Ge24060r_B_en

GE24-060R

Press tooling. Stamping tools. Restamping tools Design basics

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_____________ ______________ _____________

Guide _____________ ______________ _____________

S tatus tatus

Enforceable

Importante Note : This document has been translated from the french. In the event of any dispute, only th french version is referred to as the reference text and is binding on the parties.

Object

Define the recommendations recommendations for designing the stamping tools.

Scope of application

Renault group

Issued by

Confidentiality

65307

- Stamping Process Industrialisation

Non confidential

Approved by

Function

D. COURATIN

Head of department 65307

© RENAULT 2006

Signature

Origin: PEGI - Renault

Application date date

06/2006

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GE24-060R

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History of versions Version Update

A B

01/2005 06/2006

Object of main modifications modifications

Creation Item 4.24 modifications, compensating blocks page 60

Author

(1) B.Nouhant C.Laizé

Supersedes

GE24-060R of 01/2005 version A

Availability

Inside Renault, on the Intranet: http://gdxpegi.ava.tcr.renault.fr http://gdxpegi.ava.tcr.renault.fr Outside Renault, on the Internet: www.cnomo.com Email: [email protected]

Documents cited

Regulations

:

International International

: ISO 3755.

European

: EN 10025, EN 10293-2.

French

: A 32-054.

CNOMO

: E24.55.265.N.

Renault

: EM24.01.100, EM24.02.032, EM24.02.035, EM24.03.304, EM24.03.309, EM24.52.500, EM24.52.700, EM24.53.500, EM24.54.300, EM24.54.500, EM24.54.700, EM24.55.100, EM24.57.100, EM24.59.100, EM24.59.150, EM24.59.300, EM24.59.500, EM24.59.50 0, GE24-010R, GE24-011R, GE24-012R, GE24-013R, GE24-017R, GE24-040R.

Other internal doc

:

Other external doc

:

Coding

ICS:

25.120.10; 03.120.20

Class

E24

Key words

emboutissage, emboutissage, équipement équipement de presse, outillage de presse, fondamentau fondamentaux, x, basic, press tooling, pressing, press equipment

Language

English

(1) Have participated in writing the document Site Dept Name FASA FASA MM.Maravert / Del-Cano Valladolid / Velasco-Perez / Valencia Palencia LHA TCR

04734 65307

© RENAULT 2006

MM.Pasquier / Roulier MM.Lambert P / Olivar / Hammoudi


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GE24-060R

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Contents Page Foreword ........................... ............................. ............................ ............................ ................................... 4 1

SE panel (Simple Effect) ............................. ............................ ............................ ....................... 5

1.1

SE panel, general............................................................................. general ..........................................................................................................................................5 .............................................................5

1.2

SE panel panel with props props ................................................................................................. ....................................................................................................................................10 ...................................10

1.3

Diagrams .............................................................................. .....................................................................................................................................................16 .......................................................................16

1.4

SE panel with RG springs springs ...................................................................................... ...........................................................................................................................23 .....................................23

2

DE panel (double effect)................................... ............................. ............................ ............... 24

2.1

Typical DE panel ........................................................................................ .........................................................................................................................................24 .................................................24

2.2

DE panel with suspended suspended plunger (called "floating") "floating") ..................................................................................25

3

SD (stretch-draw)..................... .............................. ............................. ..................................... . 27

3.1

Operating principle ........................................................................................ ......................................................................................................................................27 ..............................................27

3.2

Calculations.................................................................................................................................................28

3.3

EE panel on DE press.......................................................................................... press .................................................................................................................................28 .......................................28

3.4

EE panel on SE press with props................................................................................................................29

4

Common functions and elements ........................... ............................. ............................ ....... 30

4.1

General........................................................................................................................................................30

4.2

Die 31

4.3

Plunger ......................................................................................... ........................................................................................................................................................35 ...............................................................35

4.4

Blank holder ............................................................................................... ................................................................................................................................................38 .................................................38

4.5

Frames ......................................................................................... ........................................................................................................................................................41 ...............................................................41

4.6

Handling ............................................................................... ......................................................................................................................................................43 .......................................................................43

4.7

Guides / reactions / clearances / adjustment adjustment ................................................................................... ..............................................................................................44 ...........44

4.8

Blanks centring........................................................................................ centring ............................................................................................................................................47 ....................................................47

4.9

Stops ....................................................................................... ...........................................................................................................................................................49 ....................................................................49

4.10

Blank holding..................................................................................... holding ...............................................................................................................................................52 ..........................................................52

4.11

Blank retainers ............................................................................................ ............................................................................................................................................52 ................................................52

4.12

Blank stand............................................................................................ stand ..................................................................................................................................................52 ......................................................52

4.13

Lifting................................................................................................... Lifting ...........................................................................................................................................................53 ........................................................53

4.14

Separators...................................................................................................................................................53

4.15

Detection .................................................................................... .....................................................................................................................................................54 .................................................................54

4.16

Louvers........................................................................................................................................................55

4.17

Ranges for safety jack.................................................................................................................................56

4.18

Retainers / dampers....................................................................................................................................56

4.19

Materials/grains ....................................................................................... ...........................................................................................................................................57 ....................................................57

4.20

Adjustments.................................................................................................................................................57 Adjustments............................................................................... ..................................................................57

4.21

Ranges ................................................................................. ........................................................................................................................................................58 .......................................................................58

4.22

Air evacuation..............................................................................................................................................60 evacuation..............................................................................................................................................60

4.23

Strike marks ..................................................................................... ................................................................................................................................................60 ...........................................................60

4.24

Parallelism and compensating Blocks.........................................................................................................60 Blocks.........................................................................................................60

4.25

Details on suspended plunger.....................................................................................................................62 plunger.....................................................................................................................62

4.26

Details on die base........................................................................... base ......................................................................................................................................64 ...........................................................64

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GE24-060R

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4.27

Elastic spacers ........................................................................................... ............................................................................................................................................64 .................................................64

4.28

Protective shims shims ........................................................................... ..........................................................................................................................................65 ...............................................................65

5

"Triple effect" tools ............................ ............................ ............................. ............................. 66

6

Specificity for butt welded parts ............................ ............................. .............................. ...... 67

6.1

Centring ...................................................................................... .......................................................................................................................................................67 .................................................................67

6.2

Materials......................................................................................................................................................68

7

Master Drawing ............................. ............................. .............................. ................................. 68

8

Restamping tools........................... ............................. ............................ .................................. 69

8.1

General........................................................................................................................................................69

8.2

Possible designs ................................................................................................ .........................................................................................................................................69 .........................................69

9

List of documents cited ........................... ............................. ............................ ....................... 73

Foreword This document is not a summary of "design rules". It merely reminds a few basics and examples. It cannot cover all particular cases. It is not complete. It is an information complement to standard EM24.01.100 covering superficially the design of stamping tools. It must be enriched by: !

different user projects

!

all manufacturing manufacturing and maintenance maintenance sites by the intermediate intermediate of diffe different rent DIVD.

Index / Translation abbreviation ATFMR

ramp up end end activity agreement agreement

ATLO

Buy Off

DE

Double action

EM

Stamping die line

FGL FTL

Lamellate cast iron graphite Stamping line spec

GP

Big Press

GP-DE

Big Press – Double action

GPR

Big reinforced Press

GSE

Big Single action press

HOL

Die height free

AR

Rear

MAP

Try out

PT

Transfer press

RG

Gas Spring

SD

Stretch-draw

SE

Single action

SF

Blank holder

TGSE

Very big single action press

© RENAULT 2006


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GE24-060R

1

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SE panel (Simple Effect) Loads: Check that the loads are below the press capacities: refer to the FTL standards (press technical sheets per line and per site) for the t he load graphs. When they exist, check compatibility with energy graphs. Part: Check the part remains in good position repeatedly on the blank holder (in snap rings, keys, by magnet or any other means). If impossible, implant timed gas springs (very costly solution to be used only exceptionally).

1.1

SE panel, general General rules:

2 cases to be considered: A – The part has has little risk of remaining remaining stuck in the upper upper part B- The part may remain stuck in the upper upper part Case A Separators

Punch Linked and staged gas springs Sole on lower frame Shims if trimming lines located on the blank holder surface

Plan a sufficient number of separators in the die: Separators with metal springs or gas springs. Beware compliance with the implantation guidelines for gas springs, more particularly concerning the adjustment margin for safety. (see Renault standard EM24.54.700) Case B A die base must be implanted to separate the part and refit it using a spreader to prevent distorting the part. This spreader is not required if the panel is open at the ends to ensure the die base support on the blank holder.

Dampers Die Spreader Clipping props Die base Punch

Linked and staged gas springs

Blank holder

Sole on lower frame Shims if trimming line located on the blank holder surface

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Beware compliance with the implantation guidelines for gas springs, more particularly concerning the adjustment margin for safety, (see Renault standard EM24.54.700). If the panel must be clamped on the punch upon descent, implant a mobile shim system actuated by jack or timed gas springs, prevent distorting the part upon lifting. See locking principle in paragraph 1.1.4. NOTE 1:

for GSE and TGSE tools, do not implant this system, locking at "bottom dead" dead" centre can can be ensured by the press cushion. Note: this locking function does not exist on the cushion of the transfer press PT 5400. (EM24.03.304 / EM24.03.309)

NOTE 2:

by timed timed gas springs: springs: cumbersome cumbersome and costly solution. solution.

Beware sizing of the spreader and clipping props. !

the spreader must be subject to a calculation note. (see standard EM24.01.100)

!

clipping props: proposition

Lock Lock screw screw + washer

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GE24-060R

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Example of locking with implantation of a roller: r oller:

A-A CROSS-SECTION Roler bearing bearing

Pneumatic Pneuma tic jack

© RENAULT 2006

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GE24-060R

Guidelines for implantation of blades on blank holder and die: !

blade parting parting lines must be skewed in respect of the "die entrance" line (5°min) (5°min)

!

upper parting parting lines must be offset in respect respect of th the e lower blade parting parting lines lines

!

fasteners must must be outside the blank blank and be accessible accessible with tool open open

Upper parting line Upper part : Lock screw screw + washer

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GE24-060R

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Guidelines for implantation of blades on blank holder and die: !

blade parting parting lines must be skewed in respect of the "die entrance" line (5°min) (5°min)

!

upper parting parting lines must be offset in respect respect of th the e lower blade parting parting lines lines

!

fasteners must must be outside the blank blank and be accessible accessible with tool open open

Upper parting line Upper part : Lock screw screw + washer

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GE24-060R

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Locking principle

Block

Gas springs or props

Upon attack: the blank is A l'attaque: le flan est clamped between the blank serré entre le serre flan holder and the punch et le poinçon.

Enthe fin end de remontée serrelifting: flan: At of blank holder lifting: le maintenu thefond baseest is held in highen position position haute par by the eraser and thel'effaceur shim et la cale.

Moving shim actuated by jack

At a few mmmm from fromdu bottom of A quelque bas de stroke, the shim is on the verge course, la cale est sur le point of penetrating under the eraser de pénétrer sous l'effaceur du of the de diematrice. base fond

Fin de dévêtissage. End of stripping

Bas de course: la cale Bottom stroke: the shim is s'intrepose sous l'effaceur. inserted under the eraser

Shim rearming de la cale. Réarmement

Note: implant a detector for each shim. As the shim is actuated by a jack, the latter will include a built-in detector.

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GE24-060R

1.2

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SE panel with props Props are used for SE panels fitted on presses featuring cushions: GP - SE 4 000kN x 2,7 m* and all presses type GSE – SE 12 000kn x 2.7m, TGSE – SE 20 000kN x 4.5m, station 1 PT5400. * only those fitted: refer to the FTLs per site (press technical sheets per site and per line)

1.2.1

Tooling fitted on GP-SE presses The blank holder must cover the surface of each cushion properly; the props are distributed in order to balance properly the loads over the press cushions.

n o s i h i s x u a C

Refer to the FTL document (line technical sheets per site) for the lengths of props which can be used.

s i s s x e r a P

n o s i h i s x u a C

Check that the thickness of platform + cushion stroke is compatible with the length of prop used. If the length of the props is insufficient, insert extensions between the latter and the blank holder.

The prop extensions are standardised (see standard EM24.57.100).

e l o S

Or

© RENAULT 2006


t h g i e h d n a r m h f o t g t a n l e p l e p h o t r p g : i n e d t a u r c t i d o r n p I

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GE24-060R With symmetrical parts, or from the same family, choose common locations according to the production and backup sites to reduce prop changing. This can lead to drill holes in a punch to allow the working prop displacement for another part.

o t

e l o S

Before fitting the tool, the props are recessed under the platform by a value variable according to the type of press. After fitting the tool, the props are raised by a value variable according to the type of press.

1.2.2

/B

Or

Tools type GSE, TGSE, station 1 PT 5400 Loading the blank(s) is performed: blank holder in the top stroke position. Extraction of the part(s) is performed: blank holder lifted by 15mm (25 mm for TGSE Brazil). Note: it is possible to extract the blank holder part(s) in the "top stroke" position (except PT 5400 presses station 1).

SF position for bla blank nk loa load d

e k o r t s F S

Part extraction position

e k o r t s F S

© RENAULT 2006


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GE24-060R

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Use of props on GSE, TGSE presses, Station I PT5400 All props remain in place in the press platform. They protrude by minimum 10 mm from the press platform. If the working stroke < 300, the start position of the props is according to the tooling design. Programming allows positioning the "stroke bottom" and "stroke top" points in the cushion adjustment range.

g n i t s u j d A

e g n a r

0 1

Press Press pla platfo tform rm

Recommendation: Recommendation: except in exceptional cases, do not use the extreme upper and lower positions. Note: include the passages for props with the possibility of turning the tools flat by 180°, fitting 2 GSE type tools either to the right, or to the left.

n o i t c e r i d r e f s n a r T


Assembly to plan

Assembly planned

e.g e.g.. hoo hood d lining lining

e.g e.g.. hoo hood d lining lining n o i t c e r i d r e f s n a r T

e.g e.g.. hoo hood d


Assembly to plan

Assembly planned

© RENAULT 2006

e.g e.g.. hoo hood d


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GE24-060R

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1 - Prop extension Prop extensions are part of the tooling. They are either offset or foundry single block with the blank holder. Single block with blank holder, they must have a height " 150 mm. (to prevent problems upon foundry, sand setting, and breakage when handling the blank holder)

For heights # 150 mm, offset design according to Renault standard EM24.57.100.

Prop offset with rotation lock and untighteni untig htening ng system system

0 5 1 < H

m m

Ø 80

Details on prop extensions: For H # 150 mm see Renault standard EM24.57.100 Other principles:

Single block extension

© RENAULT 2006

Screwed extension with stop plate


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GE24-060R

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2 - Props stroke

It also equals the value of the panel depth: !

without pre-acceleration of cushion C = 300 mm max

!

with pre-acceleration pre-acceleration of cushion cushion C = 300 mm max max + 25 mm mm max

The stroke of the punch / blank holder retaining pins equals C + 20 mm. NOTE: the possibility of pre-acceleration must be planned.

+ + n h i o t t p a e r d e l l e e n c c a a p - m m = e r 0 D p 2

3- Pre-acceleration

According to the type of press, it can be either fixed with a value 25mm, or programmable from 0 to 25 mm. Using pre-acceleration allows: !

reducing noise,

!

preventing shock shock between die die and blank blank holder, and and hence optimise the press reliability (props caulking, jack fatigue, etc.)

It must be planned systematically in studies . However, it is linked with stamping feasibility.

As the blank is supported only on the blank holder, holder, it can "drop" and create attack folds (this problem can sometimes be compensated by implementing blank support pads) This phenomenon can be a possibility to "feed" the panel. It is also possible to set the position of the blank holder at the blank attack. Blank Blank supp support ort pad

n o i t a r e l e c c a e r p

© RENAULT 2006

n o i t a r e l e c c a e r p


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GE24-060R

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4 – The choice of design of tooling depends on: !

the type of tool (GSE or TGSE),

!

the type of backup (DE or SE version),

!

the prop stroke. See diagrams paragraph 1.3.

5 – Number of props

To determine this, consider: !

their distribution under the blank holder span

!

the load balancing Max loads per prop (see Renault standard EM24.57.100)

6 – Prop position in height

To determine this, consider: !

stroke C,

!

min/max positions of props,

!

fragility of the punch due to clearance

for prop passage !

the construction of the punch or lower frame.

The lower and upper positions can be !

chosen inside the adjustment range

!

at any point.

NOTE: to prevent damaging the press, do not use the extreme positions of the props.

props

x a m 5 2 + 5 d e 0 d 3 l u e c s i n U : n x i o a t m a r l l e a e c c i t c e r a o e e r h t p 5 2 + 0 1 3

Up position

n i m 5 1 e s u : l a c i t e r o e h t n i m 0 1

© RENAULT 2006

Blank holder

Open tool

C e s r u o C C e s r u o C

C e s r u o C

Stroke

Low position

Props closed tool

PMR


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GE24-060R

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6 - Clearances

The props (Ø 69) not used must be opposite a machined clearance Ø 80 mm, or rough Ø 90 mm, or at least 10 mm from a rough face, with a depth equal to C + 30 mm.

0 3

n o i t + a r e l e k e o r c t c S a

Note:

10 mini

before delivering delivering tools to the production, production, backup, backup, MAP site, check passage passage of of all props: props: practical check indispensable.

1.3

Diagrams

1.3.1

GSE tools

1.3.1.1

GSE tool, GSE backup, TGSE in the axes

With prop extensions according to the value for stroke and frame or sole thickness

0 8 1 1 E S G F O H

Principle with lower frame

Principle with sole

Props: with or without extensions according to the value for stroke and frame or sole thickness. Note: handling the entire tool, in the case of the offset sole is performed by the blank holder privilege the principle with the lower frame.

© RENAULT 2006


$

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GE24-060R

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1.3.1.2 GSE backup backup tool tool PT 5400 (with riser) - PT 5400 backup: prop extensions if C > 125 mm Props supported in direct support if C = 125 mm max.

0 0 4 5 T P 0 5 6 1 F O H

0 8 1 1 F O H

0 5 4 1 F O H

U r O

o

0 7 4

0 0 2

U r O o

Caution: handling the tool in the GSE position is performed with blank holder handling.

1.3.1.3 GSE tool, GP-DE press backup GSE tool, fitted flipped.

E D P G

0 5 4 1 L P F O H

0 8 1 1 F O H

0 0 3 1 F S F O H

E S G

0 0 2

Caution: handling the tool in the GSE position is performed with blank holder handling.

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1.3.1.4 GSE tool, fitted by 2 (side by side) on TGSE or PT5400 PT5400 press station station 1, backup by 1 on GSE press

0 8 1 1 E S G F O H

Principle with lower frame Principle with sole

0 * 5 0 6 8 1 3 1 F F O O H H

0 * 7 0 4 0 2

Riser with prop step compensation spreader

* Case of fitting f itting with riser without prop step compensation, compensation by specific extensions

Note: for fitting on PT5400 station 1 the HOF must be 1650.

Outline sketch. TGSE Press GSE Press

GSE Tool

GSE Tool

GSE Tool

NOTE: riser plotted and available in "standard" section.

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GE24-060R 1.3.2

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TGSE tool, TGSE backup

L

I S T I U X O A ' D L E O X O A T

Loads under blank holder, 2 possibilities: - use press props. - implant gas springs. Beware compliance with the implantation guidelines for gas springs, more particularly concerning the adjustment margin for safety. (see Renault standard EM24.54.700)

1.3.2.1 TGSE tool, TGP DE backup Design identical to paragraph 1.3.1.5. Note: linked gas springs are used only for possible backup on TGP DE press without flipping) or on TGP SE press (if loads are compatible) Caution ! When fitting on DE press (without flipping), the die must be integrated to the blank holder ram opening, and no interference must occur during the press cycle. (Check the positions of blank holder ram: see movement graphs in the FTLs).

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GE24-060R

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1.3.2.2 TGSE tool, TGP DE press backup backup (tool (tool flipped) flipped) Design with prop/blank holder direct support, handling entire tool by the blank holder, requires the implantation of retaining pins between punch and blank holder.

0 0 5 1 F O H

0 5 6 1 F O H

Caution:

Design with prop extensions, handling entire tool by the blank holder, requires the implantation of retaining pins between punch and blank holder.

0 0 5 1 F O H

0 5 6 1 F O H

Caution: handling the tool in the TGSE position is performed with blank holder handling.

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GE24-060R

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1.3.2.3 Specifics A - Tools by 2, GSE type allocated on TGSE press: backup in degrouped on the GSE press must be forbidden for parts with delicate stamping. (type lateral door caisson) The difficulty comes from the difference in design of the TGSE and GSEcushions: "thrust points" are located differently. TGSE press

1125

Jack

E S G e p y t s i x a l o o T

jack

TGSE axis

s i x a E S G T

Jack

GSE press

Jack

GSE axis

s i x a E S G

Jack

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GE24-060R

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Other GSE press

Jack

GSE axis

s i x a E S G

Jack

Other GSE press

Jack

GSE axis

s i x a E S G

Jack

B - TGSE or GSE tools with gas springs springs for backup on DE press (without flipping) flipping) or on SE press (without props) !

very expensive solution (RG costs)

!

Risks of MAP problems (behaviour different between a cushion (with programmable loads) and RGs with loads increasing with crushing.

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GE24-060R

1.4

/B

SE panel with RG springs Specifics in respect of design with props: -

loading the blank(s) blank(s) is performed performed with the blank holder in top stroke position.

-

Extraction of the part(s) is performed performed with the the blank holder in top stroke position.

-

The gas springs are linked* linked* according to instructions mentioned mentioned in standard EM24.54.700 EM24.54.700.. The filling filling unit(s) must be accessible at front of press.

-

The gas springs will be staged: st

!

1 stage = 4 to 6 RG

!

2 stage + 16 mm stroke = 4 additional RG

!

3 stage = + 17mm = all RGs enter in action.

nd

rd

Step 1

Step 2

Step 3

Note: plate thickness 3mm and 20mm are standardised. See standard Em24.54.700 Step1: tool open with contacts of 4 to 6 RG Step 2: intermediate phase with contact of 4 additional RG hence 8 to 10 RG activated Step 3: all RGs are activated

* Gas springs linked to optimise loads and compensate potential failure of one spring.

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GE24-060R

2

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DE panel (double effect) Loads: Check that the loads are below the press capacities: refer to FTL standards (press technical sheets per line and per site) for load graphs. When they exist, check compatibility with energy graphs.

2.1

Typical DE panel

Foundry thickness

Cross-section: AA With blades Without die base and die base B

A

B

0 1 0 B 1 B

B

B

B A

Cross-section: BB

0 1 B B

B*

0 B 1 B

B

B

A

B* must be modulated according to cross-section: see guide GE24-040R paragraph 5

A

A

B

Cast iron

Steel

Cast iron

Steel

TGSE

40

40

60

50

GSE

40

40

60

50

MP

30

30

50

40

GP

30

30

60

50

TGP

40

40

60

50

In practice, the values in the table are sufficient for thickness panels (e % 0.7). They must be modulated according to particular cases with high panel thickness notably or HLE panel. Stamping loads: See Renault guide GE24-040R. The design of the foundry (thickness, number and dimension of ribs) must take these loads into account, more particularly the separation force of the die.

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GE24-060R

2.2

/B

DE panel with suspended plunger (called "floating") This type of design is required in the following cases: A - the outline of the the "die entrance" entrance" line is not included included in the press plunger plunger ram outline. outline. B - plunger fitted from "below" (outline of the die entrance entrance line very large and weakening weakening the working part of the blank holder) C - fitting on TGP DE press press (the plunger plunger rams of these presses are not fitted with snap clamps) clamps) D - tool with inner blank blank holder (e.g. body body side) E - for aspect parts and deep panels, panels, to reduce air evacuation constraints. (air contained contained in the volume defined by the clamped blank, between blank holder and die, and plunger shape with major shrinkage: shrinkage due to press kinematics) NOTE: this type of suspended fitting must be planned for all GP DE tools. The drawings for clamp clearing, RGs or pneumatic springs will be in mixed line and the elements will mention: "do not launch". Single block plunger:

Gas Ga s spri spring ng

Plunger with offset sole: Solution mandatory mandatory in the B / D cases.

Gas Ga s spri spring ng

NOTE: beware fitting under GP DEpresses (opening in the posts): the stroke of RGs must = 80 mm. For longer strokes, implant pneumatic springs "Harcross" type (See Renault standard EM24.54.700).

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GE24-060R

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Diagram with plunger connected to the press plunger ram: typical design Plunger connected to the press ram

Blank holder

Die Position : blank holder contact with panel and die

High air volume

Diagram with suspended plunger:

Suspended plunger

Blank holder

Die

Position Position : blank holder contact contact with panel and die

© RENAULT 2006

Volume of air to limit


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GE24-060R

3

/B

SD (stretch-draw) Note:

This type of of design remains exceptional, exceptional, it is currently used for parts with shapes «lending «lending well » to this design. It was used to obtain a better tension of the panel, in the case of parts with little curvature. Examples: hood panel, roof. The high consumption of material limits the cases of use.

Loads: check that the loads are below the press capacities: refer to the FTL standards (press technical sheets per line and per site) for the t he load graphs. When they exist, check compatibility with energy graphs.

3.1

Operating principle The different phases: 1 – The blank stands on the highest shape of the lower part

Upper Upper blan blank k holde holder r

2-

Descent of upper upper blank holder to clamp clamp the panel.

4-

Stamping of counters counters by the plunger effect

Plunger

Lower Lower frame

Lowe Lowerr bla blank nk hold holder er

Punch

3 – The part is clamped between the blank holder and stretching starts

Counters

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GE24-060R

3.2

/B

Calculations See Renault guide GE24-040R. It is imperative to check that for each phase in operation, the loads required are below below those of the press, refer to the FTL of the different production sites for press curves.

3.3

EE panel on DE press Typical fitting;

Suspended fitting ("floating" die base) Type A

Type B

Type A: Traditional fitting on die base, with pneumatic springs or gas springs. Type B: The die entrance line does not appear in the opening of the blank holder ram. The die base is fitted from below and linked with an offset sole. The "suspended base" function is ensured either by pneumatic springs or gas springs. The sole / die base link is ensured by M20 CHc screws and lock washers. If the die base is suspended with gas springs, its locking must be planned with the upper blank holder for fitting the sole. Note: caution, the value of HOL equals: HOF + lower blank holder stroke (if RG) + upper blank holder stroke (if RG). On GP-DE and GPR press, the total stroke must be below 80mm. RG = gas springs Check the passage in the post opening for lateral loading presses. © RENAULT 2006


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GE24-060R

3.4

/B

EE panel on SE press with props The gas springs in the lower part, under the lower blank holder, are replaced by the press props with or without extensions. Check by calculation that the loads applied by the props exceed: F springs for upper blank holder + weight upper blank holder + weight lower blank holder. Tool "TUNNEL" type

Blade holde holder r upper upp er frame frame

Blades 4 retainer pins

Upper Upper blank blank holder

Lower Lower blan blank k holder Prop exte extension nsion Punch

Lower Lower frame frame

Detai Details ls of blan blank k ho hold lder er dampening dampe ning (4 damper retainer retainer systems) systems)

Details Details on blades blades

Details Details on retaine retainers rs and presser damper (2 systems)

Note: the retaining/dampening systems are either produced from Renault standard EM24.55.100 (retaining rods with dampener), or an adaptation of the principle.

© RENAULT 2006


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GE24-060R

/B

4

Common functions and elements

4.1

General

4.1.1

For the design of foundries refer to Renault standard EM24.01.100 and Renault guide GE24-040R. Important items:

4.1.2

-

align the ribs on the foundry of the punch and/or and/or plunger plunger with the ribs ribs on the die foundry. foundry.

-

position the compensation compensation shims shims opposite the ribs on the blank holder and dies, while taking into account (when positions are known) of the press thrust points (rams and/or cushions)

To position the part, centre the outline of the die entrance line in the axes.

EM ( Die entrance )

X 1000

Start X Z 700

= l =

Y t r a t S

=

© RENAULT 2006

L

=


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GE24-060R

4.2

Die

4.2.1

DE tool

/B

-

material (according to standard EM24.01.100 and specifics per project)

-

fastenings on production and and backup press platform by 4 notches notches (see reference reference frame drawings drawings in guides GE24-010R, GE24-011R, GE24-012R, GE24-013R)

-

centring on production and and backup press press platform (see Renault Renault FTL documents, Renault Renault standard standard EM24.02.032 and reference frame drawings cited previously)

-

pneumatic, electric, electric, or electro pneumatic pneumatic fitting, electric cabinet. cabinet. (See reference reference frame drawings drawings mentioned previously and Renault standard EM24.59.100 and EM24.59.150)

-

handling of the element and overall tool

-

holes for passing consolidation tie rods

80

Tie-rod fitte d pre-stressed

3 Ø 6 0 8

-

safety jack ranges (See paragraph 4.17/ 4.21)

-

holes for contact contact tips according to Renault standard EM24.02.035.

-

ranges for adjustment adjustment spacers spacers located opposite ribs. (See Renault standard EM24.52.700)

-

ranges for balancing balancing shims shims with blank holder holder opposite opposite ribs ribs (see paragraph 4.25)

-

guides with blank holder (see paragraph 4.7)

-

blank centres (see paragraph 4.8)

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GE24-060R -

blank detectors (see paragraph 4.15)

-

blank support pads if required required (see paragraph 4.12)

-

separators (see paragraph 4.14)

-

lifting system system if required (for part extraction by "iron hand") (see (see paragraph paragraph 4.13) 4.13)

-

brushes, rollers if required (case ditto previous item)

-

snap rings, keying according to Renault standard EM24.59.300)

-

exploded view (see Renault standard EM24.53.500).

/B

- die base or inserts (usually implanted for lining parts subject to modifications), Material (according to standard EM24.01.100 and specific per project)

4.2.2

SE tooling

-


-

fastening by snap snap clamps clamps + manual clamping on press ram

-

pneumatic fitting or or clearance clearance for for GSE and TGSE presses.

-

element handling

-

holes for passages passages of consolidation consolidation tie rods rods ditto paragraph 4.2.1

-

safety jack ranges

-

holes for contact tips

-

ranges for adjustment spacers located opposite ribs

-

ranges for balancing balancing shims with with blank blank holder holder opposite opposite ribs

-

guides with blank holder or with lower frame

-

clearance of the centrers and detectors

-

housings exploded according to Renault standard EM24.53.500.

© RENAULT 2006


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GE24-060R 4.2.3

/B

EE tools In this case, the die is a die base. The design is: !

A single block with upper frame

!

B offset on an upper frame

A single block

- Material (according to standard EM24.01.100 and specifics per project) - Fastenings on press ram by fast and manual clamps - Clearance of pneumatic fitting - handling if presser built-in: - Carries the guides and presser retainers (see diagram paragraph 3.4) - carries the pressure means of the presser B offset

-

4.2.4

material (according to standard EM24.01.100 and specifics per project).

"fuse" dies Design, for parts thickness !1.25, regardless of the material grade, similar to a flanging function. -

with blades blades and/or and/or keyed blade holder: the the keys are calculated calculated to withstand the loads loads resulting resulting from the stamping of a blank, and sheared for 2 blanks. Lateral reaction load (separation) (see Renault guide GE24-040R for the load calculation) 30°

Frame

Frame

90°

Die blades Die blade holde holder r

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GE24-060R -

/B

With 1 "double blank" specific detector according to guidelines and details in drawing E1590 1051 in Renault guide GE24-017R.

" n a l f e l b u o d " r u e t c e t é d e m è t s y S

4 0 / 2 0 / 1 0 1 n o i t i d é 1 5 0 1 0 9 5 1 E " n a l f e l b u o d " r u e t c e t é D

d e t a l h s s n i l a r g t n t o E N t o i n

e m é t r m o 2 , p 1 a à l r u s r t u n e e s s m i e e a n r p a i é l o ' p t e l d a ô e g s n i t l e o l e ô z b o d t e " e t d n " e u u n s q e s a n l m c a e a p l d " e a l e e v s a m s " n a è e d t n a l s l b r y f i e s e f a t l e e n c u a r o d l e e e p m u n n i t i o o s z z à - - - -

N O I T S A E T N N A G I L P S N M I ' O C D

C I T A M O C U O J 8 2 e c 0 n 0 e 0 r é 1 f é 4 4 R

3 , 6 3 . h t

T N E M E N N O I T C N O F

© RENAULT 2006

3 , 4 2 . h t

3 , 6 3 h t


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GE24-060R

4.3

Plunger

4.3.1

DE tool

/B

2 designs: A- Connected to the press ram: general general case B-1- suspended B-2- suspended from below A- Connected to the press ram

-

Material (according to standard EM24.01.100 and specifics per project)

-

fastenings on press ram by fast fast and and manual clamps

-

handling / flipping

-

3 holes for contact tips according according to Renault Renault standard EM24.02.035.

-

Housings exploded according to Renault standard EM24.53.500.

-

brackets for for elastic spacers (between plunger and blank holder)

-

linking ribs between plunger sole and body

B- Suspended -


-

handling / flipping

-


-

Housings exploded according to Renault standard EM24.53.500. stands for suspensionsystems: suspensionsystems: pneumatic springs, RG (gas springs)

-

Note:-1 beware the value of of HOL (tool free height) for for certain lateral loading presses with low passage height -2 beware the determination determination of the number and type of pneumatic pneumatic spring (see Renault standard EM24.54.700. -

linking ribs between plunger sole and body

-

Housing, implantation of dampening dampening blocks according according to Renault standard EM24.54.500. If required, required, according according to the footprint, footprint, clear clear the snap clamp clamp zones. zones.

-

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GE24-060R

/B

C- Suspended with fitting by below

-

fitting with steel plate

-


-

handling / flipping

-


-

Housings exploded according to Renault standard EM24.53.500. for plate:

-

Stands for suspension systems (pneumatic springs); if fitting is planned with gas springs, implement retaining pins with lock between the blank holder and plunger for plate fitting. Note: - 1

beware the value of of HOL (tool (tool free height) for certain lateral loading presses with low passage height

- 2 beware the determination determination of the number number and type of pneumatic pneumatic spring (see Renault standard EM24.54.700. Housing, implantation of dampening blocks according to Renault standard EM24.54.500. Fittings of the plate on the plunger by M20 CHc screws and locking washers. if required, according to the footprint, clear the snap clamp zones.

© RENAULT 2006


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GE24-060R 4.3.2

/B

SE tooling 2 designs: !

A single block with lower frame

!

B offset on a lower frame

With or without props, with or without gas springs. A- single block with frame frame

S I X A L O O T

-


-

fastenings on press platform by 4 notches

-

centring on press platform (visible and accessible)

-

handling

-

guides with blank holder

-

retained housing of the blank holder

-

housings of punches

-

let all props pass without interference

-

RG housings if tool tool with RG and without props

-

electro pneumatic connection

-

stamping 6 to 8 for references with blank blank holder holder (see paragraph 4.20)

B- offset on frame

S I S I X X A A L L O O O O T T

-

all previous previous items + (except direct links links with the press platform) platform)

-

keying fastenings on frame Lower frame: takes over the functions of direct links with the press platform.

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GE24-060R 4.3.3

/B

EE tools 2 designs: !

A single block with lower frame

!

B offset on a lower frame

With or without props, with or without gas springs. A- EE tool with lower blank blank holder on props - Design identical to SE tool with props B- EE tool with blank holder on gas springs - Design identical to the previous without prop passage

4.4

Blank holder

4.4.1

DE tool

-

Material (according to standard EM24.01.100 and specifics per project)

-

fastenings on press blank holder ram by fast and manual clamps

-

handling points

-

safety jack ranges

-


-

ranges for adjustment spacers located opposite ribs

-

guides with die

-

guides with punch

-

elastic spacers with plunger

-

clearances for plunger handling

-

guides with plunger

-

plunger engaging protection shims

-

ranges for balancing balancing shims shims located opposite the rib according to die

-

section to dimension properly (according to Renault guide GE24-040R) guarantee a passage passage of 50mm 50mm min with the plunger (see press kinematics kinematics in FTL FTL standards)

-

n i m 0 5

© RENAULT 2006


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GE24-060R

/B

NOTE: specific case of tools with inner blank holder A- Connected inner inner blank holder holder

B- Moving inner inner blank holder in the plunger

of the outer blank holder

Specifics:

Case AThe blank holders are linked by a rolled steel plate (E295 according to standard EN 10025) or from foundry (GE280, G20Mn5 + N or 270-480W standard A 32-054, PR EN 10293-2, ISO 3755). Fasteners and keys of the blank holders on the plate by

M20 CHc screws with lock washers. The plunger must be fitted "suspended" with offset plate.

Case BIf the plunger is fitted "suspended", the inner blank holder is fitted on linked gas springs. The control unit is fitted in the outer blank holder for accessibility. Beware the deflection of the pipes. If the plunger is linked to the press plunger, the control unit is implanted on the plunger: holes must be planned in the outer blank holder for accessibility to this control unit. If required, the inner blank holder is reactioned with the inner part, retained by pins according to CNOMO standard E24.55.265.N.

© RENAULT 2006


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GE24-060R 4.4.2

4.4.3

/B

SE tooling

-


-

handling points

-

electro pneumatic fitting

-

safety jack ranges (Note: (Note: preferential preferential solution with implantation implantation between between the die and lower frame)

-


-

ranges for balancing balancing shims shims located opposite the rib according to die

-

guides with die

-

guides with punch

-

clearances for punch handling

-

protection shims engaged on punch

-

prop support support ranges or housings housings for prop extensions or ranges with shims for for tool with with gas springs

-

ranges for shimming shimming with lower lower frame (or single block punch)

-

retaining pins with punch or other retainer systems

-

blank centrers

-

blank holding system (DESTACO)

-

blank detectors

EE tools A- lower blank holder holder Ditto identical to SE Tool paragraph 4.4.2 B- upper blank holder Items identical to SE Tool (just replace punch by plunger) Particularities: retained by pins and if required retaining rods according to Renault standard EM24.55.100.

© RENAULT 2006


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GE24-060R

4.5

Frames

4.5.1

Lower frame

/B

4.5.1.1 DE tool The frame is merely a bracket for working parts. It must provide for the following functions: -

support the blades

-


-

fasteners and centring on press plate

-


-

pneumatic, electric or electro pneumatic connection

-

electric box

-

safety jack ranges

-

contact tips

-

adjustment spacers located opposite ribs

-

blank holder guide stops

4.5.1.2 SE tooling The frame is a punch bracket. . It must provide for the following functions: -

support the punch

-


-

fasteners and keying of the punch

-

fasteners and centring on press plate

-

passages of props or bracket for gas springs

-


-

pneumatic, electric or electro pneumatic connection

-

electric box

-

safety jack ranges

-

contact tips

-

adjustment spacers located opposite ribs

-

retaining of blank holder

-

guide stops: with the blank holder and possibly the die

4.5.1.3 EE tools The frame can be a punch bracket and must comply with the items cited in paragraph 4.5.1.2, i.e. a single block punch frame and provide the functions of a punch, cited in paragraph 4.3, and those for a frame cited in paragraph 4.5.1.2.

© RENAULT 2006


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GE24-060R 4.5.2

/B

Upper frame Material: FGL 175 HB or A50 according to dimensions and structure.

4.5.2.1 DE tool A- for plunger, it provides provides the following following functions: -

fasteners and keys of working parts

-

snap fitting notches and manual for press ram

-

handling of the item alone and with the working parts

-

ranges for supporting elastic spacers

B- for suspended plunger: -

plunger fasteners and keys, working part

-

clearances for snap clamps of the press plunger ram

-

handling of item alone and with plunger

-

ranges for gas spring support or extensions for pneumatic jacks

-

housings of dampers in contact with the press ram

C- for blank holder: -

required in the case of a tool with inner inner blank holder connected with the upper blank holder

-

fasteners and keys of the blank holders

-

notches for snap and manual clamping for press blank holder ram

-

handling of item alone and with blank holders

-


4.5.2.2 SE tooling Upper frame with die holder function (die blades) -

fasteners and keys of working parts

-


-

clearances of pneumatic fitting for GSE and TGSE presses

-


4.5.2.3 EE tooling on SE press Upper frame with "die base" function. -

fasteners and keying of the "die base"

-


-

clearances of pneumatic fitting for GSE and TGSE presses

-


-

upper blank holder guides

-

retainers and dampers of upper blank holder

-

possibly retainers of the presser in the "die base"

-

carries the pressure elements of the blank holder and even the presser

-

safety jack ranges

© RENAULT 2006


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GE24-060R

/B

4.5.2.4 EE tooling on DE press Plunger: Upper frame with "die base" function. -

fasteners and keying of the "die base"

-


-


-

ranges for supporting elastic spacers

Blank holder:

4.6

-

fasteners and keys of the blank holders

-

notches for snap and manual clamping for press blank holder ram

-

handling of item alone and with working parts

-


Handling -

plunger / punch handling

-

for other items, see mentions 4.1.1 and 4.1.3

© RENAULT 2006


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GE24-060R

4.7

/B

Guides / reactions / clearances / adjustment Die guiding and clearance with SE tool blank holder:

DE tool guides and clearance: Clearance : 0.2

1 to 5 long and narrow parts 4 to 5 for large parts

Machined Machined

Guiding gap 0.1

Guiding gap : 0.2 constant

Note: the values of clearance between the plunger (punch) and blank holder depend on the value of the "die input" radius. Details of the blank holder guide with plunger: Protection shim

Blank Blank holder holder Plunger Die entrance line

Blank holder guides with die (DE tool) or die with lower frame (SE tool):

A-A CROSS-SECTION CROSS-SECTION

© RENAULT 2006


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GE24-060R

/B

Die guide with blank holder ("small" SE tools): with "male and female sliders" (see standard EM24.52.500)

Blank holder guide with lower frame ("small SE tool"):

© RENAULT 2006


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GE24-060R

/B

Die reactions with blank holder:

To ensure and facilitate operator safety during loading/extraction operations (case with manual loading and extraction), do not fit the reactions on the front and/or back sides of the press in the sweep and/or access zone. Sizing of the reactions is determined by evaluating the separation force while taking into account the load on the blank holder and the slope. Case requiring reactions: - very large parts involving a small section of the blank holder. - blank holder ranges with slope ! 20°.

© RENAULT 2006


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GE24-060R

4.8

/B

Blanks centring Typical cylindrical centrer

Separation

Oriented cylindrical centrer: Anti-rotation Th. 6 mm Blade depth 8 mm

t s e u q e r n O 15 to 45°

Loctite locking Loctite locking compound

45 on flat

g n i n d r i o o t c t c a a n e e n m i e m l p r e i m t e e d h o t t o X t

70 or 130 Blading & 51 Highest point of the curve

Centrer in "lunules":

Other types of "standard" centerings : A- Sector shape

© RENAULT 2006


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Ge24060r_B_en

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