than others, which is mostly attributable to excessive
demands on close tolerance ranges of parts and on the variation in material thickness.
With some bending and drawing operations, the consistency in hardness of stock can be
essential as well. But a regular die, well designed and well built, can deliver a great load of
products before its punches begin to wear and a need for repair or sharpening arises.
Generally, it may be claimed that if the conditions of the die-operating process are kept
the same and if the tool was not dropped off the forklift or similarly mangled, the parts from
the die will emerge consistent with previous runs.

FORGING BLACKSMIT #1 PUNCHING DIES

2016-05-25T18:17:00.000-07:00

Blacksmithy or Forging is an oldest shaping process used for the producing small articles for which accuracy in size is not so important. The parts are shaped by heating them in an open fire or hearth by the blacksmith and shaping them through applying compressive forces using hammer.

Thus forging is defined as the plastic deformation of metals at elevated temperatures into a predetermined size or shape using compressive forces exerted through some means of hand hammers, small power hammers, die, press or upsetting machine. It consists essentially of changing or altering the shape and section of metal by hammering at a temperature of about 980°C, at which the metal is entirely plastic and can be easily deformed or shaped under pressure. The shop in which the various forging operations are carried out is known as the smithy or smith’s shop.

Hand forging process is also known as black-smithy work which is commonly employed for production of small articles using hammers on heated jobs. It is a manual controlled process even though some machinery such as power hammers can also be sometimes used. Black-smithy is, therefore, a process by which metal may be heated and shaped to its requirements by the use of blacksmith tools either by hand or power hammer.

Forging by machine involves the use of forging dies and is generally employed for mass-production of accurate articles. In drop forging, closed impression dies are used and there is drastic flow of metal in the dies due to repeated blow or impact which compels the plastic metal to conform to the shape of the dies.

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CRACKING DIEPUNCH #1

2016-05-22T04:52:00.000-07:00

Intergranular cracking makes its presence known by the emergence of long, vertical cracks,
reaching from the top of a shell, down to the bottom. These cracks, caused by the residual
tensile stresses within the material, may be completely invisible and yet the part may be
prone to cracking perhaps later on, already in service.
To test a drawn cup for the existence of intergranular cracking tendency, a corrosive liquid
can be used. Remaining in the cup for a certain period of time, the corrosive liquid will
eat through the cracks and these will open up like a flower.
Where the cups were stress relieved for removal of residual stresses right after forming,
no cracks will be present.
Intergranular cracking is caused by the displacement of material during the drawing
process. Where a drawn, diametrally restricted part is ejected from the die, the springback
of the material has a tendency to force its structure back, toward its basic shape, in this case
to a round blank. By doing so, the diameter of the cup bulges, giving rise to residual tensile
stresses at the same time.
With box-type drawn objects, the cracking is called compression cracking, since it
occurs at the corners, where the material is in compression. The shape and location of these
cracks resembles those of a round shell, which is logical, considering the fact the rounded
corners of the box do resemble a quarter of the shell, each.
Compression cracking is insidious in that, the part may look absolutely perfect and on
impact, or perhaps with time the cracks develop and propagate. As with round shells, stress
relieving after forming removes the residual stresses from the material and along with
them, it removes the material’s tendency to cracking.

FRICTION AND DRAWING LUBRICANTS #1

2016-05-21T04:54:00.000-07:00

Lubricants for a drawing process must have an adequate film strength in order to withstand
the high pressures and high temperatures associated with drawing. The lubricant’s wetting
ability should be considerable as well, to spread readily over the ever-expanding surface
area of the part. Oiliness control is of essence, since a certain amount of it is necessary,
while its excess may prove harmful.
Drawing lubricants, as any other lubricants, must be nonaggressive toward the part,
toward the tooling, the machinery, and the operator. Their application and removal must be
uncomplicated and economical.
There is a variation in a lubricant’s qualities with each material drawn. For example,
aluminum alloys are more plastic and may be drawn into greater depths without tearing or
fracturing. However, they also possess a high coefficient of friction, which, on the die side,
must be decreased with proper lubrication. Such a decrease should be controlled, as an
excessive oiliness of the lubricant will certainly produce slippage of the material, with
resulting damage to the part and perhaps even to the die.
When selecting the lubricant for a given drawing operation, all subsequent manufacturing
processes must be taken into account, such as heat treatment and surface treatment.
Some lubricants, usually those of high lubricating qualities, are highly adherent and for that
reason difficult to remove off the part.

DEPTH OF DRAWN SHELL

2016-05-17T04:45:00.000-07:00

The maximum depth of a box-type shell, attained in a single drawing pass, may be determined
on the basis of the following variables:
• Type of material and its thickness
• Size of corner radius through the center of stock
• Size of the bottom radius
• Ratio between corner radii and length of straight portions of shortest side
• Width of the flange
• Blank shape and overall size of the shell
• Type of die and press
The size of corner radius is the main factor in determining the depth of a square or rectangular
shell. The distance between the corner radii centers should be at least six times the
value of a corner radius. If such a distance should be smaller than 6R, the
depth of the drawn shell has to be decreased proportionately.
The bottom (bend) radius along the straight sides should be the same size as the corner radius
or larger.
Another way of determining if a given part needs more than one drawing operation is to
build a die for the last drawing station and try it.

The WORLD RECESSION HAS FABRICATED AWAITS

2016-04-28T19:40:00.000-07:00

sheet metal stamping compared with other metal machining, fabrication process using a punch and dies process is more practical and inexpensive cost, sheet metal parts already replaced many expensive items, results forged products, casted and produced with a product. The reason is obviously relative cheapness of fabrication can be mass-produced. Section, as well as the control of their aesthetic and technical parameters. That the world is slowly turning from the form of heavy, ornate and elaborate, and replace it with a functional, simple forms, Massif is easily worked on and logical tendency is increasing. Products used to be casted and has an elaborate ornamental feet worked on. It is now mostly made of coated sheet metal, or plastic. Making way for picture frames, chandeliers, wall and door hardware, kitchen sink, pots and pans, door window frames, automotive spare part was gradually replaced by the more practical and inexpensive technique. However, the wear parts of the metal sheets can also be used to imitate the design of decorative hand-made centuries earlier. Metal extrusion, wear parts and wrought, often quite complex and cumbersome, it is used to replace elements of the architecture of the handmade. Metal pipe, metal spinning products, formings, can substitute into cheaper price, from the product manual before. Metal Fabrication results used parts, perhaps the most versatile product of modern technology, is used to replace the previous parts welded together from several components. Well designed sheet metal stamping can sometimes eliminate the need for riveting or other fastening process. Wear parts can be used to improve an existing design that are often expensive and labor-intensive. Even a product repaired, with their production costs cut to the bone, it can often further enhanced, more innovation, further decreasing the cost. Metal stamping dies is the ideal tool that can generate a large amount of. The part that is consistent in appearance, quality and accuracy of dimensions. It is a tool capable of cutting metal press, bending, drawing form to sufficient depth, embossing, coining, finishing edges, curly, and if it does not change the shapes and lines of the metal parts in accordance with the design concepts of the wildest imaginable.

Forging Process Material Metal, Forging, Forging Definition

2016-04-25T06:13:00.000-07:00

Forging or forging process is a metal forming process to produce the final product to provide a compressive force with a certain loading rate. In this formation, the workpiece in at or pressed with the tool through several stages.

Wrought products have a fiber structure / flow line direction of the force he had hoped. Forging process flow lines tend habitual pattern of the outer shape of the object. In general forging process was applied to produce forms of irregular, with sizes ranging from small to large size shape.

Forging operation is generally carried out at high temperatures or hot working, especially for large-size workpieces. Most forging operation performed at low temperatures or cold working for relatively small-sized workpieces. To be able to be a final product, usually formation by forging is done in stages as shown in the picture .Produk Produced Forging Technology / Wrought

Some examples of products produced using forging forming technology can be seen in the image below. Kitchen utensils such as spoons, forks and knives to eat the products formed by the forging process. Most of automotive spare parts for motorcycles either four wheel drive vehicles also formed through forging technology.

#forging #material # metal #technology #workpiece

#automotive #motorcycle #car

Open And Closed Die Forging

2014-11-28T05:57:00.001-08:00

Based on the type of mold, or dies are used, forging operations are usually grouped into Open Die Forging and Closed Die Forging.

1. Open Die Forging, Forging Mold Open With, or without Prints

Open die forging forging is done by placing the workpiece on the die that is flat, or flat die or a simple form. This process is used for large-sized products with low productivity.

Open die forging is usually used to provide the initial shape of the workpiece to be followed by a closed die forging who use, or closed die forgings.

Some examples of open-die forgings are: upsetting, edging, fullering, drawing, swagging, piercing and punching.

Factory Establishment With Hot Forging Technology, Open Die Hot Forging Machine

2. Closed Die Forging, Forging With Closed Mold

Closed die forging is a forging operation that uses a pair of blocks that are precision die forming the desired workpiece. Die block was made by machining or casting. Die forging using this block will result in a product which has a more precise size tolerances. Die block consists of two parts, the upper die, and die bottom. Closed die forgings generally applied to relatively small-sized workpieces.

Closed die forgings applied gradually begins to process fullering and edging on the raw material to provide initial shape of the workpiece. Then do the rough with the rough forging die block. At this stage there is a change form relatively large. Final forging stage is done by finishing die to obtain a workpiece in accordance with the shape and size of the final product design.

In the forging process, the volume of the workpiece should be enough to be able to fill the entire cavity of the mold perfectly. The difficulty of determining the exact volume, the volume of the workpiece is often used relatively larger.

The advantages of this volume will cause the material flow that extends laterally outward from the die cavity and forming a thin metal ribbon commonly referred to as a fin or flash. To prevent excessive flash, or flash is too wide, the die block is provided cavity reservoir called flash gutter. After the last stage of forging, flash cut using a trimming die.

Flash serves as a safety valve cover or excess metal in the mold cavity is closed and in addition it serves as a barrier to the flow of the metal, causing a high pressure to make sure the metal will fill the mold cavity is empty.

TYPE OF DIE CUTTING OPERATIONS

2012-05-11T17:46:00.002-07:00

The operations of die cutting shearing of work materials are classified as follows :

Piercing Punching

Is the operation in which a round punch, or of other contour, cut a hole in the work material which is supported by a die having an opening corresponding exactly to the contour of the punch.

The material slug cut from the work material is often scrap.

Blanking

Fundamentally differs from piercing only in that the part cut from the work material is usable, becoming a blank workpiece for subsequent press working or other processing.

Lancing

Combines bending and cutting along a line in the work material.

It does not produce a detached slug and leaves a bent portion, or tab , attached to the work material.

A cutt off

Operation achieves complete separation of the work material by cutting it along straight or curved lines.

A notching

Operation cuts out various shapes from the edge of workpiece material a blank or part.

Shaving

Is a secondary shearing or cutting operation in which the surface of a previously cut edge of a workpiece is finished or smoothed.

Punch and die clearance for a shaving die, considerably less than that for other cutting dies, allows a thin portion or shaving to be cleanly cut from such a surface of workpiece.

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BLANGKING and FORMING

2009-06-14T20:27:00.000-07:00

CHOICE of STEEL GRADE for PUNCH and DIE

Material Type SOFT :

Al-,Mg-, Cu-alloy
Paper
Plastic
Tensile Strength below 20 kg/mm2

Thickness < 1,5 mm
Shape #ease
X. production quantity 10.000 pcs = Ar-3
Y. production quantity 10.000-100.000 pcs= Ar-3
Z. production quantity 100.000-500.000 pcs = S-3
W.production quantity over 500.000 pcs = A-1
Shape * midle
X.production quantity 10.000 pcs = Ar-3
Y.production quantity 10.000-100.000 pcs = Ar-3
Z.production quantity 100.000-500.000 pcs = S-3
W.production quantity over 500.000 pcs = A-2
Shape ^complicated
X.production quantity 10.000 pcs = Ar-3
Y.production quantity 10.000-100.000 = Ar-3
Z.production quantity 100.000-500.000 pcs = S-3
W.production quantity over 500.000 pcs = A-2

Thickness 1,5-3 mm
Shape # ease
X. = Ar-3 Y. = Ar-3 Z. =S-3 W. =A-2
Shape * midle
X.=Ar-3 Y.= Ar-3 Z.= S-4 W.= A-3
Shape^ complicated
X. = Ar-3 Y. = Ar-3 Z. = S-3 W. =A-2

Thickness 3-6 mm
Shape # ease
X. = Ar-3 Y. = Ar-3 Z. = S-3 W. = A-3
Shape * midle
X. = Ar-3 Y. = Ar-3 Z. = S-4 W. = A-3
Shape ^ complicated
X. = Ar-4 Y. = Ar-4 Z. = R-4 W. = A-3

Material Type MILD

Low Carbon Steel
Low Alloy Steel Electrical
Sheet Tensile Strength 20-50 kg/mm2

Thickness < 1,5 mm
Shape # ease
X. = Ar-3 Y. = S-3 Z. = S-3 W. = A-1
Shape * midlle
X. = Ar-3 Y. = R-3 Z. = S-3 W. = A-2
Shape ^ complicated
X. = Ar-3 Y. = R-3 Z. = S-4 W. = A-2

Thickness 1,5-3 mm
Shape # ease
X. = Ar-3 Y. = S-3 Z. = S-3 W. = A-2
Shape * midle
X. = Ar-4 Y. = R-4 Z. = S-4 W. = A-2
Shape ^ complicated
X. = Ar-4 Y. = R-4 Z. = R-4 W. = A-3

Thickness 3-6 mm
Shape # ease
X. = Ar-3 Y. = S-3 Z. = S-3 W. = A-2
Shape* midle
X. = Ar-4 Y. = R-4 Z. = R-4 W. = A-3
Shape ^ complicated
X. = Ar-4 Y. = R-4 Z. = R-4 W. = A-4

Material Type TOUGH

Stainless Steel
Heat Treated
Sheet Tensile Strength 50-70 kg/mm2

Thickness , 1,5 mm
Shape # ease
X. = Ar-3 Y. = R-3 Z. = A-2 W. = A-2
Shape * midle
X. = Ar-3 Y. = R-3 Z. = A-2 W. = A-2
Shape ^ complicated
X. = Ar-4 Y. = R-4 Z. = A-3 W. = A-3

Thickness 1,5-3 mm
Shape # ease
X. = Ar-3 Y. = R-3 Z. = A-3 W. = A-2
Shape * middle
X. = Ar-4 Y. = R-4 Z. = A-3 W. = A-3
Shape ^ complicated
X. = Ar-4 Y. = R-4 Z. = R-4 W. = A-3

Thickness 3-6 mm
Shape # ease
X. = Ar-4 Y. = R-4 Z. = A-3 W. = A-3
Shape * midlee
X. = Ar-5 Y. = R-5 Z. = R-5 W. = A-4
Shape ^ complicated
X. = Re-5/G-6 Y. = Re-5/g-6 Z. = Re-5/G-6 W. = A-4

Material Type HARD

Spring Steel
Tensile Strength over 70 kg/mm2

Thickness 1,5 mm
Shape # ease
X. = Re-5/g-6 Y. = R-3 Z. = A-2 W. = A-2
Shape * midle
X. = Re-5/G-6 Y. = R-4 Z. = A-3 W. = A-3
Shape ^ complicated
X. = Re-5/G-6 Y. = R-4 Z. = A-4 W. = A-3

Thickness 1,5-3 mm
Shape # ease
X. = Re-5/G-6 Y. = R-4 Z. = A-3 W. = A-3
Shape * midle
X. = Re-5/G-6 Y. = R-4 Z. = R-4 W. = A-4
Shape ^ complicated
X. = Re-5/G-6 Y. = R-4 Z. = R-4 W. = A-4

Thickness 3-6 mm
Shape # ease
X. = Re-5/G-6 Y. = R-4 Z. = R-4 W. = A-3
Shape * midle
X. = Re-5/G-6 Y. = Re-5/G-6 Z. = R-5 W. = A-4
Shape ^ complicated
X. = Re-5/G-6 Y. = Re-5/G-6 Z. = R-5 W. = A-4

A = ASP

Ar = UHB Arne (ASSAB DF-2 )

G = UHB Grane ( M-14 )
R = UHB Rigor (ASSAB XW-10 )
Re = UHB Regin 3 ( ASSAB M-4 ) S = UHB Sveker 3 (assab xw-5 ),UHB Sveker 21 (ASSAB XW-41)

1 = 64-66 HRC
2 = 62-64 HRC
3 = 60-62 HRC
4 = 58-60 HRC
5 = 56-58 HRC
6 = 54-56 HRC

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Specialized Industri Knowledge

2008-10-27T20:32:00.000-07:00

we make progressive dies for sheet metal parts applied in auotomotive,computer, electronic.

Contruct die punch component use CAD/CAM and CNC machining.Punch tools developed many practical solution to industry problem.

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