Showing posts with label metal stamping. Show all posts
Showing posts with label metal stamping. Show all posts

Metal stamping tool and die with engraved punch

Metal stamping tool and die design

In-house metal stamping tool and die design has exchangeable engraved punches to display company logo and part name.


Metal stamping die with engraved punch, Canada

Vortool has in-house CNC and wire EDM machining, surface grinding and heat treating to manufacture metal stamping dies.


Metal stamping die slots

Metal stamping die punches different number of slots.


Metal stamping tool and die with stock pusher.

Stock pushers help to move the strip toward.


Metal stamping tool and die with gas springs

Nitrogen gas die springs are used in this tool and die to exert force. Gas springs have greater force than coil springs.



Vortool Manufacturing


Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada


Call: 604-239-7218 | Email


Made in Canada

Corner skin form tool for low volume metal stamping production

Corner skin form tool and design

Corner skin form tool and design

Low volume products such as this "Corner Skin" require cost effective tooling to keep the budget under control yet keep the quality high to be competitive on the market.

The flat parts also known as flat blanks were laser cut and then inserted into the single station two post die set to form the edge of the specified angle and dimension.




Low Production Metal Stamping


Corner skin form tool and design

The tool consists of a form punch, a form die and a heavy spring loaded pressure plate to ensure that the part remains flat where needed. This should allow the part to be pressed against the form cavity by the upper punch.

As a result the outer rounded edge of the part formed upward in an angle, that became a perfectly smooth geometric shape for this flange.


Corner skin form tool and design



Vortool Manufacturing

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada


Call: 604-239-7218 | Email


Made in Canada



Strip layout design concept for metal stamping dies

Strip layout design concept for metal stamping dies

Strip layout design concept for metal stamping

All metal stamping designs should start with the basics. A solid foundation is required with both a visual and technical guide to progress further. The strip layout is the starting point of a metal stamping design which is the foundation or plan to manufacture and build the actual tool.

The strip layout design has several purposes. Once complete, it gives a visual representation to the manufacturing facility and to the client to have a good idea how the tool will work and how each progression or step will be made once the strip or coil is inserted into the die. The stamping can then begin.

This visual guide is the most important aid for the metal stamping die designer. It reveals details to clearly see how each feature must be made at each progression as the strip advances into the tool. Then important decisions can be made to simplify the final design or make it fit for automation and most importantly to improve it before it even starts.

The strip layout should include punches, form blocks, pilots, and some die blocks in order to make it clear how the tool will work and produce the parts. It is to ensure that the tool will do exactly what it is supposed to do.

Tool and die designers who neglect putting enough effort into this process, often end up with design errors. As a result, the manufactured stamping tools don’t perform well enough or don’t work at all. In that case costly modifications are necessary to correct mistakes before production can start. Usually these tools are notorious for break downs and require maintenance more often than others.


Strip layout design concept for metal stamping dies


The proper tool and die design of a strip layout gives a piece of mind to the tool and die designer to proceed in the right direction. It is insurance for the end user or those who finance the project and want to be sure that their investments are in good hands with the tool working efficiently for a long period of time without breaking down. This is what it is all about. The sole purpose of a metal stamping tool is to produce as many identical high quality parts as possible at the shortest amount of time without stopping. Every time the tool requires maintenance and is not producing, it takes money away and becomes less efficient.

A good metal stamping die starts with a solid foundation, a good strip layout that gives the chance to eliminate future nuances, and to build world class tools that you can count on.

Vortool Manufacturing

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada


Call: 604-239-7218 | Email


Made in Canada


Optimum cutting clearance for blanking sheet metal

At optimum cutting clearance for blanking sheet metal at any given thickness, the sheared edge or the shiny band should be about 1/3 of the material thickness. The ripped or break away surface is 2/3. 


This is an indicator that the bur does not exist or it is at its minimal.


Optimum cutting clearance for blanking sheet metal

When the band is too small, it indicates that the cutting clearance is too much. The bur is generally larger than normal, and the part may not be as flat as should be.

When the band is too large, it indicates that the clearance is too small. The bur is large and uneven, so the punch may stick in the strip and stripping is difficult. Die and or punch edges chip often. It is because the strip is extremely tight on the punch, and as it pulls out, the edge (weakest point) may rip off, especially when the ground surface is not as smooth as should be.

Generally I use 10% clearance per side between 1- 2.5 mm and 12-15% for thicker material. The thinner the material, the clearance gets smaller as well. Over time I collected data from cutting clearances and results, and I use this data as average in my calculations. There is a variable of soft, medium or hard material to be blanked. I developed an iPhone app to simply type in the material thickness and hardness of the stock that gives me the calculated clearance per side and diameter.


There is a misconception among toolmakers that absolute centered alignment of the punch and die is less critical when the sheet (stock or coupon) is thicker. This is wrong. When the components are misaligned, the bur is generally larger on one side and the other not. What happens is that the pressure required to blank, e.g. 40 tons, will force the punch out of its position and try to get back to the center. This deflection creates more problems than most people would think.

• Excess bur on one side.

• Flex, or movement while cutting. This movement will cut the life span (between sharpening by ~70%. Any side movement is the cause for most tooling problems.

• Excess strain on die components, guide pins and bushings.


• As a result of the above, the parallel movement of the die set is compromised and slightly tilted. This would compound the initial problem.


• The punch press will also suffer. The blanking pressure is shifting sideways and will wear off the press components sooner. The improper clearance also affects the tonnage required and is greater than usual. Used punch presses are generally worn and always have a little slack. It means that even a 200 ton press’ RAM could be pushed back for a moment before it can go down with full power. This slight hesitation also creates movement while cutting, and it is, again affecting the life of the punch and die edges. If this happens, the cut edge will look different. Sometimes the bottom edge can measure about the same as the upper part and the edge may have horizontal lines, small bands.

When I design metal stamping dies, it is important for me that the tool stays in production as long as possible. It makes money. When the tool is off the press, it does not only require labour, time and money but will not produce anything either, and this is an even bigger loss. So, I always ensure that the clearances are correct and the alignment is absolutely centered, regardless of the thickness of the material. I use a similar precision for alignment between punches and dies, regardless if the thickness is 0.025 mm or 13 mm.


Vortool Manufacturing

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada


Call: 604-239-7218 | Email


Made in Canada