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Copyright © 2001 Society of Manufacturing Engineers 987654321

All rights reserved, including those of translation. This book, or pa thereof, may not be reproduced by any means, including photocopyi recording or microfilming, or by any information storage and retrie system, without permission in writing of the copyright owners.

No liability is assumed by the publisher with respect to use of inform tion contained herein. While every precaution has been taken in t preparation of this book, the publisher assumes no responsibility errors or omissions. Publication of any data in this book does not cons tute a recommendation or endorsement of any patent, proprietary rig or product that may be involved. Library of Congress Catalog Card Number: 2001094396 International Standard Book Number: 0-87263-525-2 You're Reading a Preview

Additional copies may be obtained by contacting: full access with a free trial. Society of Manufacturing Unlock Engineers Customer Service Download With Free Trial One SME Drive, P.O. Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org SME staff who participated in producing this book: Cheryl Zupan, Staff Editor Sign up to vote on this title Rosemary Csizmadia, Production Supervisor  Useful  Not useful Kathye Quirk, Graphic Designer/Cover Design Frances Kania, Administrative Coordinator

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Dedication

I would like to dedicate this book to the many people that ma it possible, especially my wife Marlyn Smith who helped with t formatting and proofreading of the original training manuals th were used to produce this work. I would also like to thank me bers of the production and editorial departments at SME who w the extra mile to give this work polish and continuity. Those in viduals include Cheryl Zupan, Bob King, Rosemary Csizmad You're Reading a Preview Kania. Kathye Quirk, Jon Newberg, and Frances Unlock full access with a free trial.


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Table of Contents

Preface ..................................................................................... Contributors ............................................................................ x 1 An Overview of Basic Die Operations ................................

Cutting, Punching, and Perforating ........................................ Bending and Forming............................................................. Bending and Straightening .................................................... Stretching ............................................................................... Drawing................................................................................... You're Reading a Preview Squeezing or CoiningUnlock Operations.......................................... 6 full access with a free trial. Analytical Tools ....................................................................... Download With Free Trial

2 Troubleshooting Punching and Cutting Operations ...........

Understanding the Sequence of Operations ....................... 11 Effect of Die Clearance ......................................................... Cutting Forces ...................................................................... 2 3 Designing Large EDM Die Sections for Repairability ........ 

Sign up to vote on this title Application of EDM Technology ........................................... 27  Useful ........................  Not useful Throwaway versus Repairable Die Sections 28 Die Section Location and Retention ..................................... 2

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5 Solving Punch Head Breakage Problems ...........................

Punch Head Breakage ......................................................... 3 Safety of Personnel............................................................... 4 Function of the Punch Backing Plate ................................... 4 Ironworker- and Bulldozer-style Punches ............................ 47

6 The Cost of Punch and Die Maintenance ............................

Record Causal Factors ......................................................... The Real Cost of Die Damage .............................................. 5 The Value of Good Workmanship ........................................ 51

7 Good Maintenance Practice .................................................

Good Grinding Practice........................................................ 5 Stress-relieving Cutting Tools ............................................... 6 Shimming Die Components ................................................. 65 Ball-lock Punches and Die Buttons ...................................... You're Reading a Preview 8 Compound Dies ....................................................................

full access with a free trial. Compound Blank andUnlock Piercing Dies .................................... 73

DownloadSelection With Free Trial................................ 9 Pressure Pad and Stripper

Positive or Tunnel Strippers .................................................. 7 Pressure Systems for Pads and Strippers ........................... 81 Elastomer Strippers .............................................................. Stripping Forces ................................................................... 8 10 Anti-slug Pulling Methods ..................................................  Sign up to vote on this title

Resolving Slug-pulling Problems ....................................... 89  Useful  Not useful Overview of Methods ..........................................................

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Table o f Conte

12 Bending of Metals .............................................................

Bend Allowances .............................................................. 11 Press-brake Operations.................................................... 115 Wipe-bending Die Operations .......................................... 117 Rotary-action Die-bending Operations ............................ 119 Control of Bend Angle by Adjusting Pad Pressure .......... 122 13 Forming Flanges and Hems .............................................

Flanging Operations ......................................................... 12 Flange Types .................................................................... 12 Minimum Bend Radii ........................................................ 13 Stock Thickness Variation ................................................ 133 Hemming Operations ....................................................... 136 Pressures .......................................................................... 13 14 Drawing and Stretching of Metals ...................................

Deep Drawing of a Cylindrical Cup .................................. 141 You're Reading a Preview Stretch Forming ................................................................ 14 Unlock full access with a free trial. Bending and Straightening .............................................. 149 Drawing and Bending ....................................................... 15 Download With Free Trial 15 Stamping Analysis Techniques ........................................

Computerized Analysis Techniques ................................. 158 Circle Grid Analysis .......................................................... 15 16 Die Maintenance Documentation and Tracking .............. Sign up to vote on this title

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Die Maintenance Team ..................................................... 16  Useful  Not useful A Systematic Die Maintenance System ........................... 168 The Request for Maintenance Form ................ 175

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Continuous Improvement ................................................. 18 Spare Parts Inventory ....................................................... 19 Calculating Costs ............................................................. 19 Pareto Charting ................................................................. 20 Dealing with an Outside Vendor ....................................... 20 Used Dies ......................................................................... 20 Good Engineering Practice .............................................. 205 18 Metallic Springs as Die-pressure Devices ......................

Types of Metal Springs ..................................................... 211 Materials Used to Make Metal Springs ............................ 215 Selecting Springs ............................................................. 21 Considerations When Repairing Dies .............................. 220 Analysis of Spring Failures ............................................... 222 Winding Springs In-house ................................................ 22 Conclusion ........................................................................ 22 19 Gas and Hydraulic Die-pressure Systems ...................... You're Reading a Preview

full access with a free trial. Pneumatic CylindersUnlock ........................................................ 22 Nitrogen Die-pressure Systems ....................................... 231 Download With Free Trial Nitrogen Manifold Systems .............................................. 235 Self-contained Nitrogen Cylinders ................................... 237 Hydraulic Die-pressure Systems ...................................... 243

20 Press Selection and Maintenance ...................................

Press Terminology ............................................................ 24  25 Types of Presses .............................................................. Sign up to vote on this title Overload Protection .......................................................... 25  Useful  Not useful Mechanical Press Drives .................................................. 26 Speed Reduction and Torque Capacity ............... 268

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Table o f Conte

A Systematic Approach to Die Tryout .............................. 286 Draw Beads ...................................................................... 29 Double-action Press Operations ...................................... 295 Dirt Problems .................................................................... 29 Forming Ribs and Embossments..................................... 297 Knockout Bars .................................................................. 29 22 Waveform Signature Analysis ..........................................

Stress-strain Curves ......................................................... 30 Case Study: Webster Industries ....................................... 30 Diagnosing Hydraulic Overload Problems ...................... 307 Press-tonnage Curves ...................................................... 31 Detecting Waveform Changes ......................................... 315 Die- and Press-protection Systems.................................. 317 Conclusion ........................................................................ 32 23 Repairing Damaged Die Steels and Castings .................

You're Reading a Preview Making the Repair Decision ............................................. 32 Unlock full access with a free trial. Mechanical Repair Techniques ........................................ 325 Electrical Welding Repairs................................................ 333 Download With Free Trial

24 Die Materials and Treatments ..........................................

Characteristics of Tool and Die Steels .............................. 340 Choosing Tool Steels ........................................................ 34 Heat Treatment of Die Steels ............................................ 353 Tool Steel Production Methods ........................................ 358  360 Die Surface Coatings and Treatments ............................. Sign up to vote on this title Wrought Low-carbon Steels and Cast Irons.................... 363 Not useful  Useful Nonferrous and Nonmetallic Die Materials ...................... 365

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Die Shoes, Subplates, and Parallels .................................. 379 Die Springs ......................................................................... 38 Strip Starting Stops ............................................................ 38 Commercial Perishable Details .......................................... 383 Pads and Strippers ............................................................. 38 General Tool Steel Details .................................................. 385 Guide Pin, Bushing, Heel Block, Keeper, and Wear Plates 386 Scrap Discharge ................................................................. 38 Stock Sensors .................................................................... 38 General Good Practice ....................................................... 38 OSHA and Additional Die Identification ............................. 389 Appendix B: Case Study— Phoenix Specialty Manufacturing Company .........................

Order Entry ......................................................................... 39 Machine Shop Capabilities ................................................ 392 Plant Culture ....................................................................... 39 You're Reading a Preview Spare Parts Storage ........................................................... 39 Ergonomics ........................................................................ 39 Unlock full access with a free trial. Aluminum Die Sets ............................................................. 39 Download With Free Trial Bench Die Build Up ............................................................ 39 Quick Die Change Capabilities .......................................... 399 An Eye to the Future ........................................................... 40 Conclusion .......................................................................... 40 Index ........................................................................................ Sign up to vote on this title

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Preface

Developing a popular book on the topic of die repair has been challenging task. The goal of every shop should be to minimize maintenance expenditures through good die design. To do this, ea of the metal forming, pressworking processes need to be und stood from a simple, yet analytical, point of view. Thus, this ref ence work on die maintenance deals with metal-forming proces in an elementary way, before looking at the bigger picture of c You'reavoidance Reading a Preview containment using damage and robust die designs. Unlock full access with a free trial.


CHOOSING THE CONTENT OF THIS BOOK

A goal of this reference work is to produce a handbook that make solving stamping-process problems understandable by ne comers to the trade. At the same time, it is intended to serve t experienced journeyman with reference information for solvi difficult problems. An essential theme is that die maintenance  up to vote on this title cost that needs to be minimized. Too Sign often, die maintenance  Useful  Not useful treated as unavoidable and unacceptable, with its very real co lumped in with other overhead. Success in any critical mecha

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these skilled workers will continue to hold engineering and t management positions in the future. Most community colleges and trade schools do a good job teaching the basic principles of computer numerical control (CN machining, industrial welding, hydraulics, pneumatics, and el tronic technology. However, schools lack hands-on training in basic theories of die making and metal-forming processes. Han on experience needs to occur in a die building and/or repair fa ity under the guidance of skilled workers. Apprentices or trainees are not a source of low-cost labor builders and the manufacturers who depend on pressworking to ing in their processes have a duty and an obvious, personal sta to provide the best training to all in the trade, without regard experience level. Anything less deprives both the craftsperson a employer of the critical skills that are essential to remain inno tive and competitive in a world market. You're Reading a Preview

BOOK ORGANIZATION Unlock full access with a free trial.

An essential die-repair skill is the ability to modify existing Download With Free Trial ing to correct design mistakes and problems that can affect p quality and proper tool operation. A good understanding of met forming processes in pressworking tooling is necessary to ma tain and correct die problems. This book begins with an overview of basic die operations a continues with the anatomy of how these processes work. Troub  fac shooting, or using insight into the process, is an essential Sign up to vote on this title in problem solving. Formability theory and practice  Useful  Not useful begin w having basic knowledge of bending and stretching metals throu complex, forming states. Essential, analytical methods that a

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Pref

Troubleshooting of large dies, including casting repair, is bas on the experience of co-workers and the author with large, she metal-forming dies. The reader will find that much of the inf mation here is either hard to find, or that it has never been put print. Topics include solving dirt problems in automotive, out skin-panel, forming operations, as well as repair methods broken cast-iron die shoes. This unique text is meant to aid tho faced with these repair and troubleshooting problems. To engineering, including problem solving, is not a black art. It i discipline based mainly on mechanical engineering and mater science. The material science behind die materials, heat treatment, tool coatings is objective and based on expert review. Object information is a problem area because of large amounts of co flicting information and negative comparisons prevalent today trade advertising. This book offers detailed procedures for establishing a die ma tenance program. Problem tracking and cost control to start You're Reading a Preview improve a system are explained. Examples of die standards a Unlock full access with a free trial. generic and recast subject to applicable law and good engineer practice. Download With Free Trial It is hoped that the individuals, organizations, and firms w have contributed to this work will recognize the benefits gain from cooperation and mutual assistance that extend far beyo any financial recompense. By donating time, talent, and desi examples, contributors have provided a wealth of practical desi and troubleshooting information. Their help has made this wo  possible. Sign up to vote on this title 

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Contributors The author wishes to acknowledge the following individuals their contributions to this book: Lisa Bisson Editor Eagle Publications Novi, Mich.

Taylan Altan, Ph.D. Professor and Director ERC/NSM Ohio State University Columbus, Ohio

Rollin Bondar You're Reading aPresident Preview Gary Amin Welding, Inc. Unlock full access withMPD a free trial. Supervisor Orion, Mich. Die Design and Standards Ford Motor Company Dearborn, Mich.


Jim Austin Director of Continuous Improvement Michigan Seat Company Jackson, Mich. James Barrett, Jr., Ph.D.

Arthur Brown Publisher Eagle Publications Novi, Mich.

Douglas Burke Forms Consultant  Sign up toBusiness vote on this titleSolution Superior Not useful  Useful Mich. Kalamazoo, Bill Christiansen

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Kevin M. Fessler Electrical Maintenance Consultant Centerville, Ind. Chuck Fitch Director of Fluorescent Operations Cooper Industries Americus, Ga. Jeff Fredline President Fredline & Associates Okemos, Mich.

Bill Hays District Maintenance Supervisor Governor’s Office of Technology Frankfort, Ky. John Heffelfinger Manufacturing Manager Norlen, Inc. Schofield, Wisc. James Hicks Professor of Chemistry Cumberland College Williamsburg, Ky.

Henry H. Gehlmann Blanking Area Manager Robert Hurst (retired) President Ford Motor Company You're Reading a Preview Phoenix Specialty Woodhaven, Mich. Unlock full access with aManufacturing free trial. Company, I Leo Goepfrich Bamberg, S.C. Download With Free Trial Tool and Die Manager Casimir S. Janiszewski (retired) President and CEO Ford Motor Company Superior Die Set Corporatio Chicago Heights, Ill. Oak Creek, Wisc. Bob Green Stuart P. Keeler, Ph.D. Engineering & Facilities  President Manager Sign up to vote on this title Keeltech  Useful Technologies  Not useful Cooper Industries Grosse Ile, Mich. Americus, Ga.

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Gregory A. Kreps Tooling Engineer Capital Die, Tool and Machine Company Columbus, Ohio James L. Lehner Applications Manager HMS Products Company Troy, Mich. Ernie Levine President and CEO Admiral Tool and Manufacturing Chicago, Ill.

Harry J. Micka Manufacturing Engineer LA-Z-BOY Chair Company Dayton, Tenn.

Richard Micka Vice President of Administration LA-Z-BOY Chair Company Monroe, Mich.

Arnold Miedema President Green Meadows Engineerin Hudsonville, Mich.

Ernest E. Morgan Cecil Lewis Consulting Corporate Vice President Structural Engineer Midway Products Group, Inc. You're Reading aHenderson, Preview Ky. Monroe, Mich. Unlock full access with a free trial. Eugene J. Narbut Albert A. Manduzzi DieTrial Room Unit Leader Download With Free Supervisor (retired) Auto Alliance Internationa Die Design and Standards Flat Rock, Mich. Ford Motor Company Al Nichols Dearborn, Mich. Area Leader John McCurdy Stamping Engineering President (retired)  Auto Alliance Internationa Sign up to vote on this title W. C. McCurdy Company Flat Mich. Useful  Not useful  Rock, Oxford, Mich. Mark Nichols Bradley K. Mettert

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Pat Ontrop Applications Engineer Minster Machine Company Minster, Ohio

Brad Sauer Industrial Engineer LA-Z-BOY Chair Co. Monroe, Mich.

Dick Peoples Metallurgist Heidtman Steel Products, Inc. Toledo, Ohio

Daniel A. Schoch Mechanical Engineer, P.E. Minster Machine Company Minster, Ohio

Jim Pienta Production Manager Jostens, Inc. Princeton, Ill.

Mike Searson Machine Shop Supervisor Phoenix Specialty Manufacturing Company, I Bamberg, S.C.

Gerald A. Pool Consultant Royal Oak, Mich.

Aniese Seed President (retired) Ronald E. Prater Toledo Transducers, Inc. You're Reading a Preview President, Koppy Corporation Holland, Ohio Unlock full access with a free trial. Orion, Mich. Kenneth L. Smedberg Download With Free Trial Frank Randall President Engineering Manager Smedberg Machine (retired) Corporation Zippo Manufacturing Company Chicago, Ill. Bradford, Pa. Andrew D. Smith Anthony Rante Mechanical Engineer, T. R. Director of Engineering  Sign up toMich. vote on this title Livonia, Fitzpatrick Company Elmhurst, Ill.

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Robert Stadler Tool Engineer Ranger Tool & Die Grand Rapids, Mich.

Ed Tremblay Vice President, Engineerin and Manufacturing P/A Industries Bloomfield, Conn.

Allan Steinbock Vice President Superbolt, Inc. Carnegie, Pa.

Robert Vance Consulting Marine Enginee Glasgow, Ky.

Robert Storer President Toledo Transducers, Inc. Holland, Ohio

Bob Wahls Chief Engineer Michigan Seat Company Jackson, Mich.

Leslie Suthers Keith Weaver Manager Press Engineer Manufacturing Services Capital Die, Tool Norlen, Inc. and Machine Company Schofield, Wisc. You're Reading aColumbus, Preview Ohio Thomas A. Suthers President Norlen, Inc. Schofield, Wisc. Nick Tarkany Director Research & Technical Education Dayton Progress Corp. Dayton, Ohio Ed Tarney

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Wayne Wittaker Vice President of Operation Unisorb Machinery Installation Systems  Sign up toMich. vote on this title Jackson, 

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Die Maintenance Handbook Introduction

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