 |
 |
Multiple set punch metal stamping die
Save money with a multi set up metal stamping die.
It can punch different set of holes in two different lengths of metal.
This metal stamping die was designed and manufactured by Vortool Manufacturing.
Showing posts with label sheet. Show all posts
Showing posts with label sheet. Show all posts
Metal stamping of U clips
Metal stamping of U clips by Vortool Manufacturing
Metal stamping tool and die design considerations
When designing metal stamping dies a tool and die maker or tool and die designer must have the following information prior to start. There are several types of tools that could be built for the same part. They have special purposes to best suit both parts and metal stamping production.
The cost of the tool and die to be produced may be greatly affected by the following considerations:
If the amount of 2000 is for a day or for a week and possibly for many years to come, then you must build a tool that lasts, very efficient and easy to use or has the capability for automation. The customer may have a request for manual, semi-automated or fully automated part production.
The cost of the tool and die to be produced may be greatly affected by the following considerations:
Estimated number of metal stamped parts the tool and die should produce monthly, yearly, or in total
Eg. if the customer needs 2000 parts in total and possibly never again, then it is not wise to build a tool designed for high volume metal stamping and productivity. Make something simple and inexpensive, yet produce the correct metal stamped parts.If the amount of 2000 is for a day or for a week and possibly for many years to come, then you must build a tool that lasts, very efficient and easy to use or has the capability for automation. The customer may have a request for manual, semi-automated or fully automated part production.
The quality of the metal stamping part
Some production parts may require absolute burr-free edges without a second operation to remove the burrs. Some metal stamping production parts require straight edges all the way. Other stamped parts have such tight specifications that special tools need to be built for that request.Punch press
The metal stamping die must physically fit the punch press it is intended for, so you need the punch press specifications that may limit how you build the tool.The metal stamping part itself
Some metal stamped parts are best suited for a certain type of tool and die design for the best result. Don’t try to build something else, if you are not sure of the outcome. To decide what type is the best for that part, take a look at the sample designs, made for the same part. Vortool Manufacturing will discuss each version’s strong points that can help you to make a decision about which to choose.Corner skin form tool for low volume metal stamping production
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
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.
Ball bearing guided high precision progressive metal stamping tool and die for high speed automated production
The picture shows the bottom die set and
some of its components are being inspected,
aligned and assembled.
Ball bearing guided high precision progressive tool for high speed automated production
Stamped metal parts usually require more than one operation in one. This progressive metal stamping tool produces a high volume mounting bracket that pierces holes, blanks out a shape by cutting the strip into separate parts and finally folds the part into an L shape. At each hit a final product falls off at the end of the tool. It is made for a high production automated punch press using coil and an air feeder for continuous operation.
This progressive die design consists all the necessary features that any stamping tool should have from ease of use through high accuracy to reliable operation for a long time. It includes strip feed and guide, stripping, slug separation, and feeder actuation. As an option the tool can be used as a manually operated tool without the air feeder using strips instead of coil.
The cutting components are designed to be made of hardened tool steel that ensures the long usability. Choosing the right alloy for the application and the proper design of the tool can greatly effect the life of the tool. As a result it can operate trouble free for longer, saving on maintenance. It can also reduce or eliminate downtime and minimize costs that are associated with the value of the final product.
The progressive tooling was designed using SolidWorks 3D CAD. Shop drawings, and files generated from the models are seamlessly fit into any machine shop or tool room's profile.
Design considerations for stamping tools and dies
Design considerations for metal stamping tools and dies
Metal stamping die design considerations or decisions are driven by a number of factors in tool and die design.
However there are a few mayor points that should not be missed and must be included in the decision making process. You could design and build an inexpensive fabricated tool or you could make one that is a top of the line master piece.
How do You Decide Which One to Make?
Your customer will tell you what they need, what material the stamped parts are, how many parts should be stamped, when they want the finished parts, and how much they are willing to pay and so on.These are important guide lines toward the metal stamping die design. They tell you what you can do and what you can’t. They set some boundaries.
The part itself is one of the major contributors that guide you through what the minimum requirements are toward the tool. It will help you with what you need in order to produce the particular part.
You may raise questions that need to be answered. How efficiently will the parts be produced? How long will the tool last? How user friendly should the tool be? What are the variables that can be implement in the design?
The Above General Guide Lines Should be Specified More in Detail
- How many parts will be produced per run, monthly or in the lifetime of the tool? If the amount of production is low, you will know that the tool will likely be manually operated and be budget oriented. If e.g. 5,000 parts are to be made every week for the next two years, than you know it is a high demand tool and automation and continuous operation is required. The tool must be designed accordingly. More time and money can be spent to make the suitable tooling.
- Low production rate equals inexpensive tooling components, unsophisticated guides, supports, etc.
- On the other hand if the metal stamping tool is running all the time, then you will need to build a tool that lasts. It will require less frequent tool and die maintenance, and be built for high speed automation. The tool steel should be higher quality, and more suitable for extended use. In this case instead of using e.g. A2 or D2 material, consider using M2 with coated surfaces or Vanadis 4 Extra or comparable. For the extra cost, these tool steel will last many times longer before sharpening is required. Use a ball bearing guide system, instead of standard bronze plated bushings and standard die pins. The ball guided system is better for high speed punch presses and high speed stamping.
- Pressure plates require springs behind them to generate enough force. Consider using gas springs. They are generally suitable for high speed stamping, and about 250 spm and rated about 1 million strokes before servicing. They are also more powerful than conventional die springs with the same footprint. You can use punches with ejector pins in them to push off slugs that are serious obstacles in automated stampings. You can also use die buttons with slug control that keep the slugs in the die button, preventing slug pulling. Slugs pulled back onto the die surface area can jam the strip and cause the feeder to buckle the coil. If this happens, your tooling may be at risk for serious damage.
- Bending is generally done using a wipe form method. The parts eventually gull and have heavy marks. The form sections constantly require polishing, causing downtime and quality issues. Ready benders can eliminate most of these problems, where the bends have simple straight features. This method completely eliminates parts sticking into the form die, as they require less pressure and will not mark the part as much or just simply eliminate it altogether. It is a perfect solution for pre-painted strips to stamp.
- Stock pushers are designed for automated stamping and have a superior feature that make their use a preferred choice.
- At upstroke of the press, they release the force applied to the edge of the strip or coil entirely, allowing a resistance free strip advancement. The applied pressure is adjustable, and you can design the engagement timing as you need it. The pilot punches can locate the strip perfectly before you lock its position for the duration of the cut.
- Another contributor to your metal stamping tooling design is to know what press or presses will be used for stamping. Your tool must be compatible and fit the desired press or presses. You may want to consider making 3D models of the presses with the vital features that are necessary for your tool design.
- The general requirement toward any stamping tool and for their design is that it should cost as little as possible, yet produce the most amount of parts at the best quality, should not break down, and will last longer than the anticipated life span of the tool. This perfect scenario should be achieved at all times. Compromises sometimes must be made and accepted, but not be part of your design.
- The guide lines or restrictions that are set by your client, your tool and die manufacturing facility or your ability, will have an impact of the outcome of your design and ultimately of the stamping tools and the produced parts.
Custom specialty bench top, portable and modular presses
C frame press
AirHEAD 5 - 4 ton benchtop pneumatic box frame press
AirHEAD 5 - 4 ton benchtop pneumatic box frame press
Custom portable air-oil cylinder / shop air punch press station
AirHEAD 12-16-7 - 6 ton air to oil cylinder portable punch press station
Custom precision benchtop three platen flatbed die cutting press for steel rule die
Custom benchtop pneumatic swaging press
Custom air-oil punch press station for modular long mandrel die
Benchtop, portable and modular presses that operate with shop air
Modular press using multiple punch stations
Unit 240 19358-96 Ave.Surrey, BC V4N 4C1 CanadaCall: 604-239-7218 | EmailMade 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.
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.
• 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.
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.
Subscribe to:
Posts (Atom)