Basic

Design Guide
for

This book is a guide to designing parts for

manufacturing with the GRIPflow process.
We suggest that you have our firm reveiw
your requirements and share our manufac-
turing expertise as it relates to your spe-
cific needs.

EBWAY CORPORATION ● 6750 N.W. 21 Avenue ● Fort Lauderdale, Florida 33309 ● 954/971-4911
 DESIGN
TABLE OF CONTENTS GUIDE

TABLE OF CONTENTS

What is GRIPflow? .............................................................................Page 1

How is GRIPflow different? ..................................................................Page 2
Design your part to reduce cost ..........................................................Page 3
Die-Roll.............................................................................................Page 4
Edge Taper .......................................................................................Page 5
Radii on corners................................................................................Page 6
Tears ...............................................................................................Page 7
Close Web Sections, Small Hole Diameters and Slots ............................Page 8
Hole Tolerances.................................................................................Page 9
Tooth Forms and Gear Sections...........................................................Page 10
Projections .......................................................................................Page 11
Countersinks and Chamfers ................................................................Page 12
Offsets .............................................................................................Page 13
Flatness ...........................................................................................Page 14
Tonnage ...........................................................................................Page 15
Material Selection ..............................................................................Page 16
DESIGN
GUIDE
Page 1
WHAT IS GRIPFLOW?

GRIPflow is a patented metal stamping The following is required

process that produces highly accurate to manufacture GRIPflow
parts with smooth square edges.
Parts
The process requires a single action
GRIPflow press and precision-built dies ■ GRIPflow Press
with tight tolerances between punch
and die.
■ GRIPflow Tool
■ Malleable Material
In the stamping operation, before the
material is actually blanked, it is firmly
clamped in the area of the stamping.
The scrap material is allowed to flow
laterally. Hence, the name “GRIPflow”.

GRIPflow can:
■ Eliminate secondary machine
operations.
■ Pierce holes smaller in diameter
than the stock thickness.
■ Coin countersinks the entire
thickness of the stock material.
■ Stamp gear teeth.
■ Hold close tolerances.
■ Make the smooth-edge only
where it is required.
■ Improve your part’s flatness.
 DESIGN
HOW IS GRIPFLOW DIFFERENT? GUIDE
Page 2

Conventional stamping bends the actu- CONVENTIONAL

al blank at the start of the blanking
operation. Due to this bending, there is PUNCH
no smooth, fully continuous edge.
Approximately 30% of the thickness is
sheared while the remaining 70%
tears. Rough edges and poor toler-
ances are the evident results. Typical
edge-surface finish is 125-150 RMS. TAPER

BURR
DIE-BREAK
SMOOTH
EDGE DIE-ROLL

GRIPflow combines cutting and metal

flow to produce smooth (no tear), ver- GRIPFLOW
tical, accurate sides through-out the
entire part thickness. GRIPflow rou-
DIE
tinely holds accuracies of .001‘‘ and SHEDDER
certain dimensions are held to .0005‘‘.
Almost no difference can be measured GRIP
FLOW FLOW
between the first and the millionth part
out of the tool. This is achieved on a STRIPPER
single action punch press. Typical sur- PUNCH
face finish is 16-32 RMS.

DIE-ROLL
SMOOTH EDGE
BURR
Fineblanking requires a special triple-
action press and a “V” ring in the die to FINEBLANKED
restrict the material from moving away V-RING
from the shear zone during the blank-
ing operation (opposite of GRIPflow).
This V-Ring requires extra stock mate- PUNCH
V-RING
rial and press tonnage (maximum of PRESSURE

40% of total blanking tonnage).

Accuracies in most cases are similar

to, or equal to, those of GRIPflow. DIE COUNTER
PRESSURE

BURR
SMOOTH EDGE
DIE-ROLL
DESIGN
GUIDE
DESIGN YOUR PART TO REDUCE COST
Page 3

.375 ± .001 90% — The less smooth-edge on a part, the

smaller the burr and the lower the
EDGE
70% — price because of:
B
■ less deburring
■ less tool maintenance
■ a faster production rate

A
Why pay for a total smooth-edge
DIE-ROLL BURR stamping when only specific portions
SIDE SIDE
of the stamping require a smooth-
edge?

GRIPflow can give you the smooth-edge

only where it is required.

BASIC GUIDELINES

1.) Draw the part as it will look. The

stamped part will have die-roll on
one side and a burr on the oppo-
site side (this burr is removed by
vibratory deburring). Identify the
die-roll or the burr side on your
part.

2.) Identify the area(s) on the part that

require a smooth edge with a bro-
ken line.

3.) Specify the amount of smooth-edge

required (i.e. 50%, 75%, 90%,
etc.).
 DESIGN
DIE-ROLL GUIDE
Page 4

Y = 2X
Y
DIE-ROLL SIDE
X
DIE-ROLL = X
S

S = 100%
BURR SIDE
Material Thickness

GRIPflow DIE-ROLL IN PERCENT OF

THE MATERIAL THICKNESS

(BASED ON MATERIAL OF
57,000 P.S.I. TENSILE STRENGTH)

Die-Roll is produced on all stamped

1-10%
parts. The degree of die-roll is influ- DISHING
— OCCURS WHEN
ence by: W IS LESS THAN S

1.) Material
2.) Material Thickness 6-12%
CURVED
3.) Part Shape CONTOURS
ON LARGE
HOLES
■ The harder the material
— The less the die-roll W
■ The more acute the corner 15-25%
— The greater the die-roll 90° CORNERS
■ The smaller the corner radius
— The greater the die-roll
■ The thicker the material
0-2%
— The greater the die-roll
CORNERS
ON INSIDE
CONTOURS

4-10%
STRAIGHT
CONTOURS

0% HOLES
SMALLER
THAN
MATERIAL
THICKNESS

20-30%
ACUTE CORNERS
LESS THAN 90°
DESIGN
GUIDE
Page 5
EDGE TAPER
GRIPflow EDGE

SMOOTH The GRIPflow Edge Taper is

EDGE
influenced by:

1.) Material
■ The thicker the material
— The greater the edge taper
■ The higher the carbon
— The greater the edge taper
■ The greater the alloy content
— The greater the edge taper
LESS THAN
1 DEGREE 2.) Shape of Part
■ Outside contours have a larger
degree of edge taper than
internal contours

CONVENTIONAL EDGE

ONLY 30%
SMOOTH
EDGE

DIE-BREAK

MAXIMUM
DIE-BREAK OF
30 DEGREES
 DESIGN
RADII ON CORNERS GUIDE
Page 6

The extrusion type characteristics of

OBTUSE
GRIPflow require sharp corners to EXTERNAL CORNER
have a blending radius. This radius (OUTSIDE CONTOUR)
allows for a smooth, uninterrupted
flow of the metal during blanking.
Sharp corners should be avoided wher-
ever possible. If a sharp corner is
absolutely necessary, it may be accom- OBTUSE
plished by utilizing a progressive tool. INTERNAL CORNER
(OUTSIDE CONTOUR)
OBTUSE
EXTERNAL CORNER
(INSIDE CONTOUR)
90° INTERNAL
CORNER
(INSIDE CONTOUR)

■ The larger the radius

---The less corner tear
■ The larger the radius
---The less die wear ACUTE
INTERNAL CORNER
■ The larger the radius (INSIDE CONTOUR) OBTUSE
INTERNAL CORNER
---The less die-roll (OUTSIDE CONTOUR)
■ The harder the material
---The larger the radius
ACUTE
EXTERNAL CORNER
(OUTSIDE CONTOUR)

DESIGN GUIDELINES
TYPE OF CORNER INSIDE OUTSIDE % OF MATERIAL
CONTOUR CONTOUR THICKNESS

YES 7 - 12%
90° Corner
YES 10 - 15%

YES 11 - 15%
Acute
Corner
YES 15 - 20%

Obtuse YES 4 - 7%
Corner
YES 5 - 10%
DESIGN
GUIDE
Page 7
TEARS

Edge Tears Result From:

Material
■ being too hard
■ having a poor grain structure

Tooling
■ having a worn or chipped
punch

Corner Tears Occur Only On External

Corners. Causes May Be:

Design
■ corner radii too small

Material
■ being to hard
EDGE TEAR ■ having a poor grain structure

Tooling
■ worn or chipped punch

CORNER TEAR
CLOSE WEB SECTIONS, SMALL HOLE DESIGN
GUIDE
DIAMETERS AND SLOTS Page 8

O- Protrusion Length
V
P- Slot Width
X W
R- Hole Diameter
S- Material Thickness O
T- Web (Slots)
U- Protrusion Width (If O≥S)
V- Protrusion Width (If O<S)
W- Notch Width
X- Web (Holes) X

R
Design Guidelines based on 57,000
p.s.i. Tensile Strength (i.e. AISI 1010
hot rolled steel)
■ Minimum Protrusion Width
If 0 < S then V=1/2 S
If 0 ≥ S then U=2/3 S
■ Minimum Hole Diameter T T
O
R=1/2 S P
■ Minimum Hole Web
X=1/2 S
■ Minimum Slot Width U
P=1/2 S
■ Minimum Slot Web
T=1/2 S
■ Minimum Notch Width S
W=1/2 S

■ Minimum web sections, hole diameters

and slot widths are limited to the forces
MAY BE BETTER MAY BE BETTER that the punch can tolerate.
SUITABLE SUITABLE ■ The danger of a punch fracturing is
higher in the areas where contours
abruptly change direction.
■ The harder and thicker the material,
the larger the tolerance.
MAY BE BEST MAY BE BETTER
SUITABLE SUITABLE
DESIGN
GUIDE
Page 9
HOLE TOLERANCES

Dimensional accuracy of a GRIPflow

part is primarily dependent on the qual-
ity of the tool.

TOLERANCES Tolerance range is influenced by:

BASED ON 57,000 PSI TENSILE ■ Material Thickness
STRENGTH MATERIAL (i.e. AISI 1010) ■ Tensile Strength of Material
■ Grain Structure of Material
■ Configuration of Part

MATERIAL THICKNESS Closer tolerances can be held, if

required by designing a more involved
Hole Diameter Up to .157 .157 - .236 .236 & Up and complex tool.

.118 - .236 +.001 +.0015 +.002 Tolerances on internal contours are

-0 -0 -0 easier to maintain than outside con-
tour tolerances.
.237 - .393 +.001 +.0015 +.002
-0 -0 -0

.394 - .708 +.001 +.0015 +.002

-0 -0 -0

.709 - 1.181 +.001 +.0015 +.002

-0 -0 -0

1.182 - 1.968 +.001 +.0015 +.0024

-0 -0 -0

1.969 - 3.149 +.0012 +.0018 +.0029

-0 -0 -0

3.150 - 4.724 +.0014 +.0021 +.0034

-0 -0 -0

4.725 - 7.086 +.0016 +.0025 +.004

-0 -0 -0
 DESIGN
TOOTH FORMS/GEAR SECTORS GUIDE
Page 10

S
Tooth forms for gear wheels, gear seg-
ments and racks can be produced by
GRIPflow.

As a general rule the tooth thickness

at the pitch radius (dimension G) H
should be equal to or greater than 60
percent of stock thickness. Reductions
to 40 percent of dimension G may be G
possible depending on tooth shape and
the material hardness.

Die-Roll will be greater in cases where G = 60% MINIMUM OF S

dimension G approaches the minimum
--- especially at the tip of the tooth.

To help prevent die-break the root and

crest of the tooth must be radiused.

G S
DESIGN
GUIDE
Page 11
PROJECTIONS

DIE-ROLL SIDE
MAXIUM 85%
DEPTH OF
SEMI-PIERCE
A GRIPflow extruded projection is not
separated from the parent material.
Even after 85% punch penetration a
S uniform uninterrupted grain flow exists
(based on 57,000 p.s.i. tensile
strength material i.e. AISI 1010). The
harder the material, the larger the
connecting zone must be.

Semi-pierced projections can serve

BURR SIDE
many varied uses:
■ Contact Points
WELD PROJECTION
■ Weld Projections
■ Feet
■ Self Rivets
■ Locator Pins
■ Assembly Pins

All of the above mentioned projections

occur on the burr side. Projections on
the die roll side are possible by pro-
gressive or secondary dies.

MAXIMUM OF D IS S
 DESIGN
COUNTERSINKS AND COUNTERBORE GUIDE
Page 12

GRIPflow countersinking is very simple

as long as the countersink is on the ANY ANGLE
die-roll side. A countersink can be put
on the burr side by a progressive die.

■ No bulge will result from a GRIPflow

countersink.

■ A countersink equal to the thickness

of the material is possible with
GRIPflow.

■ Countersinks on both the die-roll side

and the burr side are possible with
a progressive GRIPflow die.

■ A counterbore with a round hole can

be produced by a progressive
GRIPflow die.
DESIGN
GUIDE
Page 13
FORMING & OFFSETS

70° IS
MAXIMUM
BEND ANGLE Offsets of 70% or less can be achieved
with a GRIPflow compound die. The
S maximum height of the offset can not
MAXIMUM OFFSET
IS 4 TIMES S
be greater than 4 times the stock
material thickness.

If an angle over 70% is required or the

offset will be over 4 times the part
thickness then a progressive tool will
be necessary.

■ The steeper the bending angle

— the higher the degree of
difficulty.
■ The harder the material
— the less the offset.
■ The thicker the material
— the less the offset.
■ The bend direction can be at any
angle in relation to the part con-
90°
tour.

GRIPflow PROGRESSIVE DIE REQUIRED

 DESIGN
FLATNESS GUIDE
Page 14

Flatness describes the condition which

exists when all points on a surface lie
in the same plane.

Out of Flatness
Out of flat conditions are undesirable
and normally result from one or more
of the following: S
■ Configuration of Part
■ Grain Direction of Material
■ Original Material Not Flat
Prior to Blanking
■ Stresses in Material from
Rolling/Slitting.

Flatness is more difficult to control on

parts with coinings, offsets, bends and
extrusions.

Flatness Tolerances For Gripflow Stamping

(Based on 57,000 p.s.i. tensile strength---i.e. AISI 1010)
Surface Length Flatness
From 0 - 5” .001” to .0015” per each inch T.I.R.*
Over 5” .004” to .006” plus .0012” per
each inch of additional length T.I.R.
*T.I.R. --Total Indicator Reading
DESIGN
GUIDE
Page 15
TONNAGE
THICKNESS OF MATERIAL IN .001 OF INCH

.032 .062 .093 .125 .156 .187 .218 .250 .281

23”

22”
.312
21”

20”
.343
19”

18” .375

17” .406
16”
L .437
E 15”
N .468
14” .500
G
T 13” .531
H .552
12”
.593
O 11” .625
F .656
10”
C 9”
U
8”
T
7”

6”

5”

4”

3”
SHEAR TONNAGE
MATERIAL 1010
2” 57,000 p.s.i.
1”

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

TONNAGE NEEDED
T= Total Stamping Tonnage = Part Contour Periphary including all cut-outs & holes in the part (in inches)
x Material Thickness (in inches) x Factor

P= Part Contour Periphery Including All Holes and Cutouts S= Stock Thickness F=Factor

MATERIAL MULTIPLIER CHART

Material Description Factor
Aluminum 9.5 Formula
Brass 17.5
T=P X S X F
Copper 14.0
Steel AISI 1006 to 1025 25.0
Steel AISI 1030 to 1090 35.0
Stainless Steel 35.0
 Suitable Materials for the Gripflow Stamping Process

Thickness Range
Material Grade < 0.125” 0.125 - 0.1875” 0.1875 - 0.250” 0.250 - 0.3125” > 0.3125”

< 3.175 MM 3.17 - 4.75 MM 4.75 - 6.35 MM 6.35 - 8.00 MM > 8.00 MM
Low Carbon Steel
SAE 1006 - 1010 E E E G G
SAE 1011 - 1025 E E G G A

Medium Carbon Steel

SAE 1026 - 1035 (Annealed) E E G A I

High Carbon Steel

(Spheroidized Annealed)
SAE 1036 - 1050 E E G A I
SAE 1053 - 1078 E G A A I
SAE 1080 - 1095 E G I I NR

Alloy Steel
(Spheroidized Annealed)
SAE 4130 E E G A I

SAE 4140, 4620, 5140, 5160, E G A I I

6150, 8615, 8620, etc.
High Strength, Low Alloy (HSLA)

Grade 050 (340 MPa) E E G A I

Grade 060 (410 MPa) E E G A I
Grade 070 (480 MPa) G G A I NR
Grade 080 (550 MPa) G G A I NR
Grade 090 (620 MPa) G G I NR NR

Aluminum
1100 E E G A I
2011, 2014, 2017, 2024 E G A I I
3003 E E G A I
5005, 5052 E E G A I
6061, 6063 E G A I I
Stainless Steel (Annealed)
Austenitic (302, 304, 304L, 316,
317L, 321) E G A I NR
Ferritic (409) E E E G A
Martensitic (410, 420) E G I NR NR

Copper - Brass - Bronze

Soft E E E G G
1/4 Hard E E G A A
1/2 Hard E G G A I
Full Hard G A I I I

Note: The part shape/contour and the material hardness may effect how the material reacts when stamped. All technical data is for comparison
purposes and this chart is to be used as a guide only. The information has been compiled from sources that we believe to be accurate but cannot
guarantee. We will be pleased to review your part prints and advise you on the expected results of a potential material.

Key: E = Excellent G = Good A = Acceptable I = Inquire Further NR = Not Recommended

Page 16