Press Tool Technology

Introduction to Press Tools

Stock Material
Theory of Shearing
Cutting Force
Cutting clearance
Basic Design of Guide Plate
Elements of Guide Plate Tool
Land and Angular Clearance.
Progressive Tool
Strip layouts
Punches and buckling of punches
Die Blocks

(An ISO 9001:2000 Certified Training Institution)

Volume 1

INTRODUCTION TO TOOLING

The word tooling refers to the hardware necessary to produce a particular product. The most common
classification of types of tooling are as follows:

Press Tools

Moulds

Jigs and fixtures

Gauges

The toolmaker manufactures the above items from the design supplied to him. On gaining experience the
toolmaker will be able to design and manufacture simple tools.
Press tools:
Press tools are special tools custom built to produce a component mainly out of sheet metal.
The principle operations of sheet stampings include cutting operations (shearing, blanking, piercing, etc.)
and forming operations (bending, drawing, etc.).
Sheet metal items such as automobile parts (roofs, fenders, caps etc.), components of aircraft, parts
of business machines, household appliances, sheet metal parts of electronic equipments, precision parts
required for homological industry etc., are manufactured by press tools.

Various operations that are performed in Press tools

The answer is we have prepared twenty types of operations, which are performed in tools.

Blanking.
When a component is produced with one single punch
and die with entire perif ery is cut is called
blanking.Stampings having an irregular contour must be
blanked from the strip. Piercing, embossing, and various other operations may be performed on the strip prior
to the blanking station.

Cut-off.
Cut off operations are those in which strip of suitable
width is cut to lengthin single. Preliminary operations before cutting off include piercing, notching, and embossing. Although they are relatively simple, cut-off tools can
produce many parts.

Parting off.
It is similar to cut off opertion except the cut is in double
line. This is done for components with two straight surfaces and two profile surfaces.Parting of produces waist.

Trimming.
When cups and shells are drawn from flat sheet metal
the edge is left wavy and irregular, due to uneven flow of
metal. This irregular edge is trimmed in a trimming die.
Shown is flanged shell, as well as the trimmed ring removed from around the edge.While a small amount of
material is removed from the side of a component or
strip is also called as triming.

Piercing.
Piercing tools pierce holes in previously blanked, formed,
or drawn parts. It is often impractical to pierce holes while
forming because they would become distorted in the
forming operation. In such cases they are pierced in a
piercing tool after forming.

Shaving.
Shaving removes a small amount of material around the
edges of a previously blanked stampingsor piercing. A
straight, smooth edge is provided and therefore shaving
is frequently performed on instrument parts, watch and
clock parts and the like. Shaving is accomplished in shaving tools especially designed for the purpose.

Broaching.
Figure shows serrations applied in the edges of a stamping. These would be broached in a broaching tool.
Broaching operations are similar to shaving operations.
A series of teeth removes metal instead of just one tooth
as in shaving. Broaching must be used when more material is to be removed than could effectively done in with
one tooth.

Horning:
Horn tools are provided with an arbor or horn over which
parts are placed for secondary operations such as seaming. Horn tools may also be used for piercing holes in the
sides of shells.

Side piercing (cam operations).

Piercing a number of holes simultaneously around a shell
is done in a side cam tool; side cams convert the up and
down motion of the press ram into horizontal or angular
motion when it is required in the nature of the work.

Bending.
Bending tools apply simple bends to stampings. A simple
bend is done in which the line of bend is straight. One or
more bends may be involved, and bending tools are a
large important class of pres tools.

Forming.
Forming tools apply more complex forms to work pieces.
The line of bend is curved instead of straight and the
metal is subjected to plastic flow or deformation.

Drawing.
Drawing tools transform flat sheets of metal into cups,
shells or other drawn shapes by subjecting the material
to severe plastic deformation. Shown in fig is a rather
deep shell that has been drawn from a flat sheet.

Curling.
Curling tools curl the edges of a drawn shell to provide
strength and rigidity. The curl may be applied over a
wire ring for increased strength. You may have seen the
tops of the sheet metal piece curled in this manner. Flat
parts may be curled also. A good example would be a
hinge in which both members are curled to provide a
hole for the hinge pin.

Bulging.
Bulging tools expand the bottom of the previously drawn
shells. The bulged bottoms of some types of coffee pots
are formed in bulging tools

Swaging.
In swaging operations, drawn shells or tubes are reduced
in diameter for a portion of their lengths.

Extruding.
Extruding tools cause metal to be extruded or squeezed
out, much as toothpaste is extruded from its tube when
pressure is applied. Figure shows a collapsible tool
formed and extruded from a solid slug of metal.

Cold forming.
In cold forming operations, metal is subjected to high
pressure and caused to and flow into a pre determined
form. In coining, the metal is caused to flow into the shape
of the die cavity. Coins such as nickels, dimes and quarters are produced in coining tools.

Compound.
Compound tools pierce and blank Simultaneously at the
same station. They are more expensive to build and they
are used where considerable accuracy is required in the
part.

The Progressive operations.

Progressive operations are those in which progressive
tools perform work at a number of stations simultaneously. A complete part is cut off, blankedat the final
station, with each stroke of the press.

Assembly tools
Represented is an assembly tool operation where two
studs are riveted at the end of a link. Assembly tools
assemble the parts with great speed and they are being
used more and more.

Sub press operations

Sub press tools are used for producing tiny clock, and instrument components, represented by the watch
needles shown. Sub presses are special types of tools used only for such precision work.
As you study the sections to follow, you will be introduced, step-by-step; to the fundamental die components
and you will learn the methods by which die designers assemble these components in designing tools. When
you have completed you will know the elements of die design quite thoroughly. Knowledge such as this is well
paid for industry. You will have acquired the foundation of a carrier that can benefit you for the rest of your life.

STOCK MATERIAL:

RELATIONSHIP OF PIECE PART AND STOCK STRIP:

PIERCED OPENING

STOCK STRIPS:
Stock strips are fed into the die and advanced by the
required advance distance at each press stroke for a
series of repetitive operations.

PIECE PART B

PIECE PART:
A piece part is the product of a die. It may be a complete
product in itself or it may be only component of a product consisting of many and different parts. The die may
or may not produce the piece part in the finished state.

SLUG

STOCK STRIP

BACK SCRAP
STAMP OPENING

LEAD END OF STOCK MATERIAL

FRONT SCRAP

PIECE PART

UNIT STOCK:
The term unit stock is applied to pieces of material, which
are fed individually into dies for processing. In the case
of large stamping, a standard mill size sheet metal might
be practical as unit stock. At times unit stock may be
produced from strip stock by means of a chop off die.
The rectangular piece of unit stock is fed into a piercing
die to produce the piece part B. Disc C is the scrap slug,
produced by
the
piercing
operation.

PIERCED OPENING

PIECE PART B

SLUG

STOCK MATERIAL:
The materials out of which stampings are made are
known as stock materials. Stampings can be metallic or nonmetallic. Metallic materials include ferrous
metals like hot rolled steels, cold rolled steels, stainless steels, spring steels, silicon steels etc and non
ferrous metals like copper, brass, bronze, phosper
bronze, aluminum, tin, zinc etc. non metallic materials like plastic, rubber, wood, cloth and paper are
also used as stock materials to produce stampings.
Every stock material l has got its own chemical and
physical properties. The product designer as well
as the tool designer should have a thorough knowledge of these properties. The following is the standards give the chemical composition and physical
properties of ferrous metals generally used in stamping industry. Surface finish of all these types can be
coarse or rough medium or fine,
dull or bright.
FERROUS METALS:
Refer Indian standards for the property of materials.
IS 513 Cold rolled carbon steel sheets.
IS 1079 Hot rolled carbon steel sheets and strips.
IS 2507 Cold rolled spring steel strips.
HOT ROLLED STEEL SHEETS:
These can be formed easily. Low carbon
hot rolled sheets are used for barrels, pails, farm
implements, lockers, cabinets, truck bodies and
other applications, where scaling and discolouration
are not objectionable, as the surfaces are painted
after forming.
PICKLED AND OILED SHEETS:
Pickling or the immersing of hot rolled steels
in acid solutions result in smooth clean scale free
surface having a uniform grey colour. Oiling protects
the surfaces against rust. Pickled and oiled sheets
are used for household appliances, automobile parts,
toys etc, because of long lasting painting it can take
due to the absence of scales.
MEDIUM CARBON STEELS:
Hot rolled steels having 0.4 to 0.5 % of carbon provide hardness toughness and resistance to
abrasion. They can be heat-treated. They are mainly
used in the manufacture of hand tools, blades etc.
COLD ROLLED STEEL SHEETS:
Cold rolled steel sheets have a smooth
deoxidized satin finish, which provide excellent base
for paint, lacquer or enamel coating. Cold rolled
sheets are produced by cold rolling the hot rolled
steels to control the size and finish.

The thickness of such sheets is maintained to the

greater accuracy. They are used in the manufacture of refrigerators, cooking ranges, panels, lockers, and electrical fixtures.
Cold rolled sheet and strips are available in
six grades of hardness (fig.) as follows: A) HARD
Hard sheets and strips will not bend in either direction of the grain without cracks or fracture.
Such steels are employed for flat blanks that require resistance to bending and wear.
B) THREE QUARTER HARD
Three quarter hard strips will bend to an
angle of 600 from flat only across the grain.
C) HALF HARD
Half-hard steel strips will bend a sharp 900
angle across the grain.
D) QUARTER HARD
This commonly used steel will bend over
flat (1800) across the grain and to a sharp right angle
along the grain.
E) SOFT
Soft grades of steel will bend over flat (1800) both
across and along the grain direction. This can be
used for moderate forming and drawing operations.
F) DEAD SOFT
This steel is widely used for severe forming and
drawing operation.
DEEP DRAWING STEEL SHEETS:
Deep drawing steel is prime quality cold
rolled steel having a very low carbon content. These
sheets are thoroughly annealed, highly finished to
deoxidized silver finish, and oiled. Deep drawing
sheets are used for difficult drawing, spinning and
forming operations such as automobile bodies, fenders, electrical fixtures and laboratory equipments.

SILICON STEEL:
These are also called as electrical steel, silicon steel is extensively used for electrical laminations. Lighter gauges are suitable for transformer,
reactors, relays, and other magnetic circuits.
STAINLESS STEEL:
These steels cover a wide range of application. They can be used with few expectations for
all application for which carbon steel are used where
corrosion resistance is a requirement.

NON-FERROUS METALS

PREPARATION OF STOCK:
Stampings can be manufactured from stock
material of different forms.

COPPER AND COPPER ALLOYS:

Due to good conductivity of heat and
electricity as well as non-corrosiveness, copper and
STOCK STRIP:
its alloys are widely used as stock material for
stamping. Copper alloys and its composition:
In steel mills, the metal is formed into large sheets
by rolling and trimming. The sheets are cut into strips
Beryllium copper Be 2%, Co 3%, Cu 97.7%
in a shearing machine. Gauges register the edges
Red brass
Cu 25%, Zn 15%
of the sheet for cutting the strips to correct width.
Low brass
Cu 20% , Zn 20%
The power shear can shear the sheet in any direcCartridge brass
Cu 70% , Zn 30%
tion across the sheet or along the sheet or at an
Yellow brass
Cu 65%, Zbn 35%
angle. The latest technique used in cutting the strip
Muntz metal
Cu 60%, Zn 40%
is by slitting. The sheet is fed through rotating cutter
Phosphor bronze
or knives and all strips are cut simultaneously. Power
Zn 4%, Zn 4%, Sn 4%, Cu 27.65%, Pb 35%
driven collars cause the sheet the advance. Unlike
the shear, which can cut strips of length only equal
2.2.2.2) ALUMINIUM AND ITS ALLOYS:
to the width of the blade at a time, the slitting maAluminium is one of the lightest metals. It
chine will cut continuously to any length of the sheet.
resists the corrosive effect of most of the chemical and
Small length of strips are hand fed into the
has high malleability combined with good thermal and
tool by the press operator, whereas strips of longer
electrical conductiveness.Aluminium is alloyed with
length and lighter gauge are coiled into rolls and
silicon, iron, copper, manganese, chromium, nickel and
fed by automatic feeding mechanism.
zinc.
Some of the aluminium alloys are strain hardenable,
UNIT STOCK:
whereas some are heat treatable. Aluminium and its
Quite frequently, it is not practicable to blank
alloys are widely employed in manufacture of aircraft,
directly from a continues strip or from a certain length
electrical equipment and utensils.
of strip. This happens when the stock material is
heavy or large in size. In such cases, unit stock is
MAGNESIUM AND ITS ALLOYS:
cut to slightly bigger size then the blank is fed into
Magnesium is relatively silver white material.
the tool, one per stroke of the press ram.
In its purest state, it does not posses sufficient strength
Scrap material left over from another tool may also
for many commercial uses. Magnesium is alloyed with
be used as unit stock if there is sufficient margin all
other metals like aluminium, manganese and zinc. Most
around.
of the forming and bending operations on manganese
0
0
alloys are done at 200 C to 300 C.Other than once
explained above, the alloys of zinc, tin and titanium
are also used in stamping industry.
RARER METALS:
Rarer metals like zirconium, tantalum, vanadium, tungsten and molybdenum and their alloys find
their place as stock material in press working.
PRECIOUS METALS:
Precious alloys like gold, silver. Platinum and
palladium are for laboratory equipment and electrical
industry.
CLAD METALS:
Clad metal strip or sheet is a composite of a
core or a backing layer and covering layer of a dissimilar material. The covering metal thickness is usually 10- 35% of the total composite thickness and it is
bonded to the backing material by the use of adhesive, solder or by molecular bonding. Commonly used
clad metals for steel are- Stainless steel nickel, copper, nickel and silver. For copper stainless steel and
platinum. For brass gold silver platinum and palladium.

THEORY OF SHEARING

The name shearing stands for the method of cutting sheets or stock without forming chips. The material is
stressed in a section, which lies parallel to the forces applied. The forces are applied either by means of
shearing blades or punch and die.
The forces necessary to bring rupture of the material depends primarily upon the shearing strength (tmax)
and the stressed section or the stressed area and secondly upon the shape, condition and position of the
shear blades.

CRITICAL STAGES OF SHEARING

STAGE 1:The pressure applied by the punch on the

stock material tends to deform it into the die opening
when the elastic limit is exceeded and by further loading,
a portion of the material will be forced into the die
opening in the form of an embossed pad on the lower
face of the material and will result in a corresponding
depression on its upper face. This stage imparts a radius
on the upper edge of the opening in the strip and on
the lower edge of the punched out material (blank or
slug). This is called the stage of plastic deformation.

STAGE 2:As the load is further increased, the punch

will penetrate the material to a certain depth and force
an equally thick portion of metal into the die. This stage
imparts a bright polished finish (cut band) on both the
strip and the blank or slug. This is the penetration
stage.

STAGE 3: In this stage, fractures will start from both

upper and lower cutting edges. As the punch travels
further, these fractures will extend towards each other
and eventually meet, causing complete separation. This
stage imparts a dull fractured edge. This is the fracture
stage.

CUTTING FORCE

CUTTING FORCE
Cutting force is the force which has to act on
the on the stock material in order to cut out the blank
or slug. This determines the capacity of the press to
be used for particular tool. The first step in establishing the cutting force is to determine the cut length area.
The area to be cut is found by multiplying the length of
cut by stock thickness.
Formula for calculating the cutting force:
Cutting force = LX S Tmax
L
S
T max

= Length of periphery to be cut in mm

= Sheet thickness in mm
= Shear strength in N/ mm2. , (taken from table)
= 80% of tensile strength ( max)

Resistance begins when the punch contacts the

stock material. The load builds up rapidly during
the plastic deformation stage and continues to increase while penetration is taking place. The accumulated load is suddenly released when fracture occurs. If proper cutting clearance condition
exists between the punch and the die the fracture
will occur when the cutting force equals the shear
strength of the material. The curve levels off near
the bottom. This last portion of the load curve represents the frictional resistance as the punch travels through the stock material and also the resistance of the blank passing through the die.
FORMULA TO CALCULTE THE PRESS FORCE
Press force =
Cutting force + Stripping force
(Stripping force = 10%-20% of cutting force.)

The following table gives the shear strength

The three critical stages of shearing action are related (max =0.2 for tensile strength max) of several materials
to cutting force.
MATERIAL
in N/ mm2
max
Steel with 0.1% carbon
240-300
Steel
with
0.2
%
carbon
content
320-400
DEPTH OF
(deep draw steel)
PUNCH
PLASTIC DEFORMATION
Steel with 0.3% carbon
360-420
Steel with 0.4% carbon
450-560
STOCK
Steel with 0.6% carbon
550-700
Steel with 0.9% carbon
700-900
DIE
Silicon steel
450-550
Stainless steel
350-450
Copper
200-400
Brass
350-400
Bronze
360-450
The figure represents the typical load curve of cutting German silver 300-320
force of blanking or piercing punch.
Tin
30-40
Zinc
100-120
Lead
20-30
Aluminium 99% pure
20-120
Aluminium
manganese
alloy
150-320
PENETRATION
120-250
FRACTURE Aluminium silicon alloy
PLASTIC DEFORMATION
Paper and card board
20-50
Hard
board
70-90
PE A
KP
O IN
T
Laminated paper
100-140
Laminated fabrics
90-120
Mica
50-20
Plywood
20-40
Leather
7
Soft rubber
7
Hard rubber
20-60
Celluloid
40-60
Laminated fabrics
90-120

Stepping of punches

Example:1.
Calculate the press force required to produce the
following component.
Sheet Thickness 2mm.
10
Material is brass

10

40

Shear

Material thickness
+ clearance

23

Shear

Cutting force = l x s x T max

= 126 x 2 x 400
= 100800 N
= 100.8 KN
Press force = Cutting force + stripping force
= 100800 + 20% 100800

Shear
Shear

Shear

METHOD OF REDUCING THE CUTTING FORCE

It sometimes becomes necessary to reduce
cutting forces to prevent press over loading.
The method of reducing cutting forces
is to step punch length. Punches or group of punches
progressively become shorter by about one stock
material thickness.
A second method is to grind the face
of the punch or die to a small shear angle with the
horizontal. This has the effect of reducing the contact
area while shearing at one time. Providing shear also
reduces the shock to the press and smoothens out
the cutting operation. The shear angle chosen should
provide a change in punch from 1 to 1.5-sheet thickness.
Various types of shear angle are
shown in the figure. Double shear angle is preferred
over single shear angle because it balances the cutting force acting on the punch. Double shear angle on
punches should be concave to prevent the stretching
of the material before it is cut. Shear angle may be
applied either to the punch face or to the die face,
depending on whether the operation is blanking or
piercingbecause shear will distort the work material.
The shear angle for blanking operation will be on the
die member, while, as the piercing operation the shear
angle will be given on the punch member.

Shear

= 120960 N
= 120.960 KN.

CUTTING CLEARANCE
CUTTING CLEARANCE:
Cutting clearance is the gap between the side
of the punch and the corresponding side of the die
opening on one side of the edge, when the punch is
entered into the die opening. Therefore the cutting
clearance should always be thought and expressed as
the amount of clearance per side.

5
EXCESSIVE CUTTING CLEARANCE:
The comparatively the large gap between
the punch and the die cutting edges allows the
stock material to react to the initial pressure on a
manner approaching that of forming rather than
cutting. Therefore the edge radius becomes
larger. It does not blend smoothly. The cut band
becomes smaller. The break shows greater irregularities due to above facts. These irregularities may effect cut band and the edge radius, and
when the break occurs heavy burrs are noticeable all along the cut contour.

MPORTANCE OF CUTTING CLEARANCE:

Proper cutting clearance is necessary to aid
the life of the die and the quality of the piece part. Excessive cutting clearance results in objectionable piece
part characteristics. In sufficient cutting clearance
causes undue stress and wear on the cutting edges of
the tool because of the greater punching effort required

TYPICAL APPEARANCE
CHARACTERISTICS
A visual examination of the press tool component will indicate the amount if clearance between them
the excessive clearance, insufficient clearance and
misalignment between the punch and the die.

OPTIMUM CUTTING CLEARANCE:

The figure shows the blank or slug made under optimum cutting conditions. The edge radius (die
roll) is the result of initial plastic deformation, which
occurred during the first stage of plastic shear action.
Highly burnished cut band results from the second stage
(penetration) of shear action. The width of the cut band
is approximately 1/3 rd the thickness of stock material. The balance of the cut is the break, which results
from the third stage (fracture) of the shearing action.

INSUFFICIENT CUTTING CLEARANCE

When cutting clearance is slightly less the
condition can be identified by greater width of the
cut band. If the cutting clearance is further decreased, two or more cut bands will be produced.
Because of steeper angle between the
punch and the die cut edges the resistance of the
stock material to fracture is increased. The resulting accumulation of pressure may cause the
initial fracture to originate at clearance rather than
at the cut edges.
In case of excessive clearance the burr
results from dragging of the material. While insufficient clearance compressive forces cause the
burr.

MISALIGNMENT BETWEEN PUNCH AND

DIE
The cutting characteristics also indicate
whether the punch and die openings are in accurate
alignment. Because of misalignment clearance on oneside increases and other side decreases. The component will show corresponding differences in the cut band

BURR SIDE:
The burr side is adjacent to the break. The burr
side is so called because of a noticeable burr condition
develops in this side. Burr should be practically nonexistent if the cutting clearance between the punch and
the die is correct and if the cutting edges are sharp.
The characteristics of the blank or slug and
the punched opening are inversely identical. The burr
side of the blank or slug is always towards the punch
(die starts shearing) the burr side of the punched opening is always towards the die opening. (punch starts
shearing).
RELATIONSHIP OF PIECE PART SIZES TO PUNCH

AND DIE SIZES:

When pierced or blanked piece parts are measured, the measurement is made at the cut band. The
actual cutting of the blank or slug is done by cutting
edge of the die opening. Therefore the die opening determines the size of the blank or slug. The actual cutting of the opening in the stock material is done by
punch. Therefore the size of a punched opening is determined by the punch.

DETERMINING THE CUTTING

CLEARANCE:

The ideal clearance could be found by the

following formula and depends on co-efficient of 'C'
Clearance for 's' up to 3 mm
= c x s x Tmax/10
For 's' above 3 mm clearance
= (1.5 x s) x (s - 0.015) x Tmax /10
Where 's' is the sheet thickness in mm
'C' is constant = 0.005 or 0.01 as
the case may be.
Tmax = Shear strength
= 80% UTS. It is expressed in N/ mm2

If we take 'c' as 0.005 we get a clearance,

which yields a better and cleanest work
piece, but requires a higher cutting force
and considerably more energy. If we take
'c' as 0.01, the cutting force energy as its
minimum, but finish is bad. The usual practice however is to take 'c' as 0.01

DETERMINATION OF PUNCH AND DIE

SIZE:
PIERCING:
Piercing punch = Pierced hole size
Die = Hole size + total clearance.
BLANKING:
Blanking punch = Blank size-total clearance
Die = Blank size

Eg.3: Determine the punch and die dimension for the component given below. Sheet
thickness 2mm, MS, Tmax is 400N/mm. C
R6
= 0.01

10

10

10

PROBLEMS
Eg.1: Calculate the clearance for punching
a 2 mm sheet. Tmax is assumed to be 300
N/mm2
Clearance = c X s X Tmax/10
= 0.01 X 2 X 300/10
=0.02 X 300/10
= 0.12 mm/ side
Therefore clearance on one side = 0.12mm

15
25
40
55
Clearance = C X S X Tmax/10
= 0.01 X 2 X 400/10
= 0.13mm/side

Eg.2:
Determine the punch and die
dimension for the component given below.
Sheet thickness 0.5mm, stainless steel sheet,
Tmax is 400 N/mm. C=0.01
15 18
R2

BLANKING PUNCH:

0
R1

50

Clearance = C X S X Tmax/10
= 0.01 X 0.5 X 400/10
= 0.03 mm/side
BLANKING PUNCH:
COMPONENT DIMENSION
50
15
R10

CLEARANCE
Add / Deduct
-0.06
-0.06
+0.03

COMPONENT
DIMENSIONS
(PUNCH)
5
R5
10
10(SLOT)
15
20
25
40
55

CLEARANCE
Add / Deduct

PUNCH / DIE
DIMENSIONS

-0.26
-0.13
-0.26
+0.26
--0.26
-0.13
-0.26
-0.26

4.74
5.87
9.74
10.26
15
19.74
24.87
39.74
54.74

PUNCH / DIE
Dimension
49.94
14.94
R10.03

Blanking die dimension is same as the

component dimensions.
Piercing
punch size is same as
component size.

Blanking die dimension is the same as the

component dimensions.
Piercing die size
Piercing punch size is the size of the pierced
= component size + clearance
opening
=10.00 + 0.26

PIERCING DIE:
CLEARANCE
Add / Deduct.

PUNCH / DIE

COMPONENT DIMENSION
R2

+0.03

R2.03

+0.06

4.06

18

+0.03

18.03

=10.26mm

GUIDE PLATE TOOL

GUIDE PLATE TOOL:

Guide plate tool is preferred when
1) Shape of component is simple.
2) The accuracy of the component is less.
3) Only fewer components are required.
The guide plate tool consist of :
1) Top plate.
2) Bottom plate.
3) Punch holder.
4) Punch.
5) Die plate.
6) Thrust plate (back plate).
7) Shank.
8) Guide plate.
9) Stopper.
10) Dowel pin.
11) Screws.

IMPORTANCE OF GUIDE PLATE

TOOL ELEMENTS.
TOP PLATE:
This plate is also known as top bolster or die
head. Punch unit is rigidly and accurately held on this
plate. Top plate should be thick enough to take the load
of punch backpressure. It is made out of mild steel or
cast iron.

BOTTOM PLATE:
This plate is also known as bottom bolster
or base plate or die shoe. Die unit is rigidly and accurately mounted on this plate. Bottom plate should
be thick enough to take the load of the punching
pressure or load. It is made out of mild steel or cast
iron.

BOTTOM PLATE

PUNCH HOLDER:
This plate is also called as punch plate.
All the punches are accurately held in this plate.
This plate should be thick enough to accommodate punch shoulder and keep the punches perpendicular. It is made out of mild steel. Punch plate
is made out of single piece and a need base it is
also made out of more than single piece.

TOP PLATE

PUNCH HOLDER

BACK PLATE:
PUNCH:
This is one of the most important element of
the tool. It is the cutting element of the tool. Punch gives
the hole size and the shape on the component. This is
made out of high carbon high chromium steel Material.
Punches are hardened and tempered to 58-60 HRC.
The length of the punch in normal condition is kept up
to 60mm. Opposite end of the cutting face is shouldered or tapered to mount on top unit.

This plate is also known as thrust plate.

This plate is mounted on top of the punch holder.
It is made out of medium carbon steel. It is hardened and tempered to 45 to 48 HRC. Punch heads
have direct contact with this plate, which will prevent the punch penetration into top plate during
punching operation.

BACK PLATE

SHANK:

DIE PLATE:
This is most on of the important element of the
tool. This is mounted on bottom plate. Die plate is the
cutting element of the tool which gives the blank size
and shape. This is made out of high carbon high
chromium steel material. It is hardened and tempered
to 60-62 HRC. Die plate thickness is decided on the
basis of stock material being cut.

Shank is a tool element. This is fixed on

the top plate. Shank is fixed in the press ram. This
should be strong enough to take the total weight of
the punch unit and stripping force. There are different types of shank standards. Selection of the shank
is based on the need base. It is made out of mild
steel. The location of the shank point is very important and different load acting on top plate is to be
considered.

SHANK
DIE PLATE

GUIDE PLATE:
This plate is also called as stripper plate. In
guide plate tool this element is known as guide plate.
This plate helps in stripping operation. It not only strips
the strip from the punch but the main function of this
plate is to guide the punch accurately and maintains
the alignment between punch and die. Hence the plate
is made with the same care as die. It is mounted on
die plate. It is made out of mild steel. In some cases
this guide plate is also made out of tool steel. A
channel is milled in the plate, which will guide the stock
strip.

DOWEL S

DOWELS

SCREWS:
This is fastening element. Screws are used
to hold the plates together. The sizes of the screws
are selected on the basis of tool size

BOX STRIPPER
SCREWS

STOPPER:
The stopper shownis a plain cylindrical pin. The
pin is mounted in the die block. The function of the
stopper is to arrest the movement of the strip when it is
fed forward to one pitch length.Various type of stoppers are available.

STOPPER
DOWEL PIN:
This is a cylindrical pin hardened and ground
on center less grinder. This dowel is made to m6 tolerance. Dowel pins keep the alignment between the plates
and prevent it from lateral movement.

ELEMENTS OF GUIDE PLATE TOOL

The guide plate tool consist of

1) Top plate.
2) Bottom plate.
3) Punch holder.
4) Punch and die.
5) Back plate.
6) Shank.
7) Stripper cum guide plate.
8) Stopper.
9) Screws and dowels.

IMPORTANCE OF GUIDE PLATE TOOL

ELEMENTS
TOP PLATE:
The punch, punch holder and back plate is
mounted on the top plate. The tool shank that locates
the whole tool centrally with the press ram is also screwed
on the top plate. The top plate is made of mild steel or
cast iron. This plate should be thick enough to prevent
bending.

2) The blank should fall clear off the die without

any obstruction.
3) The contour of the opening should be made
simple as possible.
4) The openings in no case weaken the die plate.
5) Since the sharp edges of the blank dig into the
side walls, extra relief should be provided in such
cases by drilling the relief holes.
The base plate is also made of good quality mild
steel or cast iron and should be thick enough to
prevent deformation under pressure.

TOP PLATE

BOTTOM PLATE:
This plate gives a cushioning effect to the die
as well as provides enough room for the tool to be
clamped to the press bed. There may be a opening in
the back plate which allows the blank or slug to fall
clear off the tool. They should meet the following
requirement:
1) The opening should not weaken the support of the
die.

BOTTOM PLATE

PUNCH HOLDER:
The punch holder is usually fixed in the with a
light press fit in the punch holder. Some means to
prevent the profiled punches from rotating should be
provided in the punch holder (a key or a dowel)

DIE PLATE

PUNCH HOLDER

BACK PLATE:

While performing the cutting operation the punch

exerts an upward thrust. So the punch should be
backed up by a hardened plate to prevent it from
PUNCH AND DIE:
digging into the soft top plate.
The basic elements of blanking tool are punch The hardness is about 45-50 HRC
and die. They are made out of good quality alloy steels.
They are hardened and tempered to 58 -62 HRC.

BACK PLATE

SHANK:
The tool is located and clamped to the press
ram by the shank. Diameter of the shank for a particular tool depends only on the diameter of the bore in the
press ram on which it is intended to be mounted. Shanks
are standardized to suit different press.

BOX STRIPPER
STOPPER:

SHANK

A stopper can be a plain cylindrical pin. The

pin is mounted in the die block. The function of the
stopper is to arrest the movement of the strip when it
is fed forward to one pitch length.Stoppers are designed as per the requirement

GUIDE PLATE:
While performing the cutting operation the
punch penetrates the stock material and enters into the
die. As a result of this blank or slug is pushed into the
die. In completion of the cutting operation the punch
STOPPER
withdraws from the die, but the stock strip clings tightly
arround the punch. The strip cannot be moved forward
unless the strip is removed from the punch to facilitate
SCREWS AND DOWEL PIN:
the removal of the strip from the punch another plate is
The screws are used to hold the die parts
mounted on the top of the die with the help of screws
and dowels. This plate does not allow the strip to go together and the dowels are used to align the die
parts to gather .
along with the punch so it is called the stripper.
The stripper has another function too. The channel milled on bottom face of stripper ensures that the
stock strip is guided and is fed in line with the die profile, thus maintaining the front and back scrap equal
throughout. In guide plate tool it is the stripper, which
aligns the punch with the die. Maintaining close sliding
fit between the punch and the stripper opening as well
as location in line with the die attains it. Whenever a
striper guides a punch into position it is called a guide
plate. Guide plates usually made of mild steel. If higher
production is anticipated, it is made of medium carbon
steels and hardened to 45-50 HRC.
SCREWS AND DOWELS

LAND OR ANGULAR CLEARANCE

LAND AND ANGULAR RELIEF OR

ANGULAR CLEARANCE:
In special cases, the angular clearance extends from top to bottom of the die wall completely
The inner walls of the die opening are not usually made eliminating the land. Silicon steel and stainless steel
straight through as the blanks or slugs tend to get stocks tend to bell mouth the die opening very rapjammed inside, which may result in undue stress build idly unless the angular clearance begins at the cutup. This may lead to the breakage of punch and die. ting edge
To avoid such a situation the die walls are kept
straight only to a certain amount from the cutting edge.
The straight wall is called The Land. An amount of
3mm land for stock thickness upto 3mm and the thicker
materials equal to their thickness has proved to be good
practice.

LAND:

Dies employing an ejector to clear the blanks will

have straight walls without any angular clearance,
as the blanks do not get accumulated in the die.

Land

ANGULAR CLEARANCE OR ANGULAR

RELIEF:
The die wall below the land is relieved at an
angle for the purpose of enabling the blanks or slugs to
clear the die. Generally, soft materials require greater
angular clearance than hard materials. Soft thicker
materials above 3mm require more angular clearance.
An angular clearance of 1.50 per side will meet the usual
requirements

A simple design of blanking tool or piercing tool is made

when the piece part has no internal details. When piece
part is to be produced with internal details, then altogether a different tool is to be produced by combination
of piercing and followed by blanking operation in one
tool. The piercing operation is performed in the first stage.
Stock strip is advanced equal to pitch and stopped against
final stop. In this stage i.e. 2nd stage blanking operation
is performed. Hence a piece part is produced with internal details of piercing operation.
When more internal details are to be produced
in the piece part, same procedure is to be followed. In
the first stage piercing operation is done. The strip is
advanced equal to pitch stopping against the finger. In
this stage piloting operation is performed. In the II stage
piloting operation is carried out and with piloting some
more internal detail can be performed. Hence internal
details performed in the II stage is with relation to the
pilot hole. Similarly strip can be advanced equal to pitch
stopping against auxiliary stop. Once again in this stage
piloting can be done and internal detail operation is performed. In this manner number of internal detailed operations can be performed in different stages. Finally the
strip is stopped against the final stop and blanking operation is carried out. In this progressive die piece part is
produced with internal details.
In guide plate progressive tool, piece part is produced following the above procedure. During the design
of guide plate progressive tool, the limitations of this tool
are to be understood and then the design is to be made.
The limitation is also same like guide plate tool.
Piercing punches, pilots and blanking punch is purely
guided by the guide plate. The accuracy is mainly depending on the accuracy of guide plate. Guide of tool
elements like punches and pilots and alignment is governed by guide plate tool. Hence the following factors
are to be kept in mind while deciding guide plate progressive tool.

STRIP LAYOUT

II STAGE

FEED

I STAGE STOP

A simple blanking tool is designed only when

the piece part has no internal details. An altogether different tool is designed if the piece
part is to be produced by the combination of
blanking and piercing operation. It can be done
in the following way in the same tool. The piercing is performed in the first station. Then the
stock strip is advanced to another station where
blanking is carried out. The relative position
with the previously pierced hole is maintained
during the blanking operation. The tool is
known as "progressive tool" because the processing progresses from station to station.

STOP

PROGRESSIVE TOOL

When the component profile is simple.

-When the accuracy of piece part is average (not very accurate)
-When production is less
-When number of stages are less
With the above limitations keeping in view, the decision is taken to make
the guide plate progressive tool.

SECTION AB

SECTION BB'

B'

STRIP LAYOUT
The die is constructed from the die drawing, the die drawing is made around the strip, and the strip represents
the sequence of the logical, workable operations, which
is to say, a sequence of ideas. If this sequence of operation has error, the error will be surely emerge in the
try out press and so it behaves the designer to make
certain, that his strip is cent percent sound. Other errors
in the design can be corrected but the strip sequence is
unworkable, the die is scrap

10
SHAPE OF THE BLANK:
It is mainly the contour of the blank, which
decides the way in which it is to be positioned in the
strip. While some of the blanks could be
economically produced by laying them at an angle.
It may be economical to lay others for a double pass.

PRODUCTION REQUIREMENT:

If lesser production is anticipated, more

emphasis should be given on the material
conservation without increasing the tool cost. A gang
die may be suitable for mass production whereas
the same economy can be achieved by double pass
ECONOMY FACTOR:
layout for comparatively small
production
requirement.
Stock material conservation being a decisive factor in
press working, the designer should try out every possible means to attain this, without sacrificing the accuracy requirement of the piece part. Economy of any strip GRAIN DIRECTION:
In the rolling mills, when the sheets are
layout in percentage is found out by the following forrolled the process orients the grains in rolling
mula.
direction. Standard sizes of rolled strips and sheets
will have the grain direction along its length.
Economy factor =
Bending the strip along the grain direction often
Area of the blank x number of rows x 100
results in crack and fracture. If the particular blank
Width of the strip x pitch
is to be bent at a later stage the strip layout should
A minimum economy of 60% should be aimed at while be such that the grain direction lies at right angles
0
laying a strip. The position of the blank in the strip or angles more than 45 to the direction of the bend.
decides the economy factor

BURR SIDE:
STRIP LAYOUT FOR BLANKING TOOLS:
Blanking tools produce blanks entirely from the
strip or the unit stock. None of the edges of the unit
stock or the strip form he edge of the blank. Blanking is
the most efficient and popular way of producing the intricate and closely tolerated blanks. Whatever profile and
accuracy is built into the tool will be produced on the
blank.
In the strip layout for blanking tool, blanks can
be positioned in different ways in the strip. Choice of
correct method depend upon the following factors:

It is another decisive factor in laying the strip.

In a blanking operation, burr id formed on the face
of the blank, which comes towards the punch,
whereas in piercing it appears on the faces that
come directly in contact with the die. In some piece
parts, the burr resulting from either blanking or piercing would be required on a particular face of the
blank in relation to details of the blank contour. While
deciding the strip layout the, care must be taken to
see that such requirements are met.

STOCK MATERIAL:
a) Shape of the blank
b) Production requirement.
c) Grain directions
d) Burr side
e) Stock material.

A comparative study of
material,
conservation tool cost and labour cost is necessary
while the strip layout is made. If the stock material
is precious, every means to conserve the stock
material should be employed. It should be studied
whether the higher labour, cost incurred by the
double pass layout would justify the cost of the stock
material conserved.
Various methods of laying the strips are explained
below:

SINGLE ROW ONE PASS LAYOUT.

This is the most popular way of laying out the
strip. In case the blanks are arranged in a single row
and strip is passed through the tool only once to the
punch and blanks from it.

2) Accuracy in strip width: The sheared strips

cannot be held to an accuracy closer than +
0.2 mm. If thewidth dimensions between the
parallel sides of the blank must be held to
closer limits, discard the idea of using a cut
off or parting tool
3) Accuracy of the blank: If the blank dimensions
are to be held to close limits, it should be produced in a blanking tool, regardless of the
number of parallel sides it may contain.
4) Flatness: If a blank has got to be flat, design
blanking tool because it will produce considerably flatter components than other tools.

BLANKS HAVING AT LEAST TWO

STRAIGHT PARALLEL SIDES:
In such cases the strip width should be equal
to the distance between those two parallel sides. The
blanks are produced by a cut off operation or parting
off operation. If the blank has got two sets of parallel
sides a cutoff operation is sufficient to produce he
blanks. But if the blank has got only one set of parallel
sides, these sides become the sides of the stock strip
and the other non parallel sides are produced by a parting operation

PARTING.

STRIP LAYOUTS FOR CUT OFF AND

PARTING:
Both cut off and parting are press
working operations of shearing the strip across its
entire width, either in straight or curved lines.
The difference between cut off and the
parting is that the cut off punch cuts with only one
edge, thereby producing no scrap whereas a
parting punch cuts with two opposite edges,
thereby producing a scrap.
Figure shows how combining notching, trimming
and piercing operations with cut off or parting
operations can produce the blanks.

Notching:
Notching is a cutting
operation of cutting off small portions from
the edge of a strip or a pre blank
component.

CUT OFF
BLANKS HAVING IRREGULAR COUNTERS:
The following factors must be considered before determining the best method of positioning a blank
in the strip.
1) Contour: If the blank has two parallel sides,
determine whether it can be produced by cut off or
parting off operation. The width between the parallel
sides would become the width of the strip.
Three advantages are realized when a cut off
or parting off tool is used.
a) Minimum material wastage.
b) Less tool cost.
c) No scrap strip to handle which renders the production faster.

Trimming: Just like notching, trimming is

also an operation of cutting off material
to alter the shape of the strip or blank. In
notching, only a small area of material is
cut off, whereas in trimming a larger area
of material
is removed. Trimming
operations when applied for the excess
material removal of drawn shells or forged
components removes the material along
the entire contour of the piece part.

DIFFERENT LAY OUTS:

There are two possible ways of laying out the strip: 1) Narrow run and
2) Wide run
Wide run is generally more desirable due to the
following reasons: a) Shorter advance distance of the strip promotes easy
feeding
b) More blanks could be produced from a given length
of the strip compared to narrow run. There
fore a fewer number of strips are to be handled to
produce a given number of blanks.
c) Narrow run is used when the grain direction of the GANG DIES:
A gang die consists of two or more similar
piece part has importance (example for bending
bending perpendicular to grain direction is preferred) sets of tool members so as to produce two or more
number of components during a single stroke of the
press ram. A gang die eliminates the cumbersome
process of double pass.
SINGLE ROW TWO PASS METHOD:
Gang die is the most economic means of
To save stock material, often a strip layout demass
production
of stampings. The higher tool cost
mands the strip to be fed twice through the tool.
will
be
offset
by
the
higher rate of production. But
A two-pass tool requires minimum of two stops. The stop
still
gang
dies
are
not recommended for very
used for the first pass may have to be removed, or made
complex
work.
to disappear from the working surface so as not to interfere with the second pass.
For double pass operations, the front and the back scrap
as well as the Scrap Bridge should be wider than those
for the single pass (about 50 to 100). As the two operations need nearly 20% more production time, this must
be balanced against the saving in stock material.
Two pass layouts are justified only when the
wastage is considerable and the stock material is costly.

ANGULAR LAY OUTS:

Some of the piece parts will be required to
be laid out to an angular position to make the
DOUBLE ROW LAYOUTS:
layout more economical.
Further economy is attained by positioning the
Illustration shows a comparative study of
blanks in the double rows. Especially circular blanks work the economy of different strip layouts for a typical
out more economical if they are laid out in double rows. piece part.
Strips for double row lay out will be wider and require
the back and front scrap to be more than usual amount.

Example1: Calculate the economy factor to punch the

MS washer in single row feeding.Outer diameter 30
and inside diameter 18 mm. Thickness is =2mm. Scrap
bridge width = 1.2 s

E = Area of the blank number of rows 100.

Pitch strip width.
Pitch = 30 + 2.4 = 32.4mm
Strip width = 30 + 2.4 + 2.4 = 34.8 mm
No of rows =
1
Area of the blank = d2/4
= 3.142 30 30
4
= 706.95 mm2

Therefore E = 706.95 100 1

32.5 34.8
= 70695
1131
= 62.5066 %

Example 2: Calculate the economy to produce the same washer in double row feeding.
P

SB

E = Area of the blank number of rows 100

Pitch strip width.

Pitch
= 32.4mm
Area of the blank = 706.105 mm2
Number of rows = 2
Centerline distance
between two washers = Cos 300 pitch
= 0.866 32.4
= 28.05 mm

A
G

60

Therefore strip width = 2.4 + 2.4 + 30 + 28.05

= 62.85 mm
A

G
G

Now E = 706.105 100 2

32.4 62.85

60

= 69.35 %

G
C

30

Example 3: Find the economy factor for four different pattern of the strip layout shown below:

40

10

3a)

10

E = Area of the blank number of rows 100.

Pitch strip width.
Area of the blank = (40 10) + (13 10)
= 400 + 130
= 530 mm2
Pitch = component width + scrap bridge
= 23 + 2 = 25 mm

23

W = 44

Strip width = 40 + 4 = 44 mm
There fore E = 530 100 1
25 44
= 48.18%

P = 25

3b)

3c)

Pitch
= 23+ 10 + 2 + 2 = 37mm
Margin = 2mm
Strip width = 40 + 4 = 44 mm
There fore E = 530 100 2
37 44
= 65.11%

Pitch
= 23+ 2 = 25mm
Strip width = 40 +10 + 2 + 2 + 2 = 56
There fore E = 530 100 2
25 56
= 75.71%

3d) Margin between two blanks =

=

(22 + 22 )

(102 + 102) = 14.142mm

Therefore 14.142 + 2.828 = 16.107 mm

Margin at the sides = 2 mm/ side.
1) Strip width = Sin 450 = X / 23
Therefore X = 23 0.7071 = 16.26mm.
2) Sin 450 = X/ 40
Therefore X = 40 0.7071 = 28.284 mm
Total width = 28.224 + 16.26 + 2 +2 = 48.54 mm
E = 530 100 1
16.107 48.54
= 64.34%

= 2.828 mm

PUNCHES

11

PUNCHES:
Punches are classified into three
categories
NON-CUTTING PUNCHES
1. Cutting punches.
2. Non-cutting punches.
3. Hybrid punches.

They do the operations like bending, forming, drawing etc.

HYBRID PUNCHES.
Hybrid punches do both cutting and noncutting operations like shear and form, punch, trim
etc

CUTTING PUNCHES
Cutting punches do the operations like blanking, piercing notching, trimming etc.

PUNCH GROUPS
Punches can also be grouped to as segregated punches and integrated punches

SEGREGATED PUNCHES
These punches are positioned and retained
Advantages of plain punches are:
by means of self contained screws and dowels.
1. Material saving.
2. Machining time saving.
3. Easy mounting.
4. Possibility of machining the profile straight through.
5. In case of large punches it can be splited.

INTEGRATED PUNCHES
This group of punches are
positioned by punch holders.

located and

PEDESTAL PUNCHES
The base area of the punch is larger. The
cutting force is distributed to a larger area. These
punches are recommended for heavy-duty work. In
case of narrow pedestal punch angular fillets are
used. These punches are also called as broad based
punches.

TYPES OF PUNCHES.

PLAIN PUNCHES
The sidewalls of the plain punches follow the
cutting contour originating at the cutting edge and
extending straight to the base surface. Plain punches
are self mounting straight through punches.

OFFSET PEDESTAL PUNCHES

These pedestal punches have their base BOSSED PUNCH
offset. The reason for offsetting the base are :
Punches are some times made with an
integral positioning boss similar to that in the fig
n
Space consideration for other components in shown below . Boss diameter d should be made
the assembly
a standard nominal dimension. Do not make d too
small; generally it should be the largest diameter
n
Machining and grinding accessibility. The practical for the given set of circumstances. height
distribution of cutting forces is non-uniform in these h should be restricted. As a rule, a good proporpunches.
tion is h=d/2.
The disadvantages of these types of punches
are the non uniform ditribution of forces

d
R

CHAMFER

KEY DOWEL

FLANGED PUNCHES
Fig shown below depicts a flanged punch. It is
essentially a pedestal punch which incorporates an integral posotioning boss. The extended base area may
be necessary to provide space for attachment screws,
or it may be required for stability. In most cases, both
considerations probably influence the choice of this configuration. Except for the flange, this punch is the same
KEYED PUNCH
A key is provided for non-circular punches as the preceeding punch.
to prevent their rotation.

KEYED PUNCHES

Another flanged-punch version is pictured in the fig

shown below. Here, the boss is proportionately much BEVELED HEAD PUNCHES
larger.
When the punch is made with angular seating is called beveled head punch. The bevel angle is
usually between 30 and 45. The beveled portion
may be either machined or peened.

PUNCHES MOUNTED IN PUNCH HOLDERS

HEADLESS PUNCHES
This is a plain punch except that it does not require dowels. The positioning of the punch is done by the opening
provided in the punch plate. The punch is fastened to
the top plate by means of screws.

FLOATING PUNCHES
They are made loose in the punch holder and are
guided in the stripper plate.

STEP HEAD PUNCHES (SHOULDERED

PUNCHES)
These types of punches are fitted in the punch plate
without screws and dowels.

PERFORATORS
A punch of dia.2.5mm or below is called as perforator.

HEADLESS PERFORATOR WITH

WHISTLE KNOTCH

STEP HEAD PERFORATOR

These are commonly used perforators. They have
a stepped head shank and a point diameter.
PERFORATOR

BEVEL HEAD PERFORATOR

On these types of perforators beveled seating is
machined or peened.

STEPHEAD PERFORATOR
STEP HEAD PERFORATOR SHANK LESS
These are similar to the step head perforators except that the shank diameter is more by
0.025mm than the point diameter.

BEVEL HEAD PERFORATOR

HEADLESS PERFORATORS
These punches do not have shoulders. A whistle
notch is milled on the perforator. A screw from the side
will fasten the perforator in position.

STEPHEAD PERFORATOR (SHANKLESS)

PYRAMID PERFORATORS
This type of perforator is used when there is
considerable disparity between the point diameter and
the shank.

QUILLED PERFORATORS
Slender punches are to be protected from buck- KEYED PERFORATOR:
Wherever a perforator is having other
ling. Quills are provided to prevent buckling.
than round profile, rotation of punch must be prevented. In such cicumstances keyed perforator
are used. they are many ways to prvent the rotation of perforators. They are:

a. By using rectangular key.

b. By providing cylindrical pin.
c. By seating a steel ball in a socket made
in the perforator shank.

SLUG EJECTOR PERFORATOR

To prevent slug-pulling, air pressure or spring
pins are used. These are known as slug ejector perforator.

BUCKLING OF PUNCHES

BUCKLING THEOREM:
Whenever a press tool is worked upon within the press, the punches mounted in that tool are subjected to
compression stresses. But if due considerations of these stresses are over looked during designing of the tool, the
thin punches within the tool may fail by buckling. Hence the maximum force, which a punch can withstand without
buckling can be calculated by using the formula.

FB = 2 E I
Lp2
FB = maximum force beyond which buckling occurs.
E = Modulus of elasticity (for steel modulus of elasticity varies from 200 to 220 GN/m2)
I = moment of inertia in mm4
lp = length of punch in mm
The ultimate condition is when
Buckling = cutting force required for operation = shear force on the punch.
Example: 1.
Is it possible to punch 1mm brass sheet with a 5mm square punch.
Tmax = 200 N/mm2
Length of the punch = 60mm
Shear force required to pierce the hole = l s Tmax
L = cut length in mm
S = sheet thickness in mm
Tmax = shear force in N/mm2
L = 5 4 = 20mm
S = 1mm
Tmax = 320 N/mm2
Shear force = 20 1 320
= 6400 N
= 6.4 KN.
Buckling force = 2 E I
Lp2
E = 210 GN /mm2
I = a4/12 = 54/12 = 52.08 mm2
lp = 60mm
Buckling force = 3.142 210 52.08 10-12 109
0.062
-5
= 2.99825 10 N
= 29.9825 KN
As the punch can withstand a force of 29.9825 KN and the force coming on the punch is only
6.4 KN it is possible to use the punch.

Example 2.
Find the smallest diameter of the punch to pierce 2 mm mild steel sheet
Length of the punch = 60mm. E = 210 GN/m2
Assume FB = 800 N
FB = 2 E I
Lp2
-9
800 10 = 3.142 210 I
0.062
-9
800 10 0.062 = 3.142 210 I
I = 800 10-9 0.062
3.142 210
= 2.88 10-9
2070.516
I = 1.38 10-12 m4
I = d4/64
1.38 10-12 = d4/64
d4 = 1.38 10-12 64
3.142
d4 = 2.83 10-11
d = 2.3066 mm
= 2.31 mm

DIE BLOCKS

12

The following factors influence the design of the

die block for any particular tool.
1.Piece part size
2.Stock thickness
3.Intricacy of piece part contour
4.Type of tool
5.Machinery available for manufacturing the tool.
Small tools used for producing accurate parts
usually have a solid die made by spark erosion. Die
blocks for medium sized simple shaped and less
accurate piece parts are also made solid as the die
openings can be easily machined and/or filed. Only for
intricate piece part contours the die should be split to
facilitate easy machining, hardening and grinding.
SOLID DIES:
Die blocks are made out of superior non-shrinking tool
steels and hardened and tempered to 58 - 62 HRC. This
is because of the critical nature of the dimensions
involved, the extreme pressures and wear conditions the
die is subjected to.

All the screw and dowel holes used to fasten and

align the die block should be placed at sufficient
distance from the cutting edge as well as from the
outer edge of the die block.
DIE BUSHES:
Hardened die bushes inserted in mild
steel retainer plates are commonly used in large
piercing dies. Die bushes having
profiled
openings should be prevented from turning by
suitable means.

In order to keep the manufacturing costs to the

minimum, the die block should be made as small as
possible without lowering its strength or life. Sufficient
wall thickness should be provided at the weakest point
between the die opening and the outer edge of the die
block. This will be decided by the material used, the
method of hardening, and the overall size of the die block,
its thickness, the press force and the complexity of the
contour of the die opening.
In general, the wall thickness can vary from one and a
half die block thickness on small tools to twice the die
block thickness on large tools.
The minimum thickness of the die block varies in
accordance with the severity of the specific operation,
the expected tool life and the properties of the material
used in the manufacture.
The following table has been found quite satisfactory to
enable an initial selection of proper die block thickness.

Stock
material
thickness in mm
Upto 1mm
1 to 2mm
2 to 3mm
3 to 4mm
4 to 6mm
6mm and above

For die block length For die block length

upto 125mm
125 to 200 mm
16
20
20
24
24
28
28
32
32
36
36
40

For die block length

200 to 400 mm
24
28
32
36
50
60

SPLIT OR SECTIONAL DIE BLOCKS:

A sectional die block is one, which is made up
of more than one section.
The following factors decide whether a die block should
be solid or made up in the sections.
1. Size of the die block: Bigger the die block becomes
more the advantage of sectional construction. Sectional
construction reduces the cost of material, machining
time and hardening failures.
2.Size of die opening: When the size of the die opening is too small to permit internal working the die block
should be of sectional construction.
3.Complexity of the die opening: If the die opening is of
a complicated nature, split dies will ease the manufacture. Also if the die opening consists of too many sharp
corners, the die should be split to avoid cracks in the
hardening.
4.Perishability: Sectional construction will simplify the
manufacture and replacement of relaively perishable
portions of the die block.
5.Profile ground die opening: When the contour of a
precision die does not permit the conventional internal
grinding methods, to grind the profile the die must be
sectioned to facilitate profile grinding.
Effective fastening of the sectional die block is
must, as they are subjected to tilting due to the downward thrust of the punch, as well as lateral displacement due to the lateral thrust created by the punching
action.
When thin stock material are worked upon, the
sections can be fastened with screws and dowels only.
Wherever greater lateral thrusts are anticipated, the
sections should be nested.

IInd
BLOCK

Ist
BLOCK

IIIrd
BLOCK
IVrt
BLOCK

NESTING IN DIE POCKETS:

Simplest nesting method is to fit the
sections into a pocket that is milled directly in the
die set. The die sections should fit tightly into the
pocket but the assembly pressure should not be
so great as to distort the die set. It should be
noted that nesting does not eliminate the need
for use of screws.
Liners, made out of hardened tool steel
facilitate the easy and accurate assembly of
sectional dies into the pocket.
Liners provide the following advantages:
1.Liners eliminate the possible shearing
of the walls of pocket.
2.Liners expedite accurate assembly of the
sections. Liners being the last fitted in the die
assembly, permit adjustments to be made for these
discrepancies in size and position of the pocket.
3.Liners facilitate easy dismantling of the
die assembly. The liners are pushed out first, which
let the sections free in the pocket. Therefore,
knockout holes should be provided in the nest or
pocket directly under the liners as shown.

NEST BLOCKS:
Separate nest blocks, even though costly,
are preferred to pockets directly milled into the
die set due to the following reasons:
1.Nest blocks do not weaken the die set
as the pockets do
2.Easy to handle and can be case hardened for heavy work
3.For the regrinding of the die, only the
nest block has to be dismantled
without
disturbing the assembly of the die sections in it
Figure shows die sections mounted in different
styles of nest blocks.

CARBIDE DIES:
Tungsten carbide is used as a die material for
blanking, piercing, trimming, forming, drawing and
swaging operations. They are used where the
production rates are high and the parts have closer
tolerances. Carbide dies are widely used to produce
electrical laminations at lower cost per piece compared
with steel dies.
Since tungsten carbide is fabricated by powder
metallurgy techniques, there are llimitation to sizes that
can be produced as a single piece. Round hole draw
dies have been produced upto about 500mm in
diameter.
No upper limit has been established for the
thickness of material, which can be punched with
carbide. Any limit will depend upon the type of stock and
the ratio of punch diameter to stock thickness.

DESIGN PRINCIPLES:
The principles of design of most carbide dies
are similar to those of steel dies of high precision. Draw
radii or approach angles, punch and die clearance and
relief are similar to those for steel dies.

SUPPORTING CARBIDE INSERTS:

When a carbide die insert is subjected to high
impact loads and internal bursting pressures, it must be
supported externally by pressing or shrinking the carbide ring into a hardened steel case.

Press Tool Technology

Strippers.
Stoppers.
Gauge
Pilots
Side cutters
Ejectors
Fasteners and Dowels
Shank and Shank location
Presses
Die set
Type of Press Tools
Compound Tool
Progressive Tool
Progressive Tool & Compound Tools

(An ISO 9001:2000 Certified Training Institution)

Volume 2

STRIPPERS

The main function of a stripper is to strip the stock

material off the punches after each stroke. In addition
the stripper may act as a guide for the punches, as
well as hold the strip flat and tight while the strip is
being worked on.

13
BOX STRIPPER:
A box pin stripper is shown in figure. The
overall dimensions E and D are made the same as
the die block, die shoe and stripper can be machined
together.
The back edge of the tunnel acts as the back gauge
and must be located accordingly (B + S = Back
scrap). Tunnel width X is then made equal to W + F
(W =stock width and F = desired horizontal feeding
clearance). Tunnel height H is made equal to S + G
(S = material thickness, G = vertical feeding clearance).

STRIPPER CATEGORIES AND TYPES:z

Strippers can be classified into two groups,
fixed strippers and traveling strippers. Fixed strippers
are simple and easier to make than traveling strippers.
Fewer components are required in the construction of
fixed strippers when compared to the equivalent traveling strippers. Therefore fixed strippers are economically desirable as far as die construction cost are concerned. Mechanically a fixed stripper is solid (positive)
in performance. This is an advantage where strong
stripping force is necessary. But in some situations a
fixed stripper may be impractical.
E.g.:
1. When it is necessary to clamp the strip in addition to
it's stripping function
2. When it is necessary to keep the punches engaged
in the stripper during the entire press cycle
3. A traveling stripper permits the operator to observe
the work while the tool is operating.

HOOK PIN STRIPPER:

Hook pins are made from cold drawn steel rod. The
function is shown in figure.

As a principle hard materials will have more clearance than soft materials. If the clearance is too large
it will lead to stripping distortion. Suitable lead angle
L must be provided at the tunnel entrance. The angle
facilitates starting the stock strip into the tunnel and
is very necessary for practical operation.
Strippers are generally left soft. However when required the back gauge should be hardened.

TUNNEL DIMENSION:
The tunnel width X can be determined as X = W + F
W = stock strip width at maximum tolerance
F = desirable horizontal feeding clearance
For the average progressive die, assuming
there are no other specific requirements, clearance F
may be 0.3 mm per 100 mm tunnel length
Tunnel height H = S + G,
G is the required vertical feeding clearance. G cannot
be specified in a general way.
G may be = 0.5s for flat work cutting dies with short
tunnel length, or it may be several times larger than S.
Special attention should be taken in case of a die which
incorporates forming operation, or where there is a
fixed stop.

These kinds of strippers are used when the material is not to be clamped. There will be clearance
between the stock strip and the stripper. For obtaining good flatness, clearance within 0.05 - 0.4
is recommended. The pilot registers the stock strip.
In most cases, spring strippers are an effective
device for producing good flat piece parts. A spring
stripper can prevent distortion, but will not prevent
dishing from blanking pressure. The prevention of
dishing would require a pressure pad within the
die opening to hold the material flat during the cutting process.

NON CLAMPING SPRING STRIPPERS:

X
SPRING STRIPPERS:
A spring stripper is a pressure pad stripper.
They are used when it is necessary or desirable to
hold the stock material flat (or very nearly flat), or to
provide better visibility and access when the tool is
mounted in the press. Inverted dies have stationary
punches and therefore require traveling pressure pad
strippers. Pressure pad strippers are also used for push
back applications. There are two main types of spring
strippers

CLAMPING SPRING STRIPPERS:

They are true pressure pads. They bear against the
stock material, applying pressure to it. The material is
clamped between stripper and die. Clearance must
be large enough to assure clamping.

PILOTING THROUGH SPRING STRIPPERS:

It is often necessary to employ pilots in
conjunction with spring strippers. If the stripper is a
clamping stripper, it cannot be used to strip the pilot
completely. This is because the pilot should register the stock strip before the strip contacts the material. To strip the material from the pilot, the guide
rails are used. If the pilots however are too far away
from the hooking action of the guide rail legs, the
stock material may pull up, bowing the strip. Even if
the stock material does not pull out of the rail confinement, there will be bowing action. It can cause
excessive pilot wear, seriously deteriorate the quality of the pierced opening and adversely affect the
ultimate flatness of the pierce part. When the pilot
position is too far away a non-clamping stripper is
applied, so that the stripper strips the stock strip
also from the pilot.
In some instances a clamping stripper must
be incorporated in a die inspite of favorable pilot
location. In this case shedder pins may be provided.

STRIPPER BOLT SUSPENSION:

COMPENSATING WASHER:
When cutting punches are sharpened they become
shorter. In many applications, the springs are compressed a little more and are not always desirable. A
practical method to eliminate this is to install a cylindrical washer as shown in figure. Each time the punches
are sharpened, the washer is reduced for the amount.

Compensation
washer

SPRING AROUND STRIPPER BOLTS:

Such a construction is shown in figure. This
construction has desirable features and undesirable
features.
Desirable features are
1. The bolt retains the stripper at centre of spring pressure.
2. The bolt acts to confine the spring in location. So
that double spring pocket can be eliminated.
Undesirable feature
1.The assembly needs considerable vertical space often more than available.

Bolt hole B is drilled larger than shoulder diameter

A. (clearance hole is provided). When the die is
fully closed and the stripper bolt is at its maximum
travel position distance E must be sufficient to assure adequate punch grinding life. (E is about 6
mm).
Normally, a space G should exist between the end
of the stripper bolt and the face of the stripper (G =
0.5 mm).
To ensure stripping a spring stripper should over
travel a distance S, when the stripper is at its extended position. The over travel is between 0.1 for
very light work to 1.5 for heavy work. In any case
each time the punch is sharpened, the over travel
increases. This should be corrected from time to
time by inserting a compensator under striper bolt
head as shown in figure. The stripper bolt is made
out of mild steel for light work and from tool steel
for heavy work.

GUIDED STRIPPERS:
Two typical stripper guide pins arrangements are shown
in figure. The drawings are self-explanatory.

STRIPPING FORCE:
Stripping force for most operations range from 10 to
20% of the cutting force.
If the die has more than one punch the stripping force
for that die is the sum of stripping forces required for
each punch.

STRIPPING FORCE FOR THE BLANKING

AND PIERCING:
The following factors affect stripping force.
1. Stock material: Materials, which have high friction,
value and materials, which tend to cling, are more difficult to strip.
2. Surface conditions of sidewalls: A punch, which has
smooth finish on its side, walls strips more easily than
a punch, which is not as smooth.
3.Distance between punches: More effort is required
to strip punches that are close together.
4.Area of the stock material to be stripped: Figure
shows two piece parts one larger than other.
The thickness and the type of the stock material are
identical. The pierced opening is the same size in both
parts. The cutting is the same for both the parts. But
the larger piece part requires the greater stripping effort.
The larger area of the stock material surrounding the
punch is stronger and causes the material to cling more
tightly to the punches.

STOPPERS
STOPPERS:
After each and every stroke of the press, the strip has
to be feed forward for one pitch length. This can be
accomplished by means of stopper. The function of a
stopper is to arrest the movement of the strip when it is
fed forward to one pitch length.

BASIC STOP PRINCIPLES:

It is essential that two basic definitions be associated
with the fundamental principles of stops.

STOP POSITION:
This is the location of the actual stopping position surface against which the stock strip is halted.

14
The work is located by the stop and is registered by
pilots.
The relationship between the stop position and registry position depends upon the function of the stop.
If a stop acts as a true gauge the stop position and
the registry position are one and the same. If a stop
functions as an approximation gauge, the stop position does not coincide with the registry position. It
can be said generally that if a stock strip is piloted,
it is necessary for the stop to act only as an approximation gauge, allowing the strip to be overfed.
If a stock strip is not piloted the stop then functions
as a true gauge.

STOP CATEGORIES:
All stops may be classified as belonging to one of
the following categories:
1.Primary
2.Secondary
3.Final
A primary stop is the first stop and a final stop is the
last stop in the die. The stops in between are secondary stops. Primary stops acts as true gauges,
registering the stock strip. When installing them locate the stopping position to coincide with registry
position. Secondary stops serve normally as approximation gauges. Therefore allow for overfeeding when installing them. Final stop may or may not
register the stock strip. When mounting them locate the stopping position as required.

REGISTRY POSITION:

STOP TYPES:

This is the exact location in which the stock strip must

be established in order that the work will be dimensionally correct. The registry position may or may not
be the same as the stop position.

Quite a number of different stop types are in common use - for example, solid stops, pin stops, finger stops, pivoted auto stops etc. in addition there
are many variation of each type. This diversity exists because of the wide variety of applications to
which stops must be adopted.

SOLID STOPS:
It is simply a hardened steel block securely mounted
at the required location.

PLAIN PIN STOP:

The stop is the plain cylindrical pin. The stop pin is
mounted in a die block. The pin is a light drive fit on
the mounted hole. The mounting hole is generally made
to suit a standard pin size (dowel size). A clearance
hole for the pin should be provided in the die shoe for
three reasons.
1.To permit adjusting the height of the stop pin without
removing the die block from the die shoe.
2.To allow the stop pin to be removed in order to
sharpen the die with the die block fastened to the die
shoe.
3.To allow the pin to be driven down in the event of a
misfeed, thus reducing the chance of damage to the
die.

FINGER STOPS:
Some typical finger stops shown in figure.

OPERATION:

HEADED PIN STOP:

It frequently occurs that a stop must be located close
to the die opening. In such cases the use of a plain pin
stop is prohibited because the proximity of the mounting hole to the die opening will make the die weak. For
such an applications a headed pin stop may be employed. The mounting hole can be located at the safe
distance from the die opening.

DISAPPEARING PIN STOP:

It is a spring pin located at the required stopping position. Disappearing stops offer one important advantage
over other pin stops is that they do not require clearance in apposing die members.

The stop is actuated manually. It is pushed inward

until the stop shoulders contacts the front edge of
the stripper. This distance is the travel as indicated
in the illustration. When the stop is in close position, the nose of the stop extends into the stock
channel, obstructing the stock strip. The stop is
held in closed position and the leading end of the
stock strip is fed against the stop. Then the operator trips the press and releases the stop. The spring
returns the stop to its open position where it remains until a new stock strip is fed into the die. In
the stopper shown in the figure after the stroke the
operator has to release the stopper manually

PUSHER STOPS:
These stops are special types of finger stop. They serve
a duel purpose as both stops and pushers - the spring
forces inward where it obstructs the stock strip channel. In operation the leading end of the stock strip is
fed against the pusher stop. After the press cycle, the
stop is manually pulled outward, permitting the strip to
advance to the next stop. When released, the stop in
effect becomes a pusher

TRIGGER STOPPERS:
The previously explained stoppers maintain slow rate of
production. For the fast productions mostly trigger stoppers are used. They are also called as automatic stoppers. They are of two types.
1.Front acting &
2.Side acting
In general, the working mechanism is same in
both but one is mounted in the front end of the tool and
other one at the side of the tool.
The lever shaped trigger stop fits freely in the
slot milled in the guide plate. One sidewall of the slot is
provided with a taper angle, which gives the necessary
movement to the trigger. An inclined set spring at the
other end of the trigger holds the trigger in position. When
the strip is pressed against tip face of a trigger the trigger moves backwards and stops against non-tapered
wall of the slot thus allowing the strip to advance. The
advancement is equal to one margin width. When the
tool is tripped, a knocker bar, which is fixed to the top
assembly of the tool, comes down and hits the free end
of the trigger so that it clears the strip thickness and
jumps back to its old position and falls on the strip so
that the strip can be fed forward.

Side acting automatic stops

GAUGE

15

GAUGES(STRIP GUIDE):

BULGE CLEARANCE:

In most of the press tools, the stock material is fed

into the tool in the form of long strips. For the efficient
functioning of the tool, the strip should be guided longitudinally during its travel through the tool. This is
achieved by employing gauges. If unit stocks are utilized for the manufacture of blanks pin gauges nest
them in required position. Gauges used in secondary
operation tools locate the pre-blanked or pre-formed
component in relation to the operation to be carried
out.

Thick and soft stock materials tend to bulge sidewise as soon as blanking operation is performed.
This makes it quite difficult to feed as well as to
gauge the strip further unless a bulge clearance is
provided in such stations. Bulge clearance is provided usually in the back gauge only.

BACK GAUGE

FRONT GAUGE

BACK GAUGE

STOCK STRIP
PUSHER
BULGE CLEARANCE

FRONT GAUGE

SPRING

BACK GAUGE AND FRONT GAUGE:

In a press tool whenever the stock material is fed in
the form of strip it is fed in between the back gauge
and the front gauge. Back gauge is the one, which is
on the far side of the press operator, and the front gauge
is on the near side. While feeding the strip the operator always keeps the strip pressed against the back
gauge. Back gauge is the actual gauging member and
the function of the front gauge is only to provide an
approximate gauging. The required dimensional relations are maintained from the back gauge to the die
opening.
BACK GAUGE

STRIP SUPPORT

BACK GAUGE EXTENDED

STRIP SUPPORT

STOCK

FRONT GAUGE

SIZE OF BACK GAUGE AND FRONT

GAUGE:
The gauges should be thick enough to avoid
binding of the strip between the stripper and the die
block. The recommended thickness of 3 mm for
sheets upto 1.5 mm and strip thickness + 1.5 mm
for heavier (more than1.5 mm) strip is found to be
satisfactory if automatic stops are employed in the
tool. Special care should be taken while deciding
this thickness if a tool incorporates a fixed stopper
and also if the tool performs the forming operations.
Extra thick gauges if used with solid strippers tend
to break fragile punches in the process of stripping.
The space between the back gauge and the
front spacer is made to strip width plus 0.5 mm if roll
feed is used and strip thickness plus 1 mm for hand
feeding.
For low production requirements gauges are
commonly made from cold rolled steel. They are also
made from tool steel and hardened fully or hardened inserts are fixed to the soft gauges where production requirements are high.

NESTING GAUGES:

EXTENDED BACK GAUGE:

For easier gauging usually the back gauge is extended Nest gauges are used in secondary operation tools
beyond the die on the feeding side. An amount equal to or whenever unit stock is fed into the tool.
two and half times the strip width for hand feeding and
There are three conditions to be met with, in order
equal to the strip width for roll feeding is sufficient.
to achieve the best result.
1.Accuracy: The fit between the piece part and the
STRIP SUPPORT:
gauge should be perfect and consistent through
While hand feeding the strip, to reduce fatigue to the
out the life of the tool. For gauging purpose, it is not
operator a strip support should be provided especially
necessary for the nest to fit entire contour of
while feeding the flexible strips. The strip support should
the piece part. All that is required is to provide sufbe made wider and brought closer to the die block to
ficient number of locating points, strategically
provide better support and guidance. Roll feed does not
located in relation to the piece part contour. The
require strip support.
number of locating points required for a certain
nest depends upon the size and the shape of the
piece part. A minimum of 3 points for circular and
BACK GAUGE
triangular shapes and four points for other shapes
are required.
STRIP SUPPORT
BACK GAUGE EXTENDED

STRIP SUPPORT

STOCK

FRONT GAUGE

PUSHERS:
Means are often provided to keep the strip firm against
the back gauge during its travel through the tool. Springloaded pushers are often employed to achieve this. Figure shows various constructions of pushers for medium and heavy-duty operations.

BACK GAUGE
STOCK STRIP

2.Easy and quick loading and unloading: Nest

gauges should facilitate fast and easy loading and
unloading of the components. The main factors,
which decide this, are good visibility and acces
sibility to the nest. Adequate lead angle should be
provided around the nesting profile for easy
loading.
Unloading is always more difficult than loading and
should be given a thorough consideration before
deciding upon the means to be employed. For low
production tools, simple pick-off slots machined in
the nest would be sufficient to allow the operator to
manually pick the piece out of the nest. Ejection of
piece parts out of the nest by means of lever operated ejectors is another solution. Thin piece parts
could be expelled from the nest by means of compressed air jets. Pneumatic or hydraulic devices
also could ease the unloading in mass production
tools.
3.Fool proofing: Any possibility of the piece part
being loaded in the incorrect manner by the operator should be prevented by the nest. Foolproof pins
could easily accomplish this as shown in figure.

TYPES OF NEST GAUGES:

1. Pin type nest gauges: The simplest
form of nest gauges comprises of plain or headed
PUSHER
cylindrical pins arranged in such a way as to provide enough number of locating points for the piece
FRONT SPACERpart. These hardened and ground pins are pressfitted into the die block. The arrangement of the
pins should be such that a total clearance of at lest
0.03-mm results between them and the piece part.
The upper end of the pins must be beveled for easy
loading and unloading. The apposing member
SPRING
should have relief holes drilled into it to receive these
pins. Figures show various constructions with nest
pins.

In inverted tools, the nest pins are fitted into the travelling stripper and the relief holes are to be drilled in the
die block, the opposing member. If these holes happen to appear in the near vicinity of the die opening the
die will be weakened. In such cases the nest pins
should be of the spring-loaded type and made to disappear below the face of the stripper, upon contact
with the die block. It is obvious that disappearing nest
pins are less accurate and should be used only if inevitable.

NESTING IN DIE SET:

Simplest nesting method is to fit the section into a pocket that is milled directly in the die set.
The die section should be fit tightly into the pocket
but the assembly pressure should not be so great
as to distort the die set. It should be noted that nesting does not eliminate the need for the use of screws.

SHEET

PIN
PIN EXAGERATED

Plate type nest gauge:

Plate type nest is a plate into which an opening is machined to receive the piece part. As mentioned already
the opening need not fit the entire contour of the piece
part. Plate type nests could of sectional construction for
easiness in machining and hardening. Plate type nest
gauges should be perfectly screwed and dowelled in position.
As a general rule, all gauging elements should
be made out of tool steels and hardened to 48 to 52
HRC.

Liners, made out of hardened tool steel facilitate

easy and accurate assembly of sectional dies into
the pocket.
a. Liners eliminate the possible shearing of the walls
of pocket.
b. liners expedite accrate assembly of the sections.
Liners being the last to be fitted in the die assembly
permit adjustments to made for the discrepancies
in size and position of the pocket.
c. Liners facilitate easy dismantling of the die assembly. The liners are pushed out first which let
the section free in the pocket. Therefore, Knockout
holes should be provided in the nest or pocket directly under the liners as shown.

Pocket milled in the dieset

PILOTS

The pilot positions the stock strip in relation

with the die opening. This is termed as registering the
stock strip in the required position. Usually the stock
strip is over fed than the actual pitch length. The maximum over feeding of the strip is about 0.1mm. When
the press is tripped the pilot comes down and engages
the pre-pierced hole, thus dragging the strip back into
the registry position.
When the stock strip is fed by mechanical
means pilot action is the same principle. However, the
direction in which the feed is qualified is normally reversed. Instead of being overfed the stock is underfed.

However, the thick stock materials and the stock

materials like aluminum and copper need often-bigger tolerances between the pilot and the pierced
hole.
PILOT
STRIPPER INSERT

STRIPPER

P
20

PURPOSE OF PILOTS:

14

DIE BLOCK
D

DIE SHOE

TAPER

PILOT LENGTH:

registry starting- spring stripper is descending

along with punches

Registering the strip must be complete before the

cutting punches come and engage the strip. Therefore the pilots must be longer than the punches. If
the pilots are to short, they cannot perform their
function. This creates serious consequences ranging from spoiled work to damaged pilots. Care must
be taken while setting the stroke of a press so those
pilots clear the stock strip without obstructing the
future feeding of the strip. In any case the piloting
length should extend beyond the punch face equal
to one sheet thickness.

PILOT OPENING IN THE DIE:

strip registered and clamped punches about to

penetrate.
PILOT SIZE:
The accuracy with which the work can be registered
depends upon the proper location and the diameter of
the pilot.
The following will indicate the pilot diameter:
For an average work, of pilot = & of hole to be piloted
- 0.05 to 0.1 mm
For close work, of pilot = o f hole to be piloted - 0.03
to 0.05 mm
For accurate work, of pilot = of hole to be piloted 0.01 to 0.02 mm

The opening for the pilot in the die should not be

too large. If so, the stock strip may tend to draw
into the opening. In case of thin material the pilot
may not displace the material into registry position
but may instead draw the material on one side.
Therefore it is advisable to have the opening diameter as pilot diameter +double clearance. Weaker
pilots are giuded in the stripper.

450 CONICAL STUB NOSE PILOT

Through hole is provided in the die shoe for the pilots

so that, slugs produced during misfeed are cleared. It
also helps in clearing the accumulated burrs dislodged
from the pierced hole.

The profile is used when a shorter nose profile is

desired. 450 cone increases the relative lateral forces
hence not recommended for delicate pilots used for
piloting thin soft materials.

45

PILOT OPENING IN DIE SHOE:

E
D

300 CONICAL STUB NOSE PILOTS:

A- STEP HEAD SHANK LESS
B- STEP HEAD SHANK TYPE
C- STEP HEAD PYRAMID TYPE
D- BEVELED HEAD
E- HEAD LESS. WHISTLE NOTCHED

This is same as the above pilot except the nose

angle is 300. This is a compromise between the
450 stub nose pilot and the conventional bullet nose

The main functions of the pilot nose profile are to allow smooth riding of the pilot into the stock strip. The
most commonly used nose profiles are described below:

PILOT NOSE PROFILE:

30

BULLET NOSE:

150 ANGULAR NOSE:

This small angle provides good mechanical advantages. They are used for small pilots and for
thin materials.

15

The most common pilot nose profile is bullet nose.

The billet shape is formed by radius R which is equal
to piloting diameter. For piloting in holes less than 6
mm the length of radius R can be increased to reduce
the lateral force during piloting. Bullet nose is strong
simple to make and smooth in action.
The other three commonly used pilot nose profiles are:
1.450 conical stub nose
2.300 conical stub nose
3.150 angular long nose.

TYPES OF PILOTS:
C

1.5 x 45 CHAMFER
E

In many occasions especially during hand feeding,

misfeeding occurs due to over shooting of the stock
strip over the stoppers. This creates the problem when
a tool is having pilots in it. Pilots my break or buckle
obstructing smooth functioning of the tool. To over
come this difficulty, retractable pilots are incorporated
in the tool.
Generally retractable pilots are spring loaded in such
away that they will be lifted upwards when they come
in contact with unpierced area during press descend.
Care should be taken while selecting spring so that
spring allows more telescopic movement to the pilot.

R5

RETRACTABLE PILOTS:

POLISH

PILOT IN PUNCHES:
Pilot mounted in punches is called punch pilots. Piloting size should extend beyond the punch face a
distance of atleast stock thickness, but minimum
dimensions of 1.5 mm. When pilots are mounted in
blanking punches there is a tendency of pulling the
blanks by the punch. When the blanking punch retracts spring-loaded pins are provided to prevent this
pulling of blanks.

REMOVABLE TYPE PILOTS:

Pilots break very often due to misfeeding of the stock
strip. This will be a real handicap aspect when it comes
to fast production loss due to pilot breakage. Much
consideration must be given for changing quickly the
broken pilots, preventing greater time loss during production. Removable type of pilots can overcome this
difficulty. These pilots inserted through the top bolster
into the punch holder and fastened with a back up
screw as shown in figure.

METHODS OF PILOTING:
There are two methods of piloting in progressive dies.
1.Direct piloting: Direct piloting consists of piloting in
holes pierced in that area of the strip, which will become the blank.
2. Indirect piloting: Indirect piloting consists of piercing holes in the scrap area of the strip and locating by
these holes at subsequent operations. Direct piloting
is the preferred method, but certain blank conditions
require indirect pilot.

PILOT IN HOLES IN PIERCE 2 HOLES IN

SCRAP, BLANK OUT PART & 2 HOLES IN
SCRAP.
PARTS

Station 2

PILOT IN HOLES,
BLANK OUT PARTS.

6.Blanks without holes - piloting is done in the scrap

area whenever the blank does not contain holes
7.Projection in hole - whenever the hole in the blank
contains weak projections which could be bent
downby the pilot, indirect piloting should be selected.

Station 1

PIERCE 2
HOLES

Station 2

Station 1

PART CONDITIONS:

There are seven conditions that require indirect piloting.

1.Close tolerance on holes - pilots can enlarge holes
by pulling a heavy strip in position.
2.Holes too small - frail pilots can break or deflect in
operation.
3.Holes too close to the edges of the blank - distortion
can occur on the blank because of enlarge
ment of holes.
4.Holes in weak area - piloting in projection tabs is impractical because they may deflect before
the strip is pulled to position.
5.Holes spaced too closely - piloting closely spaced
holes does not provide an accurate relation ship between holes and outside edges of the blank.

SIDE CUTTERS

17

SIDE CUTERS
Side cutter is an accurate method of stopping
arrangement used mainly for thinner strips where it is
difficult to accommodate the other types of stoppers.
A side cutter is a trimming punch, which trim
the side of the stock material, providing a shoulder.
This shoulder is stopped against a hardened insert,
provided in the spacer. In small tools the spacer may
be the fully hardened to avoid the insert. The width of
the side cutter is equal to the pitch. The allowance for
side cutting depends on the type and thickness of the
stock material. Tables give the allowances for side
cutting for different materials.

No
1

Material
Steel
Brass
Bronze

Copper
Zinc
Aluminum
Leather paper
Fibers
Card board

S
0.2 0.4
0.2 0.6
1.0 1.5
1.5
0.2 0.5
0.5 1
1 1.5
0.4
0.4 1
1

C
2.5
1.5
2.5
1.5 s
3
2
2.5
5
4
3s

The size of the side cutter will be more then the pitch
by 0.05 - 0.1 for the purpose of registry of the strip with
the pilot. But in the case of tools without pilot, the side
cutter is made equal to the pitch. The stop position
and the registry position will be the same.

THE ADVANTAGES OF SIDE CUTTERS:

Due to the unbalanced cutting force acting on the side
cutters, the side cutters are provided with heels. The
under cuts provided on side cutter eliminates the difficulties of feeding due to thorn formation. Thorns are
small projections, which occurs on the side of the strips
due to the punch wear out. In side cutting there is the
tendency of the slugs being coming up with the punch,
causing difficulties in further punching. Slug pushers
are used to avoid this. A standard side cutter shape is
shown in the figure.

THORN
HARDENED INSERT.

1.It is the safer method than stop pins.

2.Avoids the danger of the deformation of margins
of thinner strips by the stop pins, when pressed
against it.
3.Preferred for small punching where it could be
difficult to employ other types of stops.
4.It is economical and avoids complications in tools
where the number of stages is more.
5.Pilots can be avoided for punching components
with moderate accuracy.
The side cutter is installed in the first position of the
tool. This eliminates the extra stops and simplifies
both construction and operation of the tool. Usually
the side cutter is located along the front edge of
stock strip, because of the fact that the strips are
usually meant to gauge against the back gauge of
the tool.
Two side cutters, one on each side are used
where the number of stages are more or if the pitch
is less.

EJECTORS

18

In conventional drop through type blanking tools, the

punch forces the blank into the die. The blank will be
retained in the die cavity till the subsequent blanks push
it past the land. Then it falls down through the opening
in the die shoe and subsequently through the opening
in the press bed.
Shedders and ejectors are used when it is not possible to remove the blanks in the conventional methods due to the following reasons.
1.Size of the blank does not allow it conveniently pass
through the opening in the press bed.
2.Contour of the blank is such that it tends to stick and
get distorted during its travel through the die cavity.
3.Opening in the press bed is fitted with the die cushion, which will interfere with the piece part disposal.
4.Close tolerance specified for the flatness of the blank.
5.Tools of inverted nature.

E
SHEDDERS:

EJECTORS:
In the conventional tools die is the lower member of the tool. (Being clamped to the die shoe). If the
expulsion of the blank is achieved by forcing it upwards,
the action is known as "ejection". The element of the
tool, which ejects the blank, is called an "ejector".
Ejectors may be actuated by compression
springs, rubber, pneumatic devices or hydraulic devices. Ejectors if used with spring strippers always return the blank into the strip due to the simultaneous
stripping and ejecting action. In some progressive tools,
the blanking station is provided with an ejector to return the blank into the strip to be carried forward to the
next station for further operations, known as cut and
carry method.

Another way to accomplish the expulsion of the

blanks from the die cavity is by making use of the
knockout mechanism on the press. For this purpose, the tool should be of the inverted design.
In inverted tools, die becomes the upper
member of the tool, being clamped to the press
ram. The expulsion of the blanks is achieved by
forcing them downwards. This action is generally
known as "shedding" and the element of the tool,
which sheds the blanks, is known as the "shedder".

POSITIVE SHEDDERS:
Shedders operated by the knockout mechanism on
the press are called "positive shedders".
The knockout arrangement of the press is usually
of a bump type knockout bar, mounted through slot
across the press ram. The knockout bar is free to
move up and down within the slot, as well as it could
ride up and down together with the ram. Figure
depicts the operation of a positive shedder.

COMPRESSION SHEDDERS:
Shedders backed up by compression springs,
hard rubber or disc springs are called compression
shedders. Such shedders always tend to return the
blank into the strip if employed with compression type
travelling strippers.
Compression shedders could be used to great
advantage to produce flatter and neatly sheared blanks.
They are also used if the blanks are too large to allow
the incorporation of an efficient positive knockout system.

Therefore, regardless of conditions of the stock, the

installation of shedding pins must be considered to
be absolutely necessary. Shedding pins will be more
effective if applied to one side of the shedder face
rather in centre.
All ejection and knockout elements are to be case
hardened to 48 - 52 HRC. Depending on the severity
of operation.

Typical knock out usedin large dies.

Pins (A) guide and transmit fofrce to the knockout
block

Typical small knock out of the spring operated varieties.

SHEDDING PINS:
The stock material is usually coated with a rust
preventive solution. It is obvious that any liquid or oil
deposit left on the stock material will cause the blanks
to stick to face of the shedder. Spring-loaded shedding
pins are employed to overcome this problem. Even absolutely clean and dry stock material tends to adhere
to the shedder face, due to the atmospheric pressure.

Spider knockout plate in this die has been flame cut

KNOCKOUTS:
Positive knockouts are classified into two groups.
1.Direct knockouts
2.Indirect knockouts.

DIRECT KNOCKOUTS:
In a knockout system if the knockout rod is directly
in contact with the shedder the system is known as
direct knockout shedder.

INDIRECT KNOCKOUTS:
As the passage of the knockout rod is through the
shank, any punch which comes in line with or near to
the centre line of the shank will obstruct the knockout
rod from coming in direct contact with the shedder.
In such cases an indirect knockout system should be
employed.
In addition to the shedder and the knockout rod, it
consists of a knockout plate and transfer pins as
shown in figure. The location and number of transfer
pins depend on the size and shape of the blank.

FASTNERS AND DOWELS

19

DOWELS:
Dowels hold parts in perfect related alignment
by absorbing side pressures and lateral thrusts. Also
they facilitate quick disassembly of parts and reassembly in their exact former relationship.
Dowels are precise with accuracy both in dimensions and in their physical characteristics. They
are made of alloy steels and heat-treated (case hardened). Dowels are available readily in a range of sizes
from 1.5 to 20 mm in various lengths.
The dowels are made in IT 6 grade and are
finish ground. The fit between dowel hole and dowel
pin is H7/m6. The surface finish is maintained in 4 - 6
microns. This extremely smooth finish reduces the
possibility of seizing when driven into their respective
holes.
There are two types of dowels in common use.
They are
1.Solid dowels used in through and through
hole applications
2.Removable type dowels. These types are
used where blind hole applications exists.
Shape of the dowel is shown in the sketch.
The dowels are driven inside the reamed holes
or in a jig ground holes. The hole sizes are maintained
to H7 tolerance.

SCREWS:
Various types of fasteners are used in tooling construction. The main function of a fastener is to hold
or clamp two or more tool elements together in position.
The fasteners are divided into two types.
1)Threaded fasteners
2)Non-threaded fasteners.

THREADED FASTENERS:
In this group all types of screws and bolts are included. But only those used in tool making are discussed here.

SOCKET HEAD SCREWS:

These are generally used to fasten the plate elements of a press tool like punch holder assembly to
the die top and die - stripper assembly to the die shoe.

Exploded view of die showing number of

fasteners used.

COUNTER SUNK SCREWS:

These are used to fasten elements like nest gauges,
spacers, plate stoppers etc.

CHEESE HEAD SCREWS:

These are used to fasten sheet metal elements like
spring holders, leaf springs etc.

COUNTER SUNK SCREWS:

These are used to fasten elements like nest gauges,
spacers, plate stoppers etc.

SET SCREW (Grub screw):

These are used to fasten parts, which are to be confined within a hole, like spring's etc.

EYE BOLTS:
Eyebolts are used for lifting heavy die sets or mould
housing. It is also called as carrier bolts.

NON - THREADED FASTENERS:

This group includes the elements like rivets and cotter
pins.

SHANK AND SHANK LOCATION

20

SHANK:
A shank is an element of a press tool. The shank is
mounted on the tool and acts as a connecting link from
press tool to the press. The diameter of the shank fits
the bore within the press ram. The shank diameter is
standardised in relation with the press ram bore, which
is varying from press to press depending on the capacity of the press.
There are four ways in which the shank is mounted to
the tool top. They are as follows:
1)By riveting
2)By press fitting
3)By means of a thread
4)By making as integral part of top plate.
5)By making flange fastening.

SELF ALIGNING TYPE SHANK:

This is a special type of shank, which permits quick loading, and unloading of a press tool on
a press. This type of shank differs very much in design when compared with other regular shanks. A
Tee coupling mechanism is made in two sections.
The one half, which is mounted on a tool, is a male
member, whereas the other half, which is fixed to
the press ram, is a female member. They are usually case carburised and hardened. The working
mechanism is explained in the sketch.

PRESS RAM

FEMALE COUPLE
2

MALE COUPLE

LOCATION OF SHANK ON A TOOL:

4

However threaded types are used commonly. The

shank should contain a spanner flat milled, to facilitate
it's fastening to tool top.

The balancing of the cutting punches is one of the

most important aspects to be considered during the
punching operation. Unbalanced force distribution
on the tool top may cause undue wear on the punch
and die as well as on the pillars.
The resultant force of all the cutting forces, acting
on many different punches should pass through the
shank centre. The position of the resultant force of
all the partial cutting forces can be found applying
the following methods.
1.
By calculations
2.
By polygon system (Graphical).

(X6)61
REF EDGE

(X5)57
(X4) 48 (X7)
(X3)37.9

(X2)30(X8)
3

(X1)25

6
8

43

90(Y7)

100(Y6)

116(Y5)

120(Y4)

117.09(Y3)

112(Y2)

86.815(Y8)

101(Y1)

26(Y10)

10

(X10)30

REF EDGE

By calculation: The resultant force should be found for

both X and Y-axis by applying the following formula.
X = (L13 X1) + (L2 3 X2) + (L33 X3)
L1 + L2 + L3
Y = (L13 Y1) + (L23 Y2) + (L33 Y3)
L1 + L2 + L3
Calculate the shank point for the die layout
shown in the sketch.
L X Distance
Product
550
1. 20325
2. 10330
300
476.02
3. 12.56337.90
480
4. 10348
644.67
5. 11.31357
6. 20361
1342
1248
7. 26348
471.30
8. 15.71330
1080.84
9. 25.136343
471.30
10. 15.71330
** 170.42
7064.13
**(indicates) = Total.
Therefore X = 7064.13/170.42
= 41.45 mm

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
**

L Y Distance
203101
103112
12.563117.09
103120
11.313116
203101
26390
15.71386.815
2.136348
15.71326
170.42
and Y = 14865.52/170.42
= 87.20 mm

Product
2020
1120
1470.72
1200
1131.96
2020
2340
163.86
1206.52
408.46
14,865.52

Polygon system:
To find the line of the action of resultant then follow the
reference below.
1.Draw the forces to scale in a straight line.
2.Draw the arrow heads at the ending points of each
force as shown.
3.Draw two more lines at 450 angle from the starting
and finishing points of the total length of the forces
so as to form an equilateral triangle and call the intersecting point as pole.
4.Draw the lines from each arrow head joining the pole
point and call them as pole beams.
5.Draw the forces to scale at the given distance.
6.Draw the lines parallel to the pole beams, cutting
force line graphically.
7.The line of action of the resultant goes through that
point where those two-pole beams intersect.

1+6

10

2+8+10

4+7

POLE BEAMS - Y-AXIS

POLE CENTRE

REF EDGE

POLE BEAMS- X-AXIS

2
1

f e d

SRY 85

10

REF EDGE
Y

0
a
b

c d e

SRX 42

PRESSES

GLOSSARY OF PRESS TERMS:

CAPACITY OF A PRESS:
The rated capacity of a press is the force in MN, which
the slide will safely exert near the bottom of the slide.

PRESS BED:
The stationary and usually the horizontal part of a press
that serves as a table to which a bolster plates or lower
die assembly is mounted.

PRESS SLIDES:
The common name for the reciprocating member of a
press guided in the press frame and to which the punch
or upper die member is fastened. On a hydraulic press
it is called the platen.

PLUNGER SLIDE:
The inner slide of a double action press upon which
the punch is mounted.

BLANK HOLDER SLIDE:

The outer slide of the double action press usually operated by toggles or cams.

BOLSTER PLATE:
A plate secured to the press bed for locating and supporting the tool.

PITMAN:
Connecting rods to convey power and motion from the
main shaft to the press slide.
.

CLUTCH:
A coupling used to connect or disconnect a driving
machine member such as the flywheel to or from a
driven machine member such as the main shaft.

STROKE:
A stroke of a press is the reciprocating motion of the
press slide. It is the distance between terminal points
of motion.

STROKES PER MINUTE:

This is specified as the continuos running speed. It is
not the number of single trippings of a press and does
not measure the available production per minute except when a press is run continuously.

21

SHUT HEIGHT:
It is the distance from the top of the bed to the bottom
of the slide with the stroke down and the adjustment
up.

DIE SPACE:
Die space is the area available or mounting tools in
the press.

CLASSIFICATION OF PRESSES:
Presses are classified by one or a combination of some
of the following characteristics, which include source
of power, method of actuation of slides, number of
slides incorporated, frame type, bed type and their intended use.

SOURCES OF POWER:
The source of power for presses is either manual,
mechanical, hydraulic or pneumatic.

MANUAL:
These presses are hand or foot powered through levers, screws or gears. Fly presses, arbor presses and
toggle joint presses come under this category.

In all three types a flywheel stores energy. The source

of power is an electric motor.
The flywheel type drive transmits the energy of the
flywheel to the main shaft of the press. Thus these
presses are generally applicable to lights shearing
operations or light high-speed application. The single
reduction gear drive transmits the energy of the flywheel to the main shaft through one gear reduction
and is recommended for heavier shearing operations or shallow drawing.
The multiple gear drive transmits the energy of the
flywheel to the main shaft through two or more gear
reductions. These reductions reduce the strokes per
minute of the slide without reducing the flywheel
speed.

FLY WHEEL
1.
2.

MECHANICAL:
There are three major types of mechanical drives.
1) Non geared or fly wheel type.
2) Single reduction gear type.
3) Multiple reduction gear type.

FLY WHEEL
MAIN SHAFT
3.

Most presses have their drive mechanism on the top.

The slide is pushed down to perform the operation.
The under drive type has the mechanism under the
bed with connecting linkage in the uprights to pull the
slide downward. The mechanisms of the large under
drive presses are below the floor level, thus requiring
minimum space above the floor level.

HYDRAULIC PRESSES:
In these types of presses oil pressure in a cylinder with
a closed and reacting against a piston moves the slide.
A pump supplies the pressure to the cylinder. Constant
pressure and speed can be maintained throughout the
entire stroke. A few large presses use an accumulator
to supply the energy.

Knuckle joint presses exert high tonnage's only at

the bottom of the stroke. This type incorporates a
crank or eccentric main shaft, which moves a joint
consisting of two levers that oscillate to and from
dead center and results in short powerful movement
of the slide with slow travel near the bottom of the
stroke.
Toggle press blank holder slides are actuated by a
crank or eccentric working through a series of levers moving together through two or more dead
center positions.
In hydraulic and pneumatic presses the levers are
actuated by hydraulic and pneumatic cylinders respectively

PNEUMATIC PRESSES:
Such presses are operated by pneumatic
power.pneumatic cylinders provide the necessary forces.

NUMBER OF SLIDES:
With respect to the action upon the material the presses
are classified as single action, double action and triple
action.
A single action press has only one slide. These presses
are employed for operations such as blanking, piercing,
bending, shallow drawing, forming etc.
A double action press has two slides arranged one within
the other and moving independently of each other. The
outer one serves as a blank holder and the inner one
carries the punch.
A triple action press has three slides, two of which are
located above and one within the bed. Such presses are
used for complicated deep drawing operations.

METHOD OF ACTUATION OF SLIDES:

PRESS FRAMES:.
Press frames are broadly classified into two general types, gap frames or C frame and straight side.

GAP FRAME:
The housings of a gap frame press are cut back
below the gibs to form the shape of letter C. this
permits the feeding of wide strips from the side. They
have a solid back or an open back to permit feeding from front to back or ejection of finished parts
through back. The frames are in a fixed vertical
position or in fixed inclined position or a frame that
can be inclined. The inclined position allowed the
parts to fall out by gravity.

STRAIGHT SIDE:

The slide of the press travels downward between

The crankshaft is not commonly used for actuating slides.
two straight sides or housings. These presses are
For comparatively short strokes the throw is obtained by
used for heavy work.
means of a full eccentric machined on the shaft. Crankshafts are used for longer strokes.

CLUTCHES AND BRAKES:

Timing and control of the intermittent reciprocating
movement of the slide in a mechanical power press
are provided by a clutch. The clutch is placed between
the fly wheel and drive mechanism. The flywheel rotates continuously and engagement of the clutch
causes the drive shaft to rotate and start the slide on
its working stroke. As soon as the stroke is completed
the clutch is automatically disengaged.
The clutches are divided into three main groups.
1.Positive clutches in which the driven and driving
members of the clutch are intertouched in engagement.
2.Friction clutches.
3.Eddy current clutches.
Because of the inertia the press components will slide
or rotate after the clutch has been disengaged. The
brake stops the slide after the clutch is disengaged.

bushing is prevented by lock clutch whose projections engage depressions in the bushing. The front
end of the crankshaft is threaded to receive the nut
whose shoulder connects it with the lock clutch.
When unscrewed the nut shoulder will draw the lock
clutch away from its place and thereby disengage
clutch and bushing. After this the bush is free for
adjustment by turning it through the required angle.
Clutch is connected with shaft by key.
The maximum slide stroke is equal to the run of the
eccentricities of bush and the shaft. The stroke is
minimized by setting the eccentricity of the bushing
opposite to the eccentricity of the shaft. The distance from the bed to the lower plane of the slide is
adjusted by the screw screwed into the shank of
pitman and resting against the spherical bearing.
The adjusted screw is fixed in position by slide block.

DIE CUSHIONS:
PRESS SELECTION:

Drawing can be done in presses used for blanking

operation if the stroke is suitable and the press is
equipped with die cushion. But the operating seed
should be slower. Long stroke hydraulic presses are
recommended for deep drawing, redrawing and ironing operations.

When a single action press is used for drawing operations the manner in which pressure is applied to
the blank holder to control the flow of the metal is
important. The application of the pressure to the
blank holder is one of the features of the double
action press. Single action presses lack this feature
and therefore require supplementary blank holding
equipment.
Tools are sometimes built with a blank holder using
compression springs or PUR springs. The pressure
exerted by the compression springs increases, as
they are depressed. In order to obtain a small increase in pressure during the stroke, extremely long
compression springs are required. On shallow draws
the pressure increases due to the compression of
springs usually does not affect the quality of the work
piece. On deep draws the increase in the blank
holder pressure and the decrease of flange area
under the blank holder result in the increase in the
blank holding pressure. This will lead to the tighter
gripping of blank and the draw force required to pull
the blank into the die will exceed the strength of the
material. This will result in the fracture of the drawn
component.
The most common type of pressure control mediums for single control mediums for single action
press and drawing operation are the pneumatic and
hydropneumatic diecushions.

STROKE ADJUSTMENT IN PRESSES:

PNEUMATIC DIE CUSHIONS

The method of adjusting the stroke in a crank press is

explained below.
The overhanging end of the crankshaft carries eccentric bushing and bronze bushing. The latter enters the
cavity of the head of the pitman. The eccentric bushing has blind holes drilled over its circumference. The
bushing can be turned around the shafts. Turning the
bushing changes the eccentricity of the crank and consequently the slide stroke. Spontaneous turning of

These types of die cushions are recommended when

air pressure is not more than 7 105 Pa is required.
A pneumatic design normally uses one pitman and
cylinder. However two or more cushions may be
placed on top of one another if a higher capacity
cushion is required in a limited bed area where vertical space is available. A multiple pneumatic die
cushion is preferable over a hydropneumatic die
cushion because of speed restriction of latter.

Depending upon the operational requirements the

press is to be selected.

CUTTING OPERATIONS:
Majority of the work can be done on short stroke mechanical presses.

BENDING:
Straight side up frame or inclined single action press
with a stroke to suit the operation can be selected.
Hydraulic presses and press brakes are also suitable.

FORMING:
Upto 75 to 100 mm-deep forming operations can be
done on mechanical presses. Forming with die cushion is more accurate on mechanical presses, because
the depth of the from is regulated by the throw of the
crank.

DRAWING:

Die cushions are used in double setting presses to

keep the bottom of the blank flat or to hold it to shape
to prevent distortion or slippage while drawing.

HYDROPNEUMATIC DIE CUSHION:

These die cushions are used where the capacity required is more than that can be obtained with
7 x105 Pa air pressure on the pneumatic cushion. But
they are slower acting than the pneumatic cushions.
The principle of oil to air intensifier is used.

rect amount of stock unwound in form of loop. The

press feeding mechanism draws stock from this
loop. Unpowered loops require external power
source. They are equipped with an automatic or
manual brake to stop the reel after sufficient coil
has been uncoiled

STRIP STRAIGHTENING
ARRANGNMENT:
STRIP FEED ARRANGNMENT:
For simple dies the strip feeding is done manually. But
when the production rate is very high automatic feeding is employed. This also helps the steel mills to prepare strips in large coils.

COIL UNWINDING EQUIPMENT:

The basic equipment used for this are the reel and
coiled cradles. Power driven reels have mechanism
which switch off the power to be drive when enough
coil is uncoiled. Thus the reel always keeps the cor

Feeding gripper

The function of this device is to remove wrinkles

and curvature after uncoiling. This is an intermediate step between uncoiling and feeding into press.
The mechanism consist of a series of roll that bend
the stock back and forth past its elastic limit for economic purpose straightening rolls are combined with
feed rolls or coil cradle.
After uncoiling and straightening the stock is fed into
the press. Different types of strip feeding equipment
are available. Their factors depend upon factors such
as width, thickness and surface condition of the material, feeding interval, feeding length and feeding
speeds.
Check gripper
Set fine feed length

11

Mounting space

BASIC FEED TYPES:

There are two basic types of feed used with coil and
strip stock, namely slide feed and roll feed.

MECHNICAL SLIDE FEED:

The basic principle of the mechanical slide
feed is the use of feed block actuated between the
A positive strip that advances the material to exact
distance required at each stroke. They have high accuracy and are suitable for use with coil stock. When
strip stock is used it is necessary to feed the strip ends
into the press manually.
When the stock is to be fed with the slide feed,
stock guides should be used to overcome any tendency of the stock to buckle.
A slide feed id powered by the crankshaft of
the press. The rotation of the crankshaft is transmitted to the feed through a eccentric mounted on crank
shaft.

PNEUMATIC FEED:
The working principle is shown in the figure. The pneumatic system grips the stock and takes it forward and
then returns it to start position.

HITCH FEED:
They resemble mechanical slide feed and the stock
is pushed forward by gripper plate. The feed is operated by a cam mounted on the punch holder. The propelling force is generated by one or more springs that
are compressed by the action of the cam as the punch
holder descends. The springs feed the stock into the
die on the up stroke of the press. Hitch feed can be
used to feed the stock in any direction and can be
used on presses that do not have any accessible
crankshaft.

ROLL FEED:
A roll feed consists of a pair of rolls that can turn in
only one direction. They exert force on the stock by
means of springs. They are rotated by means of press
crankshaft. As they rotate they push the stock forward that is the function of angle of rotation. Rolls feed
are suitable for use with extremely thin material. Polished surfaces of the stock will also not be spoiled.
Roll feed eliminates manual feeding of end sections
when the strip is proceeded. Double roll feeds are used
when a sizable scrap skeleton remains after the press
operation.

DIAL FEED:
Dial feed is a rotating table. It may be built into the
press bed, or it may be fixed to the press bolster or it
may be a separate piece of equipment. Its function is
to position one or more dies under a punch or punches
mounted on the press slide. Dial feed may be powered with press crankshaft or independently.

The mechanical principle by which it operates

varies, ratchet and pawl arrangement, system of
dogs and pins or barrel type indexing cam.

DIE SET
After all tool details have been designed, a die set of
the proper size and style is selected f rom a
manufacturer's catalogue and drawn in position. Between five and ten percent of total design time is spent
in selecting and drawing the views of the die set. This
allowance may be increased considerably if the designer does not thoroughly understand the principles
underlying die set selection and representation.
Die sets are manufactured in a bewildering variety of
sizes and shapes and it is the purpose of this section
to acquaint you with the various styles as well as to
indicate proper methods of selection and placement.
Advantages realized when tool components are retained in a properly selected die set are:
Members are kept in proper alignment during the cutting process even though some looseness may exist
in the press ram. Thus, uniform clearance are maintained around the cutting edges for producing blanks
free of burrs.
1.Tool life is increased.
2.Tools can be installed in the press in the minimum
amount of time because they are self contained units.
3.Storage is facilitated. There is no possibility of loss of
loose parts.
4.Properly designed tools can be sharpened without
removal of cutting members.
Standard die sets range from 3 by 3 inches to 45 by 60
inches. Bottom plate and top plate thick nesses range
from 1 to 3 inches, by quarter inches.

ACCURACY:
Die sets are manufactured to two standards of accuracy precision and commercial. Top plate and bottom
plate tolerances are same for both. The difference between them occurs in the closeness of fit between bushings and guide pillars. For precision sets, tolerances
between bushings and guide pillars are maintained from
0.0002 to a maximum of 0.0004 inches. This tolerance
assures extremely accurate alignment between
punches and corresponding holes in die blocks. For
this reason precision die sets should be specified for
all tools which perform cutting operations.
Commercial die sets are given more liberal
clearances between bushings and guide pillars. These
range from 0.0004 to 0.0009 inches. Commercial die
sets should be specified only for tools which perform
bending, forming or other non-cutting operations.
Selection of the material from the die sets are to be
made will depend upon the strength requirements.

15
There are three choices:
1.Semi-steel
2.All steel
3.Combination-in which the top plate is
semi-steel and bottom plate is all steel.

SEMI-STEEL:
In manufacturers' catalogs the material of
the die set is listed as either steel or semi-steel.
Semi-steel contains only about 7% of steel in its
composition and is considered to be cast-iron. Semisteel die sets are cast to shape and then machined.
Some manufacturers may cast top plate and bottom plate of meehanite which may be considered a
high-grade cast iron.

STEEL DIE-SETS:
When a large hole is to be machined trough
the die set for blank removal, it is considered good
practice to specify a steel die holder if placed over
a large hole in the bolster plate, which is done occasionally even in the best press shops. It happens
too frequently that a cast iron die holder is actually
broken in two because o0f the weakening effect of
a large hole in conjunction with insufficient support
under pressure.
Steel die sets are thoroughly stress relieved
by manufacturers before final machining or grinding. Stress relieving removes any stresses introduced in the material in rolling at the mill and other
stress added during rough machining. If such residual stresses are not removed, they are gradually released with consequent distortion and dimensional change, which can ruin a precision die.
Obviously, it behooves the designer not to
incorporate anything in the design which can introduce stresses in the die set while the die is being
built. Welding anything to a die set must be provided. Rough machining of deep pockets should
be done by the die set manufacturer before the
stress relieving operation and a print showing necessary machining operations should accompany the
purchase order.To illustrate the importance of stress
relieving in the manufacture of die sets with deep
milled pockets and through holes, here is a representative order of operations actually employed for
a larger die holder.
1.flame-cut holes
2.stress relieve
3.surface grind
4.rough machine pockets
5.stress relieve
6.surface grind
7.finish-machine

SELECTING THE DIE SET:

TOP PLATE:

Ten elements of die-set information must be

decided before a die set can be ordered:
1.Make or manufacture
2.Type
3.Size
4.Material
5.Thickness of the die holder
6.Thickness of punch holder
7.Type and lengths of bushings
8.Lengths of guide posts
9.Shank diameter
10Grade of precision

The upper working member of the die set is called

the top plate. The name is easy to remember because of its relationship with punches, which are
normally applied above the strip and fastened to
the underside of the top plate. Surfaces 'A' are finished. They are employed by the die maker for
squaring and locating punch components of the die.
Surfaces 'B' are also finished surfaces. The upper
one bears against the underside of the press ram.
Punch components are fastened to the lower finished surface.

In selecting a die set from a catalog, first consider the

dimensions from front to posts and from side to side.
This is the die set area or usable space, to which die
details can be fastened. Next in importance is the thickness of the die holder and of the punch holders.

INVERTING THE TOP PLATE:

DIE SET COMPONENTS:

These are
A. Top plate
B. Guide bushings
C. Guide pillar
D. Bottom plate
When the die set is assembled, the lower ends of the
guide pillar are pressed securely into the die bushings
and the turned down portions of the guide bushings
are pressed into the top plate. The bushings engage
the guide pillars with a close sliding fit to provide accurate alignment.
The illustration typifies small and medium size die sets
made of both cast iron and steel, although different
manufacturers may incorporate slight variations.

On the die drawing the top plate is shown inverted

or turned over. At the upper portion of the illustration the bottom plate is shown at the left and the
top plate at the right, exactly as they appear on the
drawing. At the bottom is shown how the top plate
is removed from the guide pillars and inverted to
an upside down position for drawing.
At the upper right view the punch shank is represented by a dotted circle and the bushings by concentric solid circles. The top plate is drawn inverted
in this manner because this is the position in which
it is placed on the die makers bench for assembly
of the punches. Also, punches can be drawn with
solid object lines which makes, the drawing easier
to draw and read.

PUNCH SHANK:
The punch shank projects above the top plate
and it aligns the centre of the die with centerline of
press. In operation, the shank is clamped securely in
the press ram and it drives the punch portion of the
die, raising and lowering it for cutting and other operations.
For semi-steel die sets, the punch shank is
cast integrally with the body of the top plate and it is
then machined. For steel die sets, it is electrically
welded to the top plate and then machined.
Punch shanks may also be ordered separately.
These are turned down at one end and threaded for
engagement in a large tapped hole in the top plate.
Punch shank diameter depends upon the press selected. It is usually determined from a company standards book and it should be checked carefully for accuracy. After the diameter is known, the length can be
found listed in a die set catalog. The round A at the top
of the punch shank and the fillet B at the bottom were
it joins the top plate or given a 1/8 inch radius on the
drawing.Larger die sets are not ordinarily provided with
a punch shank, or the shank is employed only for centering the die and not for driving. Instead, such die sets
are clamped or bolted into the under side of the ram
because of the considerable weight of large top plate
and punch members. The relatively small punch shank
would not be a safe method of driving.
To supplement their holding power of the
shank, socket cap screws are often inserted upward
through the top plate to engage hole tapped in the press
ram. Where this practice is followed the designer specifies and dimensions the mounting holes to match the
hole pattern in the ram, and he must make certain that
they clear punch components. Dimensions fore mounting holes are ordinarily taken from a company standards book.

BOTTOM PLATE:

Usually, the bottom plate is made thicker than the

top plate to compensate for the weakening effect
of slug and blank holes which must be machined
through it. Common proportions for small and medium size dies are:
Top plate thickness-11/4inches.
Bottom plate thickness-11/2inches.

GUIDE PILLAR:
Guide pillars are precision-ground pins
which are press fitted into accurately bored holes in
the bottom plate. They engage guide bushings to
align punch and die components with a high degree of closeness and accuracy. Illustrated are 6
types:
1.Small guide pillars are usually hardened and center less ground, particularly for the commercial die
set grades.
2.Larger diameter pillar are usually ground between
centers after hardening.
3.Pillar may be relieved at what will be the die set
surface. This relief is usually applied to precision
pillars.
4.A non sticking pillar end may be incorporated. This
provides for quick and easy assembly and disassembly.
5.Shoulder guide pillars are employed in conjunction with shoulder guide pillar bushings. The large
shoulder is the same diameter as the press fit portion of the guide bushings. In the manufacture of
special die sets the top plate an bottom plate are
clamped together and holes are bored through both
for engagement of bushings and guide pillars.
6.Removable guide pillar can be easily removed
from the die set for sharpening. They are employed
for large dies and for dies having more than two
pillars

The bottom plate is the lower working member of the die sets. Its shape corresponds with that of
the top plate except that it is provided with clamping
flanges A having slots for bolting the bottom plate to
the bolster plate of the press.
Machined surfaces B are employed for squaring and locating die components. Surfaces C are also
finished. The lower one rests on the bolster plate, and
the die block and other components are fastened on
the upper surface.
B

A
C

REMOVABLE GUIDE PILLARS:

Often guide pillars must be removes for die

sharpening, especially in large dies and in dies having more than two pillars of the back pillar style. We
will look at three types:
1.The first kinds of removable guide pillars have an
axial hole machined through them are tapered at
one end to engage a taper pin A. the pillar end is
slotted. By driving the taper pin, the pillar is expanded
against the wall of the hole in the bottom plate. To
remove the pillars, along rod called a drip is inserted
from the top and taper pin is pressed out.
2.In the second type of removable guide pillar, the
taper pin B is advanced for locking the pillar by
means of a socket cap screw C.
3.The third removable pillars has a taper at the lower
end to engage a sleeve for bushings, which is
pressed into the bottom plate. A socket cap screw
engages in retaining cap to clamp the pillar to the
bushing. Removal of the socket cap screw allows
the pillar to be lifted up and removed.

6
Guide pillars for precision die sets are hard chromium
plated to provide a high degree of resistance to wear.
Also, the addition of chromium surface reduces friction by more than 50%.
For secondary operation dies, guide pillars
should have sufficient length so that they never leave
their bushings in operation. This is a safety feature to
prevent possible crushing of fingers accidentally introduced between pillars and bushings as the die operated.
Guide pillars are specified at least inch
shorter than the shut height of the die as listed on the
drawing, (the shut height being the bottom of the bottom plate to the top surface of the top plate, excluding
the shank, and measured when the top plate is in the
lowest working position). This provides a grinding allowance to assure that the top of the pillars will not
strike the under side of the press ram when the upper
die is lowered as punches are sharpened.

NON-STICKING GUIDE PILLARS:

Sticking or jamming in initial stages of engagement of top plate and bottom plate has long been a
problem because of the close fits maintained. Sticking occurs until the bushings have engaged the pillars
sufficiently for complete alignment. Die must be assembled and disassembled to great number of times
in their manufacture, try out and in sharpening.
Illustrated at 1 is popular, as well as a commercially available, pillars that features the following
characteristics:
A.A ground taper guides the bushing over the pillar.
B.A narrow land of the same diameter as the pillars
centers the bushings. The land is narrow enough to
allow rocking of the bushing over it
C.This clearance area represents the sticking range.
Because metal has been removed, sticking cannot
occur.
D.This is a ground lead which guides the bushing to
engagement with the full diameter of the pillars.
Shown at 2 is a pillar that features a radius at the leading edge to align the bushing.
A
B
C
D

OFFSET PILLAR ENDS:

In another method of assembly employed by a commercial supplier one if the guide pillar is made longer
thins a other. The top plate engages the long pillar first
and it is thus aligned before engagement of the other
pillar occurs. Dimension A is usually made inch.

GUIDE BUSHINGS:
Accurately ground sleeves, or guide bushings, engage guide pillars for aligning the top plate with the
bottom plate. Most bushings are made of tool steel
although they are also available in bronze. There
are two types:
1.Plain bushings are simple sleeves, pressed into
the top plate.
2.Shoulder bushings are turned down at one end
and they are pressed into the top plate against the
shoulder thus formed. They are recommended for
all dies which perform cutting operations.
Length of guide bushings vary ,depending
upon the manufacturer. In general, we may recognize two different lengths for plain bushings,- regular and long. shoulder bushings are furnished in
three lengths- regular, long, and extra long. The
length selected will depend upon the accuracy requirement of the tool. the longer the bushing, the
more accurate will be the alignment of the punch
and die members. this is particularly important in
cutting operations, especially, for thin stock when
clearances between cutting edges are small.
Pillars and bushings are assembled by shrink fitting
into holes bored in the top plate and the bottom plate.
The pillars and bushings are subjected to deep
freezing, thereby reducing their diameters. They are
then inserted in the top plate and bottom plate and
upon warming to room temperature, they expand to
provide a tight fit between components.
Each guide bushing is provided with a fitting for lubrication. Helical grooves are machined in
inside surface for retention and distribution of lubricant.

Pillars and bushings are assembled by shrink fitting

into holes bored in the top plate and the bottom plate.
The pillars and bushings are subjected to deep freezing, thereby reducing their diameters. They are then
inserted in the top plate and bottom plate and upon
warming to room temperature, they expand to provide
a tight fit between components.
Each guide bushing is provided with a fitting
for lubrication. Helical grooves are machined in inside
surface for retention and distribution of lubricant.

SELF OILING GUIDE BUSHINGS:

Shown is a guide bushing made of porous
powdered alloy steel. Internal pockets are cored in the
walls, and these are filled with at manufacture. In use,
the oil meters through the porous wall by capillary action. Stored lubrication is sufficient for the life of the
bushing.

DEMOUNTABLE GUIDE BUSHINGS:

DIRECTION OF FEED:
Direction of feed of strip will influence
selection of die sets. strip may be fed through a
press in any of three directions:
1.Front to back. This method may be employed for
long runs when the strip is fed automatically.
2. Right to left :This is the most commanly used
feeding direction .It is used when the strip is
advanced by right hand.
3. Left to right: This is used ocassionally when strip
is feed automatic.

PILLAR ARRANGEMENT:
Guide pillars are position in six ways
Two pillars may be positioned in different ways

Rear pillar die set

Rear pillar die set used for bending tools,
econdary tools operation.

These are shoulder bushings provided with

clamps that engage and annular groove machined in
the bushing wall or shoulder. Socket cap screws are
threaded into the top plate to effect clamping. The
turned down portion of the bushing is not a press fit
into the top plate. Instead, it is ground to an accurate
sliding fit for ease in disassembly.
These bushings are available in both steel or
bronze and they are provided with either two clamps or
three clamps, depending on size. Demountable guide
bushings are specified for long runs, when it is anticipated that bushings and posts will require replacement.

BOSS BUSHINGS:
Demountable bosses may be employed as guide bushings in large die sets. They are used for heavy duty
work whelk long runs are expected. The bosses are
turned down for location in holes in the die sets and
they are fastened wit h socket cap screws for easy
replacement. There are three types of boss bushings:
1.Flange mounted - the greater portion of the
surface is within the die set.
2.Demountable- employed as bearing and also
as guide pillar supports
3.Long bearing- these have a bearing surface
extending below the mounting flange and supported
by ribs.

BALL-BEARING DIE SETS:

Some die sets are provided with ball bearings instead
of guide bushings. Guide pillars are pressed into the
top plate and they engage linear ball bearings, which
in turn are guided in hardened sleeves. the bearings
are pre loaded to remove looseness or side play.
Lubrication is by cup grease applied at set up and this
is usually sufficient for the entire run. Ball bearings
take more room than conventional guiding methods
and they reduce die space a small extend.

Centre pillar die set

Centre pillar die set is used for round or
rectangular working area

Diagonal pillar die set

THREE PILLAR DIE SETS:

Diagonal pillar die set is used for progressive tools

with rectangular working area.

The addition of a front pillar to a back pillar die set

provides increased stability for unbalanced cuts
and when greater precision is required. These are
incorporated only in square or rectangular steel
sets. For hand feeding, the extra pillar is applied
at the front, left corner as at A. when the feed is
automatic it is centered as at B.

Four pillar die set

Four pillar die set is used for heavier press working
operation.

FOOL PROOFING :
Center pillar and diagonal pillar die set are provided
with different diameter pillars, dimensions A and
B.Thus, the top plate cannot be reversed on the
bottom plate. This is an important precaution for
symmetrical tools.

FLOATING-ADAPTER DIE SETS:

NON STANDARD DIE SETS
These die sets are made for a particular design
when standard die sets are not suitable or not
available. These are usually made of mild steel with
case hardened pillars and bushes.

STYLES:
Back pillar die sets are made in five different
styles or shapes:
1.This style is most common. It is used for small
medium size die sets ranging from 3 X 3 inches to
about 16 X 18 in both semi-steel and steel.
2.Large, semi-steel die sets ranging from 22 X 6
inch to 25 X 14 inches have sides wider than the
distance over the pillars.
3.The larger ranges of steel die sets are made square
or rectangular in shape.
4.Many tools have relatively small punch members
which occupy little top plate room. For such tools die
sets with v-shaped punch holders provide a better
proportioned design as well as greater visibility for
loading and unloading work.
5.For round punch members a round die set may be
used.

In blanking and piercing thin stock and for shaving

and broaching operations very little clearance can
be allowed between the punch and die members.
The slightest lateral movement would cause
nicked or dulled cutting edges. The floating adapter
shank A is clamped in the ram of the press in the
regular way. However, by using this adapter the
ram can only impart an up and down motion to the
top plate. Any inaccuracy or wear in the slide of
the press will not be transmitted as stresses on
the die set guide bushings and guide pillars. The
top plate therefore is actuated independently of
the press slide. Long shoulder bushings should
be used with these die sets because, in operation
the guide pillar must always be guided within them.

LARGE DIE SETS - SEMI-STEEL:

Large semi steel die sets are available in the back
pillar A, center pillar B, diagonal pillar C, or four
pillar D styles. All are provided with clamping
flanges for shoulder bushings unless otherwise
specified.

LONG, NARROW DIE SETS:

This type of die set is used to retain tools for
cutting, bending and forming of long, narrow parts.
They are back pillar sets, and they are available with
either two or three guide pillars. Two pillar are specified
for sets ranging from 12 to 72 inches in length and
three pillars for sets ranging from 84 to 240 inches in
length.own at B are available in diameters ranging from
4 to 48 inches.

ROUND DIE SET :

These die sets are selected for retaining round dies
such as drawing tools, trimming tools, and the like.
There are two style: back pillar style as shown at A
and center pillar style as shown at B are available in
diameters ranging from 4 to 48 inches.

RECOMMENDED THICKNESSES:
The bottom plate and top plate of a large die set
must be given sufficient thickness. Die set catalogs
recommend specific thickness in relation to sideto- side and front -to-back dimensions and these
recommendations should be followed. When plates
are too thin in relation to their width and length,
they will warp causing misalignment of punch and
die numbers and binding of guide pillars in guide
bushings. Conversely, when plates are too thick
the overall die cost increases.
This table provides a useful guide to the
specification of top plate and bottom plate
thi ckness. O bserv e t hat t here are two
considerations, die-space dimensions A&B ,and the
force in tons required to perform the work that is to
be done by the tool. Select the values for C and D
opposite whichever is greater.

CENTER PILLAR DIE SET :

These die sets are ordinarily employed for secondary
operation work such as piercing, coining, and the like.
Parts are loaded from the front. The die sets are
available in semi steeland steel in the style illustrated
in fig.Components may be supplied in combination,
with a steel bottom plate used in conjunction with a
semi steel top plate as at C.
Another important application for center pillar die sets
is the performing of secondary operations on work
pieces having a right and a left hand. Parts of one hand
may be conveniently loaded from one side. When the
other hand is to be run, th die set is turned around
1800 in the press for ease in loading.

LARGE DIE SET - STEEL:

Large steel die set are made of plate. They have ground
surfaces and they are square or rectangular in shape.
Two-pill ar sets are giv en one of three pil lar
arrangements. At A is shown the back pillar, at B the
center pillar, and at C the diagonal pillar style. Sizes
are not limited. That is, they may be specified to any
length, width, and thickness of top plate and bottom
plate.

Eg:- If the die set area for a particular die measures

30 by 20 inches and the force in tons is less than
30, the values of 1 inches for C and 2 inches for
D would be selected. however, if the force in tons
were 60, we would use the values opposite
pressure in tons of 50 to 70, and the value for C
would be 2 inches and for D 3 inches.

SPECIAL DIE SETS:

Despite the large number of styles and sizes of
standard die sets available, it is occasionally
necessary to design a special die set for a specific
job. This occurs particularly for parts which are
exceptionally large or which contain severe offsets.
Provide adequate strength by applying ribs or
gussets at highly stressed sections. Specific rules
can not be given because of the variety of
conditions encountered.
Special die sets are designed by the die
designer and a pri nt is sent to a die set
manufacturer where the die set is actually built.

BALL-BEARING DIE SETS:

Some die sets are provided with ball bearings instead of
guide bushings. Guide pillars are pressed into the top
plate and they engage linear ball bearings, which in turn
are guided in hardened sleeves. the bearings are pre
loaded to remove looseness or side play. Lubrication is
by cup grease applied at set up and this is usually sufficient for the entire run. Ball bearings take more room
than conventional guiding methods and they reduce die
space a small extend.

A
B

Self-Lubricating Ejector Bushings

These self-lubricating bushings contain graphite plugs
which are impregnated with oil. When the bushing reach
80-90F as a result of friction between the bushing and
guide post, oil is drawn from the plug,thus lubricating
the wear surface. A dark smear pattern is created on
the wear surface as the oil and graphite are imbedded
into the bronze or steel grain. This provides the
lubrication necessary for continuous performance of
the tool.

TYPES OF TOOLS

23

In previous sections of this book, you have learned the

elements that go into building a complete tool. In addition, you have learned how to design a tool, that is,
how to arrange those elements - the die block, punches,
stops, gauges, die set and all the others into a functioning tool. Also the preparation of tool drawing was
explained in detail so your comprehension would be
thorough one.
The next step is to learn about the types of
dies, the function, and how they operate. There are
twenty types of tools and each is distinct and different
from all the other types. However, as you study the
descriptions to follow, observe how the elements that
you learned previously are applied and re applied with
suitable modifications to adopt them for each particular job to be performed.
BLANKING TOOLS:
A blanking tool produces a blank by cutting the
entire periphery in one simultaneous operation. Three
advantages are realized when a part is blanked.
1.Accuracy. The edges of the blanked parts
are accurate in relation to each other.
2.Appearance. The burnished edge of each
blank extends around its entire periphery on the sane
side.
3.Flatness. The blanked parts are flat because
of the even compression of material between punches
and die cutting edges.
The insert at A shows a material ready to be
run through a blanking tool. At B is shown top view of
the tool with punches removed. The section view at C
shows the tool in open position with the upper punch
raised to allow advance of the strip against the automatic stop. At D the tool is shown closed with a blank
pushed out of the strip.
Blanking tools may produce plain blanks as
shown in the inset E, but more frequently holes are
pierced at one station and the part is then blanked out
at the secondary station. Such tools are called "pierce
and blank tools" and they have been described fully in
preceding sections of the book.

D
E
A

PIERCING TOOLS
Piercing dies pierce holes in stampings. There are two
principle reasons for piercing holes in a separate
operation instead of combining piercing with other
operations:
1.When a subsequent bending, forming, or drawing
operation would distort the previously pierced hole or
holes.
2.When the edge of the pierced hole is too close to
the edge of the blank for adequate strength in the die
section. This occurs in compound and combination
tools in which piercing and blanking are done simultaneously.
In the inset at A is shown a flanged shell requiring four
holes in the flange. If the holes where pierced before
the drawing operation they would become distorted
because of the blank holder pressure applied to the
flange in the drawing process.
The shell is located in an accurately ground hole in
the die block. Piercing punches are retained in the
punch holder fastened to the top plate, and a knockout effects stripping after the holes have been pierced.

CUTOFF TOOLS:
The basic operation of a cutoff tool consists in severing strips into short lengths to produce blanks. The
line of cut may be straight or curve, and holes and
notches or both may be applied in previous operations. The cutoff tools are used for producing blanks
having straight, parallel sides because they are less
expensive to build than blanking tools. In operation,
the material strip A is registered against stop block
B. Decent of the upper tool causes the cut off punch
C to separate the blank from the strip. Stop block B
also guides the punch while cutting occurs to prevent deflection and excessive wear on guideposts
and bushings. A conventional solid stripper is employed.

COMPOUND TOOLS:

EXTRUDING TOOLS:

In a compound tool, holes are pierced at the

same station as the part is blanked, instead of at a
previous station as is done in the pierce and blank tool.
The result is greater accuracy in the blank. Whatever
accuracy is "built in" the tool will be duplicated in every
blank produced by it. Compound tools are inverted
tools. The blanking punch A is located on the tool holder
of the die set instead of being fastened
The tool block B is fastened to the punch
holder and it is backed up by a spacer C which retains
piercing punches. A positive knockout removes the
blank from within the die cavity near the top of the press
stroke. A spring stripper removes the material strip from
around the blanking punch.
Although most compound tools are designed for producing accurate, flat blanks, they are occasionally used
for producing blanks that are too large for production
in more than one station. Since all operations are performed at the same station, compound tools are very
compact and a smaller die set can be applied.

The function of all the tools discussed so far is to

perform work on the sheet material - to cut sheet
materials into blanks, to perform further operations
upon the blanks, or to perform the operations on
the workpiece bent, formed or drawn from the
blanks. We come now to interesting classes of tools
that perform secondary operations on small thick
blanks called slugs. In this dies the slugs are severely deformed to make parts having no resemblance to the slug from which they were made. The
first class is called extruding tools. In this type of
tool each slug is partly confined in a cavity and extremely high pressure is applied by a punch to cause
the material in the slug to extrude or squirt out, much
life tooth paste is extruded when the tube is
squeezed. In the illustration the slug A is to be extruded into a thin wall shell having a conical closed
end. The slug is placed in die block B, backed up
by a hardened plate C the bottom of the cavity in
the die block is formed by the end of the knockout
rod D. when the press ram descends extruding
punch E first squeezes the material in the slug until
it assumes the shape of the die cavity and of the
working end of the extruding punch. Continued
descent causes the material to extrude upward
between the walls of the punch and die wall of the
cavity. The amount of clearance too determines the
thickness of the wall of the extruded shell. The extruding punch is retained in punch plate F. and because of high pressure involved; it is backed up by
backing plate G.

COMPOUND DIE

D
C

COINING:

COLD FORMING TOOLS:

Cold forming tools produce work pieces by applying pressure to blanks, squeezing an d displacing the material
until it assumes the shape of the punch and die. In the
illustration at A, a slug is to be formed into a flanged part
in the cold forming die. It is placed on the punch B located within spring loaded V gages C. Descend of the
upper die causes the material under the upper die block
to be displaced outward to form the flange. As the flange
increases in diameter, the gauges are pushed back as
shown. When the die goes up, the part is carried upward
within it and it is ejected near the top of the stroke by
knockout plunger D actuated by knock out rod E.

Coining is the operation of pressing material in a

die so that it flows into space in the detail of the die
face. Coining differs from embossing. In coining the
metal flows, whereas in embossing the metal does
not change in thickness to a great extent.
Coining operations are generally performed cold.
Coining has two major advantages.
1)Ornate detail can be produced with excellent surface finish.
2)Tolerances can be held to very closer values.

BROACHING TOOLS:
Broaching may be considered to be a series of
shaving operation performed one after the other by the
same tool. A broach is provided with a number of teeth,
each of which cuts a chip as the broach traverses the
surfaces to be finished. Internal broaches finish holes;
surface or slab broaches finish outside surfaces.
Two conditions make broaching necessary:
1.Blanks are too thick for shaving. A considerable metal
must be removed from the edge of the thick blanks; a
series of shaving tools would be required to produce
smooth finish. It would then be more economical to use
a broaching tool.
2.When considerable metal must be removed. This occurs when ridges or other shapes are required in the
edge of the blank such shapes directly because the cutting edge would be weak and subjected to breakage.
In the illustration, a blank at A must have small
pointed serrations machined in the sides. The die is provided with two broaches B supported during the cutting
process by hardened backing blocks C. The blank is
located in the nest D . Pressure pad E, backed up by
heavy springs, clamps the blank securely before the
cutting begins. The first three or four of the broach are
made undersize and they ordinarily do no cutting except
if an oversize blank is introduced into the die. The last
three or four teeth are sizing teeth. Intermediate teeth
are called working teeth and they take the successive
chips to machine the serration.

HORN TOOLS:
A horn tool is provided with a projecting post
called a horn. Bent, formed, for drawn work pieces
are applied over the horn for performing secondary
operations. The illustration in a blank has been reverse bent in a previous operation and the ends
are to be hooked together and seemed in a horn
tool. The horn D is retained in a holder C fastened
to the bottom plate. When the ram descends, seaming punch D strikes the workpiece to form the seam.
Many other operation such as piercing, staking, and
the like are also performed

E
C
D
B
C

C
B

SIDE CAM TOOLS:

Side cams transform vertical motions on the
press ram into horizontal or angular motion and they
make possible many indgenious operations. In the illustration A, a flanged shell requires two holes pierced
in its side. The shell is placed over die block B of the
tool. Descend if the upper tool causes pressure pad C
to seat the shell firmly on the block. Further descend
causes side cam D to move the punch - carrying slides
E for piercing the holes. Spring strippers strip the shell
from around the piercing punches, as they are withdrawn.

C
D

B
F

BENDING TOOLS:
A bending tool deforms portions of flat blanks to
some angular position. The line of bend is straight
along its entire length, as differentiated from a forming tool, which produces work pieces having a
curved line of bend. In the illustration a flat bank is
to be given a double bend to form a U shape. The
blank is inserted in gauges A fastened on bending
blocks B. The bending blocks, in turn are fastened
to the bottom plate. Upon the descend of the upper
tool, the bending punch C grips the blank between
its lower face and pressure pad D. Pins E extend to
the pressure attachments of the press. Shedder F
strips the workpiece from the punch.

At the bottom of the stock, knockout block F applies

the final form. It bottoms against a hardened spacer
fastened to punch holder thus "setting" the form.
When it ascends, the part is carried up within the
form blocks D. Near the top of the stroke it is ejected
by knock out F.

FORMING TOOLS:
The operation of forming is similar to bending except
that line of bend is curved instead of straight and plastic
deformation in the material is more severe. In the illustration the flat blank at A is to be formed into a part having a curved contour. The blank is positioned in nest B
composed of two plates mounted on pressure pad C.
When the ram descends, the blank is gripped between
the bottoms of forming blocks D and surface of pressure pad C. Further descends causes the sides of the
blank to be formed to the curved shape of forming blocks
D and forming punch E.

TRIMMING DIES:
Trimming tools cut away portions of formed or
drawn work pieces that have become wavy and irregular. This condition occurs because of un even
flow of metal during forming operations. Trimming
removes this unwanted portion to produce square
edges and accurate contours.
The illustration at A shows a flanged shell after the
drawing operation. A trimming tool is required to
trim the irregular edge of the flange. The shell is
placed over a locating plug B and decent of the
upper die causes the scrap ring to be cut from the
flange. After trimming, the shell is carried up in the
upper die and a positive knockout ejects it near the
top of the stroke. The scrap rings are forced down
around the lower trimming punch until they are split
into two by scrap cutters C applied at the front and
back of the die. The scrap pieces fall to the sides,
away from the operation of the press.

B
A

SHAVING TOOLS:
Shaving is the operation of removing small amount of
metal from around the cut surface of the blank or hole.
In order to improve the surface. A properly shaved blank
has a straight, smooth edge and it is held to a very accurate side. Many instruments, business machine, and
other parts are shaved to provide better functioning and
longer wear.

In the illustration, a blank A is to be shaved, both

along outside edges of the walls of the two holes.
The shaving tool for this workpiece consist an inverted shaving punch B fastened to the bottom plate,
and the shaving die block C fastened to the top plate.
A spacer D backs up the die block and it retains the
shaving punches for the holes. The blank is located
in the nest E beveled to provide clearance for the
third chip. The nest is mounted on the spring stripper plate guided on two guide pins F the shaved
blank is carried up, held in the die block with considerable pressure, and it is ejected near the top of
the stroke by positive knockout. Shaving dies are
ordinarily held in the floating adapter die sets for
better alignment. This is necessary because less
clearance is applied between punches and die
blocks.

DRAWING TOOLS:
The operation of drawing is similar to forming, although
there is more severe plastic deformation in the material. The difference between the two occurs in the extent of closure of the form. Consider a drawn cup such
as a metal ringing up. The material extends all around
the sides and therefore the part is said to have been
drawn. In a formed part the material does mot extend
completely around to surround a space, even though
the formed contour may be quite intricate.
In the illustration at A over a flat disc is to be
drawn into a cup. The blank is placed on pressure pad
B of the drawing tool and it is located by four spring
loaded pins C. descend of the upper die causes the
blank to be grip securely between the surface of the
pressure pad B and the lower surface of draw ring D.
Further descend of the ram causes the blank to be
drawn over punch E until it has assumed a cup shape
shown in closed view at the right. Pressure pins F extends to the pressure attachment of the press.
The amount of pressure must be adjusted carefully. Excessive pressure would cause the bottom of
the punch to be punched out. Insufficient pressure
would allow wrinkles to form. With the proper amount
of pressure, a smooth, wrinkle-free cup is produced.
Drawing is extensively used for producing stampings
ranging from tiny cups and ferrules to large shells for
vessels, ships, aircraft's, and missiles producing.

In the illustration at A, a drawn shell is to be bulged

at its closed end. The shell is placed over punch b
of the bulging tool and its lower end is confined in
lower die C. the upper end of punch B is a rubber
ring within which is applied a spreader rod D. this
rod is conical at it upper end and it helps the rubber
to flow outward to the desired shape. When the
press ram descends, the upper die applies a force
to the shell bottom and since the rubber cannot
compress, it is forced outward bulging the walls of
the shell. When the ram goes up, the rubber returns to its original shape and bulged shell can be
removed from the tool. After bulging a shell is shorter
than it was previously.

B
D

BULGING TOOLS:
A bulging tool expands a portion of a drawn
shell causing it to bulge. There are two types: fluid dies
and rubber dies. Fluid dies employ water or oil as the
expanding medium and a ram applies pressure to the
medium. In rubber dies, a pad or block of rubber under
pressure moves the walls of the workpiece to the desired position. This is possible because rubber is virtually incompressible although it can be made to change
its shape, the volume remains the same.

CURLING TOOLS:
A curling tool forms the material at the edge of a work
piece into a circular shape or hollow ring. Flat blanks
may be curled; a common application is a hinge formed
of two plates, each of , which is curled at one side for
the engagement of the hinge pin. More often, curling
is applied to edges of the open ends of the cups and
shells to provide stiffness and smooth, rounded edges.
Most pans used for cooking and baking foods are
curled.
In the illustration, a drawn shell shown at A is
to be curled. The shell is placed in the curling tool where
it rests on knockout pad B. descent of the upper causes
the knockout pad to push down until it bottoms on the
bottom plate. Further descent causes curling punch C
to curl the edge of the shell. Near the bottom of the
stroke, the lip of the material contacts an angular surface machined in curling ring D to complete the curl.
When the punch goes up, the knockout raises the shell
for easy removal.

SWAGING TOOLS:
The operation of swaging, sometimes called necking, is exactly the opposite of bulging. When a
workpiece is swaged a portion is reduced in size
and this causes the part to become longer than before it was swaging. In this illustration at A, a shell is
to be swaged at its open end. It is inserted in the
swaging die where it rests on knock out pad B. and
its lower end is surrounded by the walls of block C.
When the ram descends swaging die reduces a portion of the diameter of the shell and this becomes
longer.

C
D
D
C
B

DINKING TOOL:

FLARING TOOL (LUGGING TOOL):

To cut paper, leather, cloth, rubber and other soft materials a dinking tool is used. The cutting edges penetrates the material and cuts it (like knives). The dinking
punch digs into the base plate. The base plate is made
of wood, fiber, or hard rubber. The dinking tool can be
used to cut the inner and outer shapes of component.

The process of forming an outward flange on parts

is called flaring operation.

LANCING TOOL:
This is a continues bending and cutting operation along
a line in the work material. No metal is cut free during
the lancing operation.

PLANISHING TOOL:
Planishing tool is used to straighten blanked components. Very fine serration points penetrate all over
the surface of the component in order to release
stress and straighten the component

Serrations

PROGRESSIVE TOOLS:
In a progressive tool the strip is moved in
stages from station to station. Different operations are
performed on it and at each station except at idle ones
applied to provide room for components. A complete
work piece is removed from the strip at the final station. All the operations described previously may be
performed in progressive tools. For example, a single
die of this type may do piercing at the first station, trimming at the second station, bending at third, forming
at the fourth etc. a progressive tool may thus be considered as a series of different tools placed side by
side with the strip passing through each successively.
This analogy has some merit although it does not give
a true picture of the extremely close inter relationship
between the various stations.
In the illustration at A, pierced, trimmed and
bent part is to be produced complete in a simple progressive tool. At the first station strip is notched and
pierced and at the second station the blank is cut-off
and bent. You should easily recognize all of the elements in this tool- the die block, piercing punch, trimming punch, knockout, stop block, and all the others.

SUB-PRESS TOOLS.
Sub-press tools blank and form very small watch,
clock and instrument parts. An example would be
the small instrument cam shown at A. The tool components are retained in a sub press which is, as its
name implies, actually a small press operated in a
larger one. The sub press is composed of base C,
barrel B and plunger Die set along, tapered Babbitt
bearing E provided with longitudinal key slots which
guides the plunger and prevents the rotation. Tightening spanner nut against bearing E causes it to
close around plunger D, to remove all looseness.
The top portion of the plunger D is engaged by an
actuator G threaded into a central tapped hole. The
slot of the actuator is engaged loosely by a yoke fastened to the press ram. Thus the press ram does
not guide the sub press in any way. It simply applies
the up and down motion. Sub press tools are usually
of the compound type because of the considerable
accuracy obtained.

COMBINATION TOOL:
In combination tool two or more operations such as
forming, drawing, extruding, embossing may be combined with each other or with various cutting operations such as blanking, piercing, broaching etc.

NOTCHING TOOL:
This operation removes a small amount of material from the edges of the strip or a blank. Notching
serves to shape the outer contours of the work piece
in a progressive tool or to remove excess metal
before a drawing or forming operation in a progressive tool.

COMBINATION TOOL

EMBOSSING:
PERFORATING TOOL:
If more no.of holes are pierced, it is called perforating
tool.The process of piercing a series of holes in a given
blank or workpiece is known as perforating.

Embossing is the shallow forming operation in which

the work piece material is stretched over a male die
and made to conform to a male die surface by a
mating female die surface. The finished product will
have depressed detail on the other.

PARTING OFF TOOL:

The parting off operation separates the work
material along a straight line or angle or an
iregularin double line cut. The piece removed
by the punch is scrap.

C
A
B
E

PARTING OFF.

FIXED STOP.

FINGER STOP.

ASSEMBLY TOOLS:
Assembly tools assemble two or more parts together by press fitting riveting, stacking or other means.
Components are assembled very quickly and relationship between parts can be maintained closely. In the left
a link and two studs are shownthat are to be riveted
together in an assembly tool. The studs are positioned
in die block A and they seat on plungers B. The link is
then positioned over the studs, the turned down ends of
the studs engaging in holes in the link. Descend of the
press ram causes riveting punches C to deform the ends
of studs into the shape of rivet heads. A hardened plate
D backs up the punches to prevent the heads from sinking into the relatively soft material of the die set. Another
hardened plate E backs up the plungers.

COMPOUND TOOL
COMPOUND DIES:
A common characteristic of compound-die design is the inverted construction, with the blanking die
on the upper die shoe and the blanking punch on the
lower die shoe. This construction commonly calls for
the pierced slugs to pass through the lower die shoe.

BLANK-AND-PIERCE DIES:
Compound dies are particularly useful for producing pierced blanks to close dimensional and flatness tolerances. Generally, the sheet material is lifted
off the blanking punch by a spring-actuated stripper,
which may be provided with guides to feed the material and a stop to position it for the next stroke. The
blank tends to remain in the die, from which it is removed by a spring stripper or by a positive knockout.
A positive knockout is most satisfactory when blanking relatively hard or heavy materials that remain flat
without the use of a hold down or pressure pad. A
combination spring-actuated blank holder and knockout is used for blanking thin and springy materials
when flatness and accuracy are required. It also is
used when a press has no positive-knockout attachment, or when the blank is too large to eject properly.
Ejection of the blank from the die by spring or positive
knockouts makes angular die clearance unnecessary,
assuring constant blank size through the entire life of
the die.

23
A typical example of a compound (blanking and
piercing) die is shown in fig. During the cutting cycle,
the stock is held flat between the faces of the stock
stripper and the blanking die. The blanking die
makes contact with the stock slightly before the
piercing punch, which pierces the hole in the center of the piece after it is blanked out of the strip. As
the piece is blanked out, the strip is carried below
the cutting edge of the blanking punch brought back
slightly above the punch level by the lower stripper.A
compound die for blanking and piercing, a clutch
disk. The clutch disk is made of 1.83 mm. half-hard
cold-rolled sheet steel. The blank is produced from
a 254 mm. wide strip, and a 165 mm. diameter hole
is pierced in the center. Subsequent operations in
other dies pierce 12 small holes in the disk and bend
up the ears on the five tongues. In this two-section
compound die, the blank is cut from the strip and
forced downward into the die by the punch.
The piercing punch (D1) is a solid block
and fits a counterbore in the die shoe. The blanking
die (D2) also is fitted in the counterbore in the die
shoe. A pressure pad (D3), located between the die
sections, is supported and operated by four pressure pins. Two stripper plates are operated in connection with the punch, one (D4) being located on
the outside of the outer cutting edge, and the other
(D5) on the inside of the inner cutting edge.

UPPER DIE SHOE

BLANKING DIE
PIERCING PUNCH
STOCK
STRIPPER

BLANKING PUNCH
cum PIERCING DIE
LOWER DIE SHOE

Helical springs furnish stripping pressure for the plates.

The construction of this compound tool is substantially
the reverse of that shown in fig. Because the blanking
die and piercing punch are supported by the lower die
shoe.
A compound die for making a pierced blank
for a washer is shown in fig. One press stroke punches
the center hole and blanks the piece from 0.38 mm.
cold-rolled-steel strip. The piercing punch is attached
to the upper die shoe. And the blanking punch is attached to the lower die shoe. (The piercing punch contacts the material slightly ahead of the blanking die).
The part is stripped from both the blanking die and
piercing punch by a positive knockout. The blanked
strip is lifted off the blanking punch by a spring-loaded
pressure pad.

In the blanking and piercing die shown in fig. the

blanking die is made in three pieces whose cutting
edges form the outside shape of the part. The part
is blanked from 1.27 mm cold-rolled-steel strip. A
blanking punch mounted on the lower die shoe
mates with a sectionalized blanking die mounted
on the upper shoe. Piercing punches mounted in
the upper shoe pierce two small in the part as it is
being blanked from the strip. A stripper plate removes the work from the blanking punch,
and a shedder pin strips the blank from the small
punches.
Three washers and a slug are produced at
a single stroke of the press by the die shown in fig.

TRANSFER PINS
BLANKING DIE
PIERCING PUNCH
SHEDDER
PRESSURE PAD

Helical springs furnish stripping pressure for the plates.

The construction of this compound tool is substantially
the reverse of that shown in fig. Because the blanking
die and piercing punch are supported by the lower die
shoe.
A compound die for making a pierced blank
for a washer is shown in fig. One press stroke punches
the center hole and blanks the piece from 0.38 mm.
cold-rolled-steel strip. The piercing punch is attached
to the upper die shoe. And the blanking punch is attached to the lower die shoe. (The piercing punch contacts the material slightly ahead of the blanking die).
The part is stripped from both the blanking die and piercing punch by a positive knockout. The blanked strip is
lifted off the blanking punch by a spring-loaded pressure pad.

STOCK STRIP

Three concentric pinches are attached to the upper

shoe, and the concentric sleeve dies are attached to
the special combination die block and lower shoe.
Two concentric ejector sleeves fit between the
punches and two concentric strippers for the blanking dies, one between the dies and one outside the
outer die. The outermost of the three upper punches
functions as a blanking die, cutting on its ID only. It is
seated firmly in a groove in a punch holder and held
in the place with a screw-on ring. The intermediate
blanking punch and the solid center piercing punch
are integral and are screwed to the bottom of the
punch holder. The ejector sleeve and knockout assembly slide freely between the punches,

and gravity holds the ejectors down when the die is

open. The knockout ejects the two washers when the
press ram reaches the top of its stroke. The spring is
intended to balance the weight of the ejector knockout
so the washers will not drop out accidentally.
The strippers, which hold the stock and remove both the pierced stock and the intermediate
washer, are actuated by a die cushion through pressure pins. The solid slug falls through the center die.
All punches and die edges are sharp except the OD of
the outside punch. This die cuts cardboard washers
from 1.59 mm and 3.18 mm stock but also could cut
thin metal. A progressive die could be used to make
these washers and automatically sort them.

In fig (A). the assembly is shown, as it would appear with the punch holder removed from the die
shoe this is the condition when the assembly is
being checked for proper relationship between the
die block, shedder and knockout. The shedder
flanges are resting on the die opening edge. The
shoulder on the knockout rod is seated against the
bottom of its counterbore. In this condition, the shedder should be beyond the die face.
Knockout Rod

Punch Holder Shank

punch holder

die block
shedder

shedding pin

Plan of die

BLANKING
PEIRCING
STRIPPERS PUNCH
DIE
PUNCH

Figure(B) depicts the shedder relationship at the

bottom of the press stroke (die closed). The punch
entry distance is shown at E. the stock material thickness is T. The shedder is forced upward into the die
opening a distance A= E + T. with conditions as
shown, gap D should normally be a minimum of 2
T or 3.0 mm, whichever is greater. Gap D is an
important safety factor: in the event of either shedding-pin or knockout malfunction, gap D should permit the accumulation of at least two extra piece parts
within the die cavity. This gives the operator an opportunity to notice the malfunction and stop the
press. It is obvious that an accumulation of doubles
can have serious consequences including damage
to the die and/or punch press as well as possible
injuries to persons in the vicinity.

30

SHEDDERS AND KNOCKOUTS

Positive Shedders

PUNCH
E

A positive shedder can be described as one, which is

not actuated by springs or other compression media.
Figures A,B,C-illustrates a very basic positive shedder
actuated by means of a simple knockout rod. The shedder and knockout rod assembly shown is functionally
typical for inverted type dies. This shedder is a flanged
shedder. The flanges are, an integral part of the shedder, act as keepers, retaining the shedder within the
die cavity.

The assembly in fig (D) is somewhat more sophisticated. This is necessary because of the nature of
the shedder contour. Since it is essential for knockout force to be evenly distributed with respect to
shedder contour, the knockout- shedder assembly
must be designed specifically for each application.
This, of course leads to considerable variation in
construction. It does not, however, change the basic principles associated with positive-shedder assemblies. In principle, the relationship described for
figs (A to C) are essential for positive shedder applications the requirements for dimensions A and B
in fig (D) are same as for A and B in fig (A). Gap
can be derived, by association, from fig(B). In fig(D),

Punch press knockout bar

J K
G

D=E+T+A+2 T min
Where E= punch entry distance
T= stock material thickness.
Space G must not be less than D. to facilitate die making, G should be made 0.8mm or more
larger than D however, when determining the required pocket depth J, always check and be certain
Always provide a slight fillet radius at F. do not make
that dimension K will be adequate. Do this before
this corner sharp; a fillet radius as small as 0.5 mm is
machining the pocket.
far superior to a sharp corner.
Shedder contours determine the location
The top end of the knockout is chamfered. A
of shedder flanges. Locate the flanges to facilitate
30 chamfer, as shown, is generally optimum. It will
grinding and /or machining. Flange location should
eliminate peening and spalling while providing maxibe balanced out around the periphery of the shedmum end area for contact against the punch press
der. The no. Of transfer pins required, as well as
knockout bar.
the location, must be appropriate for the specific
Immediately following the condition shown
shedder. The transfer pins must distribute the knockhere, the knockout rod and the shedder drop free to
out force evenly through the shedder. Avoid unbalthe condition shown in fig (A).
anced condition. Be especially careful in cases
Do not underestimate the significance of the
where shedders have areas of cross section which
relationships shown; they are vitally important to sucare comparatively delicate.
cessfully shedder functions. Note also the function of
Among the many possible knockout variathe shedding pin, and remember that the shedding pin
tions are those in fig(E). Here the transfer pin is
in this and similar applications is mandatory. The imassembled by peening then into s thin plate. In view
portance of an adequately functional shedding pin canA, the peen plate and knockout rod are also f fitted
not be overemphasized; an inadequate one is too oftogether and secured by peening. This method is
ten the primary cause of a wrecked die.
practical for any light duty, where the knockout
forces evenly distributed and very well balanced in
relation to the shedder contour. The complete upKNOCKOUT
per die assembly is shown here in order to emphaSHANK
size the existence of the normal shedder knockout
PUNCH HOLDER
TRANSFER PIN relationships even though the die different construction. The knockout assembly shown in view B is
THRUST PLATE
much stronger here, knockout rod is welded to the
pin plate. This knockout would be capable of withDIE BLOCK
standing more severe service.A generalized restriction to transfer-pin location is indicated in fig.(F).
Do not permit more than one-half of the pin diamSHEDDER FLANGE (3 PLACES)
POCKET COUNETR
eters A to bear against the flanged portion of the
KNOCKOUT FLANGE
shedder. Whenever practical, have the entire pin
SHEDDER COUNTER
PUNCH HOLDER SHANK
diameter located behind the body of the shedder.
On occasion, laminated construction may
be used to advantage. The shedder in fig(G) is for
SHEDDING PIN
a compound pierce and blank die. The flange is a
TRANSFER PIN (3)
separate ring, secured to the shedder body by
screws.

The size and contour of this particular shedder make

laminated construction feasible. Its size permits installation of screws, which are adequate in size,
sufficient in number, and strategically disposed. Its
contour is such that the straight-through machining
permitted as a result of lamination is a definite asset. However, in spite of its advantages, this construction should not be used indiscriminately. It can
at times be tempting enough to encourage gambling upon its adequacy, but keep in mind positive
shedders are subject to severe impact conditions,
and employ laminated construction only where it is
practicable.
The knockout constructions in fig.(H) are
variations of transfer-pin knockouts. They are not
heavy-duty knockouts but are limited to applications
where the span of the transfer pins can be contained within the punch-holder shank. They are desirable from the die cost standpoint and are practicable for many applications. The knockout in view
A is more economical to make. In addition to the
cost advantage, it permits a wider span for the transfer for the transfer-pins. However, in some punch
presses, the cavity in the ram may not be deep
enough to accept the top bridge. This condition
worsens in proportion to the knockout travel. Such
an objection, of course, does not apply to the knockout in view B. for applications, which require a long
knockout travel; the long slender pins may be too
susceptible to bending if considerable knockout
force is required.

KNOCKOUT

pinplate

thrustplate

punchplate

shedding pin
VIEW A

WELD

VIEWB

Travel

Travel

A
A/2 maximum

Keeper lugs (flanges) are not required on the shedder, which appears in fig.( I ). The knockout -rod 1 is
peened into assembly with the shedder 5. A collar
ring 2 is assembled to the knockout-rod by means of
a cross pin 3. The collar acts as a stop, limiting the
protrusion distance A of the shedder. The collar impacts against the top of the shank and subjects the
cross pin to considerable force, which is suddenly
applied. Therefore, the cross pin should be made of
drill rod and left soft. Do not attempt to use a standard dowel pin for this or any similar application.

In the case illustrated, the shedding pin installation differs from those previously shown. This type of installation is not feasible in round shedders unless some
means of preventing shedder rotation is provided. A
much stronger shedder assembly is pictured in fig(J).
Here the knockout shaft is engaged (threaded) in the
shedder and secured by a lock nut. Two locknuts are
jam-tightened on the shaft, stopping the shedder travel
as required. Wrench flats should be provided on the
knockout shaft to aid in positioning and tightening the
lock nuts, especially the lower lock nut. The shedding
pin 1 shown here is actuated by a flat spring 2.

By definition, the arrangement in fig.(K) is a stripper. Its function is to strip either the workpiece or
the stock material scrap (whichever the application
requires) from the punch. It is included here because
the construction and action exactly parallel those of
a positive shedder. Thus the allowances and relationships given earlier for positive shedders apply,
as equivalents, to positive knock-off strippers.
A spider-type bridge plate 2 is shown. The spider
operates within a suitably contoured recess, which
is milled in the punch holder. In this case, the transfer pin is threaded studs. The studs are secured
with lock nuts to maintain the required spacing between the stripper plate 4 and the spider.
Spiders, which are often which are often used in
conjunction with large shedders and strippers, permit a long span between the transfer-pin centers. In
addition, the contoured recesses permit punches
(or other components) to be mounted directly to
punch holders. Before milling the recess, check and
be certain that the security of the shank will not be
endangered.
One or more shedding pins are required for this kind
of stripper. In the case illustrated, standard commercially available spring pins 5 are employed. They
are the type which is installed in tapped holes and
secured with lock nuts, as shown.
A knockout arrangement for large work is
represented in fig.(L) where it is applied to a positive knock-off stripper. It would apply to large shedders, as well. The mechanical relationships are the
same as for the center-poised knockout-shedder
arrangements previously described. Center distance
M between the knockout rods must be made to suit
the specific punch press in which the die will be
operated.

Spiders, which are often which are often used in conjunction with large shedders and strippers, permit a
long span between the transfer-pin centers. In addition, the contoured recesses permit punches (or other
components) to be mounted directly to punch holders.
Before milling the recess, check and be certain that
the security of the shank will not be endangered.
One or more shedding pins are required for this kind
of stripper. In the case illustrated, standard commercially available spring pins 5 are employed. They are
the type which is installed in tapped holes and secured
with lock nuts, as shown.
A knockout arrangement for large work is represented
in fig.(L) where it is applied to a positive knock-off stripper. It would apply to large shedders, as well. The
mechanical relationships are the same as for the center-poised knockout-shedder arrangements previously
described. Center distance M between the knockout
rods must be made to suit the specific punch press in
which the die will be operated.

Shankless punch holders are often used for large dies.

In other instances, the shanks are used
only to position the die centrally in the press.
In these situations the punch holders are normally screw-attached to the ram. Also some presses
may be equipped with special adapters. All of these
factors must be taken into considration when determining specific knockout constructions.
As with many other aspects of die making,
variations of shedder-stripper-knockout constructions
can be virtually endless. However, the basic relations
principles may, by associations, be generally applied
on all postive constructions of this type. The combination arrangements shown in fig.(M) server to emphasize the fact. The illustrated arrangement cannot be
considered a common application, and yet in spite of
this, the A and B relationships shown here are the same
as those shown earlier in fig (N), view A:
1.The shedding pin is located at the center of the shedder. Because of this, there is no leverage advantage
for the shedding pin. This error can result in failure of
the shedding pin to displace the blank from the face of
the shedder. The final result could be just as disastrous as if the shedding had been omitted entirely.
2.Length L is too short. It does not provide grinding life
on the shedder. This would not apply, of course, to situations where grinding life is not required.

In view B, the shedding pin is correctly installed. It

is located off-center, which permits it to lever the
blank away from the shedder face as shown. Also,
length L will permit the shedder face to be ground
away, as required, in the course of die maintenance.

SPRING SHEDDERS
The basic spring-actuated shedder appears in
fig(O). It is a flanged shedder. Flanged proportions
are indicated at H and W. These should be
H=2W min
Space D should be treated the same as for a positive shedder.

Protrusion distance A will vary according to the specific application. Range A will be from zero (flush) to
approximately 0.8mm., as dictated by the specific requirements of the specific application. If it is intended
to push the blank back into the stock strip, protrusion
A should range from zero for light gage stock to 0.127
mm. For heavier stock. For light gage material, two or
more shedding pins should be installed in the shedder. They should be symmetrically located. The springs
which actuate the shedding pins should not too strong.
If they are, or if the shedding pin locations are not
balanced, the blank may be pushed through the stock
strip. For heavier material, shedding pins may not be
necessary. However, holes should be provided in the
shedder anyhow, to permit the installation of shedding pins if this should prove necessary.
For applications where the shedder is not intended to be a pushback shedder, protrusion A may
be 0.8 mm., if desired to facilitate die making. In the
case of heavy, crude work, this may be increased, if
desired to, 1.5mm., which should be ample to facilitate die making even on crude work. For shedders,
which are pushback shedders, only one shedding pin
is usually required. Installation is generally the same
as for a positive shedder.
In fig.(P), the shedder actuating spring is contained within the punch holder shank. The spring applies pressure to the plunger 2, and transfer pins 3
transmit the spring pressure to the shedder 4. The
plunger flange is slip fit in the spring pocket. The tail,
or shank, of the plunger is a slip fit in the hole in the
screw plug.1. This stabilizes the spring action, eliminating cocking or tilting forces on the shedder and
transfer pins. Stripper bolts are a practical means of
suspending larger shedder in the manner typified in
fig.(Q) Construction practices for such shedders are
identical for spring strippers. Remember to associate
the spring and stripper-bolt locations to provide balance, in order to prevent deflection of the shedder
plate. Keep in mind that the most common errors in
this type of construction
are:
1.Poor stripper-bolt-to-spring association.
2.Stripper bolts, which are too small for the application.

PROGRESSIVE TOOL
PROGRESSIVE BLANKING AND PIERCING TOOLS
A simple blanking tool is designed only when
the piece part has no internal details. An altogether different tool is designed if the piece part is to be produced by the combination of blanking and piercing operation. It can be done in the following way in the same
tool. The piercing is performed in the first station. Then
the stock strip is advanced to another station where
blanking is carried out. The relative position with the
previously pierced hole is maintained during the blanking operation. The tool is known as "progressive tool"
because the processing progresses from station to station. Before designing the tool the piece part drawing
should be studied carefully. This is to plan the operations to be carried out in different stations. Then the
drawing of the stock strip is planned. The drawing will
be similar to the stock strip, as it will appear after it has
gone through all the stations till a finished part is removed from it. This layout is known as the "strip layout". It must be fully dimensioned and should carry all
informations necessary to start the design of the tool.
The informations are
1.Feed direction.
2.The amount of pitch by which the strip should advance
after each stroke of the press.
3.Position of stoppers.
4.Width of the strip.
5.Scrap bridge dimensions.
Fifty to seventy percent of the cost of stamping is on
the material. The method employed in laying out the
strip influences the economic success or failure of any
pressing operations. The strip layouts should be such
that the maximum area of the strip is utilized for the
production of stamping. In the tool shown the finished
piece part is produced when the strip passes through
three stations. The strip is stopped at the first station by
the auxiliary stopper (finger stopper). During the first
stroke of the press ram two holes are pierced by piercing punch.
The strip is then advanced to the next station. To do
this the first finger stopper is withdrawn and the second
finger stopper is engaged. Now the pierced hole comes
in line with the two pilots. The pilots are longer than the
piercing punches. Their nose is conical shape with a
radius at the tip. During the next stroke of the press
ram the pilots enter into the previously pierced holes
and locate the strip (second station). In the first station
the piecing punches again pierce two holes in the strip.
Again the strip is advanced and brought to stop against
the final stop. During the third stoke of the press ram
the pilots enter the pre pierced holes and locate the
strip. In the first station the two piercing punches produce two holes. In the third station the component is
blanked and the piece part is obtained. This part will
conform to the piece part drawing.

25
Once the first blank is removed from the strip, the
strip is lifted to clear fixed stopper, the strip is fed till
it again stops against the newly formed edge of the
opening in the strip created by the removal of the
first blank. Only when a new strip is introduced into
the tool the auxiliary stoppers are used again.
PROGRESSIVE DIE DESIGN:
A progressive die performs a series of fundamental
sheet-metal operations at two or more stations during each press stroke in order to develop a
workpiece as the strip stock moves through the die.
Each working station performs one or more distinct
die operations, but the strip must move from the
first station through each succeeding station to produce a complete part one or more idle stations may
be incorporated in the die to locate the strip, facilitate interstation strip travel, provide maximum-size
die sections, or simply their construction.
The linear travel of the strip stock at each
press stroke is called the "progression", "advance",
or "pitch" and is equal to the interstation distance.
The unwanted parts of the strip are cut out
as it advances through the die, and one or more
ribbons or tabs are left connected to each partially
completed part to carry it through the stations of
the die. The operations performed in a progressive
die could be done in individual dies as separate operations but would require individual feeding and
positioning. In a progressive die the part remains
connected to the stock strip which is fed through
the die with automatic feeds and positioned by pilots with speed and accuracy.
When parts are made from individual
blanks moved from die to die by mechanical fingers in a single press, the dies are known as transfer dies.
Selection of progressive dies:
Whenever the total production requirements for a given stamping are high, a progressive
die should be considered. The savings in total handling costs by progressive fabrication compared with
a series of single operations may be great enough
to justify the cost of progressive die.
The present application of computer aided
die design, together with the general use of wire
burn EDM for making die sections, has greatly simplified the designing and construction of progressive dies.
The quality of stampings made on progressive dies is often higher than that produced on individual dies. There is less chance for off-gage conditions due to part locating problems. The human
factor has less influence on part quality. Often the

savings in labor costs together with the more

consistent quality progressive die stampings have been
the deciding factors in justifying the greater material
cost of coil stock over producing automotive stampings
from offal in recovery dies.
The fabrication of parts with a progressive die
should be considered when:
1.Stock material is not so thin that it cannot be piloted.
2.Coil handling equipment, stock straighteners, and
feeders are available or can be justified.
3.The overall size of the die, which is determined by
part size, number of stations, and strip length, is not
too large for available presses.
4.The total press tonnage capacity required is available.
5.The press is level and in good condition. Problems
with worn gearing, loose gibbing, and worn bearings
can result in alignment problems that can damage precision tooling.
6.Quality and part consistency requirements are high.
7.Quick die change and flexible manufacturing requirements exist.
STRIP DEVELOPMENT FOR PROGRESSIVE DIES:
The individual operations performed in a progressive
die are usually simple, but when they are combined in
several stations, the most practical and economical strip
design for optimum operation of the die requires careful analysis. The sequence of operations on a strip and
the details of each operation must be carefully developed to ensure that the design will produce good parts
without production or maintenance problems. The following strip development sequence is applicable to both
manual and computer aided design.
A tentative sequence of operations should be established and the following items considered as the final
sequence of operations is developed:
Step 1. Analyze the part
a.What is the material and thickness?
b.What hole dimensions - size and location- are
critical?
c.What surfaces are critical?
d.What forms are required?
e.Where can carriers be attached?
f. Is direction of material grain important?
Step 2. Analyze the tooling required.
a.What production is required per month, per year, total?
b.What presses are available? It is important to know
bolster area, shut-height, feed height,strokes per
minute, air cushion, etc.
c.What safety conditions must be met?
Step 3. Make dummy drawings.
A part dummy drawing shows the finished part and all
positions in which the part will be formed in order to
achieve the final form. Provide for proper metal movement for drawing or forming operations.

a.Tips for dummy drawings:

1.Show the complete part.
2.Show all positions necessary to form part in and
elevation views.
3.Show over-bend positions if they are critical.
4.Show all necessary views to achieve clarity.
5.Show work lines and set-up lines.
6.Provide vertical and horizontal center lines for
measuring when assembling the strip layout.
7.Show the strip carriers, if known, before strip layout is assembles.
8.Trace dummy from part print, if part print is dimensionally accurate (less time and lesser errors)
9.Use design aids:
a.Wax for sample parts and carriers.
b.Rubber skins.
c.Plastic skins.
d.Models
10.Check accuracy.
Step 4. Make strip layout. A strip layout for a progressive die is a series of part dummy drawings
marked up to indicate the die operation to be
performed on each station of the die. How to
construct a strip layout:
a.Determine the proper progression for the part.
b.Tape on a drawing board a series of prints of the
plan view of the part in die position using the horizontal center line for alignment.
c.Apply clear tapes over prints in order to hold prints
together after removal from the drawing board.
d.Mark all die operations on each station that will be
performed in the die. (Use red color pencil for cutting operations and blue or green for forming operations)
e.Mark operations directly on prints or use overlaysheet for preliminary layout, but mark directly on the
prints for final layout to prevent something being
missed during die design.
Step 5. Discuss proposed process with another
person to check for errors. Use a checklist when
analyzing the preliminary strip layout.
a.What stations can be eliminated by combining with
another station?
b.Are good die steel conditions maintained?
c.Does movement of part between stations require
a stretch web?
d.Are idle stations provided to permit "breathing" of
strip, if stretch is not feasible?
e.Provide for pitch notch(s), if possible, to maintain
proper progression.
f.Avoid sight stop for first hit, if possible.
g.If possible, pierce in first station and pilot in second station to establish pitch control.
h.Provide adequate pilots for all subsequent stations.
i.Is there room for stock lifters to permit free flow of
strip during feed?
j.Are close tolerance holes pierced after forming to
eliminate development of hole location?

k.Use an overlay sheet to run a simulated strip through

the die to check each operation and to spot any loose
pieces of scrap which might be left on the die.
Step 6. Draw plan views by tracing proper part
positions for each station from the strip layout.
Step 7. Draw the plan of the punch over the plan of
the die to permit tracing as much as possible and
to reduce scaling errors.
Step 8. Make views and notes to communicate
properly to the die maker (Remember to assume is
to blunder).
Step 9. Problem areas to watch:
a.Part lifters.
b.Part gages.
c.Part control-pilots, etc.
d.Pad travels.
e.Scrap ejection.
f.Part ejection.
g.Poor die steel conditions.
h.Will the die fit the press?
i.Will the die fit production requirements?

The hour-glass cutout made in two sections by

piercing two separate angular shape cutouts and
lancing or notching the material between them in a
second section. The cutouts shown at F and G provide an expansion type carrier ribbon that tends to
straighten out when the draw is performed. These
cutouts are made in two stations to allow for stronger die construction. Satisfactory multiple layouts
may be designed using most of the reliefs by using
a longitudinal lance or slitting station to divide the
wide strip into narrower strip as the stock advances.
The I-shaped relief cutout in H is a modified hourglass cutout used for relatively wide strip from which
rectangular or oblong shapes are produced.Straight
slots or lances across the stock are sometimes used
on very shallow draws or where the forming is in
the center portion of the blank. On the deeper draws,
this type of relief tends to tear out the carrier strips
or cause excessive distortion in the blank and is
not recommended.

(B)

Step 10. Receive preliminary design approval.

Step 11. Finish design layout.

(C)
Providing for carrier strip distortion:
The strip development for drawing in progressive dies
must allow for movement of metal without affecting the
positioning of the part in each successive station. Fig.
shows various types of cutouts and typical distortions
to the carrier strips as the cup shaped parts are formed
and then blanked out of the strip. Piercing and lancing
of the strip around periphery of the part, leaving one or
two tabs connected to the carrier strip is commonly used
method. The semi-circular lancing as shown at B is
used for shallow draws. The use of this type of relief for
deeper draws places an extra strain on the metal on
the tab and may cause it to tear. The carrier strip is
distorted to provide stock for the draw. A popular cutout for fairly deep draws is shown at C. this doublelanced relief suspends the blank on narrow ribbons,
and distortion takes place in the carrier strip. Two sets
of single rounded lanced relief of slightly different diameters are placed diametrically opposite to each
other to produce the ribbon suspension. The hour-glass
cutout in D is an economical method of making the
blank for shallow draws. The connection to the carrier
strip is wide, and a deep draw would cause considerable distortion. An hour-glass cutout for deep draws is
shown in E, which provides a narrow tab connecting
the carrier strip to blank. The cupping operations narrow the width of the strip as the metal is drawn into the
cup shape.

(D)

(E)

(F)

(G)

(H)

Good general practices:

The following are good progressive die design
practices.
1)Pierced piloting holes and pitch notches in the first
station. Other holes may also be pierced that will not
be affected by the subsequent non cutting operations.
2)Use idle stations to avoid crowding punches and die
blocks together. Idle stations also permit the use of
larger die blocks and punch retainers. An added advantage is that future engineering changes can be
incorporated at low cost.
3)Use solid spring-loaded stock guide rails rather than
spool lifters where possible.
4)Plan the forming or drawing operations either in an
upward or downward direction, which ever will assure
the best die design and strip movement.
5)The shape of the finished part may dictate that the
cut off operation should precede the last non-cutting
operation.
6)Locate cutting and forming areas to provide uniform
loading of the press slide. If this is not practical, and
the press is large enough to permit the die to be offset, determine the required offset and have instruction to the die setup placed on the die.
7)Design the strip so that the scrap and part can be
ejected without interference. The best way to eject the
apart is to cut it off and drop it through the lower die
shoe.

Stock for
expansion

R1

COMPONENT DRAWING

Material
: Copper
Sheet thickness : 2mm
2
Shear strength :20kg/mm

31

R1

R1

COMPONENT DRAWING

STRIP LAYOUT
Material
: Copper
Sheet thickness : 2mm
2
Shear strength :20kg/mm

R1

35

Feed direction

56

31

E.F : 63.5%

36.0

S4
GS1

12.0

M8x55

M6x15

D3

SK1

98.0

SK1
M8x75

D1

M6x15

S2

GS1

46.0

S1

FRONT VEIW-SECTION A-A

S2

GP

S2

GS1

S2

SK1

S1

SK1

SK1

S1

D1

D1

S1

296.0

SK1

D2

D2

D1

D1

S1

S2

S2

GP

GS1

A
S2

TOP VEIW-BOTTOM HALF

296.0

179.5

M10x80

22.0

S2

S3

ADVANTAGES AND DISADVANTAGES OF

COMPOUND TOOLS OVER
PROGRESSIVE TOOLS.
ADVANTAGES
1. Piece parts produced from compound tools
are very accurate and identical because all operations
are carried out in a single station. This is possible because the accuracy of the piece does not depend on the
accuracy of the advance of the strip or the accuracy of
the layout of the stations as in the case of progressive
tools.
2.Scrap stocks from the other tools can be employed to produce piece parts in a compound tool. But
progressive tools always need stock strip sheared to
size
3.In a compound tool burrs resulting from the
piercing and blanking are on the same side of the piece
part. Piece part produced on a progressive tool will have
burr on both sides.
4.Cost of manufacturing a compound tool is
normally lesser than that of a progressive tool for the
same component. This is because of the smaller size of
the tool and the easier manufacturing methods required.

DISADVANTAGES
If the pierced holes are too near to the outer
edge of the piece part, the blanking punch of the compound tool, which accommodates the piercing dies, will
become very weak. This is a major disadvantage because the punch may break either during manufacture
or during the course of the tool life. When the piece parts
are having pierced holes are too near to their outer edges
progressive tools are preferred.

26

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