CHAPTER 4 :

TOOL AND DIE

(PART 3)

1
OBJECTIVE :
4.3 Complete the Die designing
a. Die block
b. Punch and punch plate
c. Pilot, strippers and pressure pad
d. Force mechanism involved in die operations
e. Blank size
f. Bending methods
g. Bending allowances and bending pressure
h. Percent reduction, depth of draw, drawing force
2
4.3 Complete the Die designing
Punch and Die Components a toggle mechanism
driven by a servo
motor.

Components of a punch and die for a Die Ram- Servo Drive

blanking operation. 3
 Punch and Die Components
1. Top die shoe
2. Bottom die shoe
3. Guide plate
4. Top back-up block
(backing plate)
5. Bottom back-up block
6. Guide pin
7. Punch
8. Punch retainer with
adjusting plate
9. V-Ring plate
15
10. Guide bushing
13. Ejector
14. Die
15. Piercing punch holder
http://www.partechfineblanking.com/design_guide/tool_standards.htm
16. Guide bushing 4
 Die Components
The main foundation and supporting structure upon which the
bed
operating parts of the machine are mounted and guided.
A plate that is designed to hold in place the lower die shoe.
bolster plate The bolster plate is attached to the top surface of the press
bed.
A hardened steel tube that provides the opening for the punch
die button
during operation. During a shearing operation, the slug or
(Matrix)
blank passes through this opening.
die holder Another term used for the lower die shoe.
A hardened steel block containing machined impressions or
die retainer cavities that shape the metal as the punch descends from
above. The die retainer also holds the die button.
A hardened rod positioned in the lower die shoe that fits into a
guide post bushing in the upper die shoe to guide the punch during
operation.
guide post A hardened steel tube that slides over the guide post and
bushing directs the upper die shoe during operation.
lower die The lower plate of a die set that supports the die retainer and
shoe die button. 5
 Die Components
A long, slender punch with a rounded tip used to position the metal
pilot sheet by entering a previously formed hole. Pilots are longer so that
they enter the sheet before other tools form the metal.
A type of press with an open frame and very wide bed. Press brakes
press
are often used for bending operations, and they are typically
brake
manually operated.
The tool typically attached to the upper portion of the die set that
punch (7)
shapes or penetrates the sheet metal.
punch
Another term for the upper die shoe.
holder (1)
punch
The device used to mount the punch on the upper die shoe.
retainer (8)
The main upper portion of the press that slides up and down within
ram
the press frame. The upper die shoe is attached to the ram.
A plate designed to remove sheet metal stock from the punch as it
stripper
pulls away from the die during the operation.
upper die
The upper plate of a die set that secures the punch retainer.
shoe 6
Die Design Fundamental

7
a. DIE BLOCK
INTRODUCTION

• Four factors influence the design of a die block for any

particular die. They are:
1. Part size
2. Part thickness
3. Intricacy of part contour
4. Type of die

• Small dies, such as those for producing business- machine parts,

usually have a solid die block. Only for intricate part contours
would the die block be sectioned to facilitate machining.
• Large die blocks are made in sections for easy machining,
hardening, and grinding.

8
• Figure below show a photograph of a die block for a large piercing
die. Large die blocks such as this one are composed of sections
for easier machining, hardening, and grinding. Observe that each
section is provided with working holes, that is, holes which
engage punches to perform cutting operations on the material
and with screw and dowel holes that fasten each section to the
die holder.

Die block for a large piercing die 9

Applying The Die Block
• Figure below shows a method of applying a die block to a die.
Machined into the die block (lower left illustration) are blanking
opening C and piercing holes D. Holes E, located at each
corner, are tapped completely through, and two dowel holes F
are reamed completely through the block.

Method of applying a die block 10

a. DIE BLOCK
• Construction component
housing the opening and
receiving punches.

i. Die Opening Profile

ii. Fastening To The Die Shoe
iii. Sectioned Die
iv. Calculation Of Die Block Dimensions

11
a. Die blocks
i. Die Opening Profile
a) Gives the highest quality workpiece, the most expensive.
Blanking parts having complex contours with greater accuracy.
b) Making small parts with low accuracy.
c) The simplest, making relatively large parts.
d) To punch small-diameter (d < 5 mm) holes.

12
a. Die blocks
ii. Fastening To The Die Shoe
a) Socket head screws are inserted from the
bottom of the die shoe into threaded holes
in the die block.Dowels are used to prevent
a shift in the position of the block.
b) Held in the retainer (has a shoulder)
c) Pressed into the retainer (has no shoulder)
d) Fastened into the retainer with a ball and
screw
e) A bushing is used at the bottom a)

13
a. Die blocks
iii. Sectioned Die
Workpiece- large,
Die opening - complicated,
Contours - difficult to machine

14
a. Die blocks
iv. Calculation Of Die Block dimensions
A=a+2e,
B=b+2e.
Rectangular:
Fl
σ s = 0.75 2
≤ σ sd
( B − b) H
Circular:
2.5 F  2d 
σs = 
 1−  ≤ σ sd
H  3d 0 

15
b. Punch and punch plate

PUNCH
Main consideration when design:
• Do not buckle;
• Be strong enough to withstand the stripping force;
• Not be able to rotate as a result of the cutting action.
i. Punch Face Geometry
ii. Methods For Assembling Punches
iii. Punch Calculations
16
Punches
i. Punch Face Geometry
• Flat punch-double bevel die
• Concave punch-flat die
• Bevel punch-flat die
• Flat punch-concave die

a) Flat, b) Concave, c) Bevel, d) Double bevel 17

Punches
ii. Methods For Assembling Punches
Backing plate: P=F/A>Pd
iii. Punch Calculations
• Compression stress:
• Buckling calculation:

π 2 EI min
lmax =
4 LT (0.8UTS )
π 2 EI min
lmax = 2.8
4 LT (0.8UTS )
18
How to Design Punch Plates
By J.R. Paquin
From Die Design Fundam entals, 3rd Edition

INTRODUCTION

• Punch plates hold and support piercing, notching, and cut-off

punches.
• They are usually made of machine steel, but can also be
made of tool steel that has been left soft for high grade dies.
• Punch plates range from small simple blocks for holding
single piercing punches to large, precision- machined plates
for holding hundreds of perforators.
• Important design considerations include:
1. Adequate thickness for proper punch support.
2. Good doweling practice to insure accurate location.
3. Sufficient screws to overcome stripping load.
19
METHODS OF DESIGNING AND APPLYING PUNCH PLATES
Design Conception :
Punch Plates for Single Punches
• A punch plate for holding a single punch (Figure below) is made square and
with sufficient thickness for good punch support.
• Two socket cap screws, applied at the corners, resist stripping pressure,
while dowels at the other two corners provide accurate location.
• Minimum distance from plate edges to screw centers A is 1 1/2 times screw
diameter B.

Punch plate for a single punch. 20

c. Pilot, strippers and pressure pad
Pilots
What is the definition of pilot?
• A long, slender punch with a rounded tip used to position the
metal sheet by entering a previously formed hole. Pilots are
longer so that they enter the sheet before other tools form the
metal.

Pilot Nut

Blanking Punch
Pilot

Pilot in fully descended position accurately locates the strip 21

Pilots
• Pilots are used in progressive dies. In the design of progressive dies,
the first step is to establish the sequence of operations. In this
sequence, the piercing operations are placed first.
• After the holes have been pierced, these holes are used for piloting the
blanking punches so that the blank formed is truly concentric to the
already punched hole.
• This piloting is achieved by means of pilots secured under the blanking
punch. To be effective the pilot must be strong enough to align the
stock without bending.
• Pilots are made of good grade of tool steel heat treated to maximum
toughness and to a hardness of 56 to 60 Rockwell C.

carbide pilots

Pilot Punches 22
Types of pilots: there are two types of pilots:
(a ) Direct pilot:
– Pilots which are mounted on the face of a punch are called direct pilots.
The pilot holder is generally a block of steel which can be fastened to
the punch holder.
(b) Indirect pilot:
– Such pilots are well guided through the hardened bushes in the stripper
plate.

23
Strippers
• After a blank has been cut by the punch on its downward stroke, the scrap
strip has the tendency to expand. On the return stroke of the punch the
scrap strip has the tin deny to adhere to the punch and be lifted by it. This
action interface with the feeding of the stroke through the die and some
device must be used to strip the scrap material from the punch as it clears
up the die block. Such a device is called “stripper” or stripper plate.

24
How to Design Strippers
By J.R. Paquin
From Die Design Fundam entals, 3rd Edition

INTRODUCTION

• Stripper plates remove the material strip from around blanking and
piercing punches.
• Severe adhesion of strip to punches is characteristic of the die
cutting process.
• Because of their low cost, solid strippers are the most frequently
used type, particularly when running strip stock.
• Spring strippers, though more complex, should be used when the
following conditions are present:
1. When perfectly flat, accurate blanks are required, spring
strippers flatten the sheet before cutting begins.
2. When very thin material is to be blanked or pierced, to prevent
uneven fracture and rounded blank edges.
25
 3. When parts are to be pressed from waste strip left over from
other operations, spring strippers provide good visibility to the
operator for gaging purposes.
4. When stripping occurs immediately, small punches are not as
subject to breakage.
5. When conducting secondary operations, such as in piercing dies,
increased visibility provided by spring strippers allows faster
loading of work and increased production.

• Stripper plates may be made of cold-rolled steel if they are not to be

machined except for holes. When machining must be applied to clear
gages, the plates should be made of machine steel, which is not as
subject to distortion.

26
Pad
• A pad is simply a pressure-loaded plate, either flat or
contoured, that holds, controls, or strips the metal during the
cutting and forming processes.
• Several types of pads are used in stamping dies. Depending
on their function, pads can be made from soft low-carbon
steel or hardened tool steel.
• Contoured pads must fit very closely to the mating die
section.
• Precision requirements determine whether the pads are
positioned with guide pins and bushings or left unguided.

Pad Guide Block Pad Guide Block Conner Guide Type27

Stripper Pads/Plates
• Stripper pads are flat or contoured spring-loaded plates that pull, or
strip, the metal off the cutting punches (see Figure 1).
• When it is cut, metal naturally tends to collapse around the body or
shank of the cutting punches; this is especially true during piercing.
The stripper pad surrounds the cutting punches and mounts to the
upper die shoe.

Figure 1 : Keys locate and heel die sections and components. 28

Stripper Pads/Plates
• As the punch exits the lower die, the spring-loaded pad holds the metal
down flush with the lower die section, which allows the cutting punches to
withdraw from the sheet metal or piece part.
• Often stripper pads are inserted with a small block of steel called a pad
window. This pad window usually is small and lightweight and can be
removed easily to allow the die maintenance technician to remove the ball
lock-style pierce punch from the retainer without removing the entire
stripper pad. Stripper pads also function to hold the metal flat or to the
desired shape during the cutting process.

Figure 1 : Keys locate and heel die sections and components. 29

Pressure Pads/Plates
• During the wipe bending process, the metal must be held down tightly
to the lower die section before the forming punch contacts the metal.
• Pressure pads must apply a force that is at least equivalent to the
bending force (see Figure 2).
• Most pressure pads use high-pressure coil or gas springs. When loaded
with very high-pressure springs, contoured or flat pads also can form
sheet metal. These pad types often are referred to as power punches.

Figure 2
During the wipe bending process,
the metal must be held down
tightly to the lower die section
before the forming punch contacts
the metal. Pressure pads must
apply a force that is at least
equivalent to the bending force.

30
Draw Pads
• Draw pads control metal flow during the drawing process (see Figure
3). In drawing, the amount of pressure, or downward force, exerted
on the sheet metal determines how much metal is allowed to flow and
enter the draw die cavity. Too much pressure may stop the metal from
flowing and cause splitting; too little downward force may allow excess
metal to flow inward and cause loose metal or wrinkling.
• Draw pads, often referred to as binders or blank holders, usually are
made from hardened tool steel. They can be flat or contoured,
depending on the piece part shape. Most drawing dies use a single
draw pad; however, in special cases, some use two.

Figure 3
Draw pads control metal flow
during the drawing process.

31
d. Force Mechanism Involved
In Die Operations
• Power presses:
– Mechanical Press,
– Hydraulic Press
– Hydro-Mechanical
Press

• Most pressworking operations performed with

conventional punch-and-die tooling (Custom-designed for
particular part)
• The term stamping die sometimes used for high
production dies. 32
Power and Drive Systems
• Hydraulic presses - use a large piston and cylinder to
drive the ram
– Longer ram stroke than mechanical types
– Slower than mechanical drives
– Suited to deep drawing

• Mechanical presses – convert rotation of motor to linear

motion of ram
– High forces at bottom of stroke
– Suited to blanking and punching

33
Mechanical Press
• A mechanical press brake uses a motor, flywheel and
eccentrics to convert the rotary motion of the motor and
flywheel into a vertical or reciprocating motion for the
punch/ram.
 Advantage: High speed flywheel rotation
allows a large number of cycles per minute.
When the flywheel approaches stroke
bottom, it often has enough momentum to
drive the dies beyond the rated capacity of
the press.
 Disadvantage: at the exact bottom point, the
tonnage capability of the press is limited only
by the capacity of the frame. This may cause
tool damage or/and locking of the press at
the Bottom Dead Center (BDC).
34
Hydraulic Press
• Hydraulic Press utilizes a motor and a pump to move
hydraulic oil into the top of the cylinder to exert pressure
to move the punch/ram. The tonnage of a hydraulic press
brake is directly proportional to the oil pressure and the
area of the piston under pressure.

Advantage: The punch speed

can be controlled easily by
adjusting the oil flow.

Disadvantage: Compared with

mechanical press, fewer cycles
per minute, and no additional
tonnage capability available.
35
Hydro-mechanical Press

• A single hydraulic cylinder

powers a mechanical linkage
system to bend, punch or
form material (A press in
which the forces are created
partly by a mechanical
system and partly by a
hydraulic system).

36
Stamping Press

Components of a typical mechanical drive stamping press

37
Types of Stamping
Press Frame
• Gap frame
– Configuration of
the letter C and
often referred to as
a C-frame

• Straight-sided frame
– Box-like
construction for
higher tonnage

38
Gap frame press for sheet
metalworking (photo courtesy
of E. W. Bliss Co.); capacity =
1350 kN (150 tons)

39
Press brake (photo
courtesy of Niagara
Machine & Tool Works); bed
width = 9.15 m (30 ft) and
capacity = 11,200 kN (1250
tons).

40
Computer numerical control turret press (photo courtesy of Strippet, Inc.).

41
Sheet metal parts produced on a turret press, showing variety of hole
shapes possible (photo courtesy of Strippet Inc.).
42
e. Blank size
 Die size determines blank size Db
 Punch size determines hole size Dh
 c = clearance

43
e. Blank size

44
Example:
A blanking operation is to be performed on 2.0 mm thick cold rolled
steel (half hard). The part is circular with diameter = 75.0 mm.
Determine the appropriate punch and die sizes for this operation.
Hint:
For cold rolled steel, the clearance allowance or Ac is 0.075 and
clearance c = Ac . t

45
Solution:
Clearance:
Since a = 0.075, the clearance is given by,
c = 0.075(2.0) = 0.15 mm.
In blanking operation the desired diameter of the
part is equal to the diameter of the die.
In punching operation, the desired diameter of the
remaining hole is equal to the diameter of the punch.

Die diameter, Db = 75.0 mm.

Because we have a blanking operation and
diameter of the die = diameter of the part

Also:
Punch diameter, Dh = Db - 2c
= 75.0 - 2(0.15)
= 74.70 mm.
f. Bending Methods
• Bending is usually defined as "the plastic
deformation of a sheet metal along a straight
line".
Both compression and
• It is used to increase the rigidity of shaped parts tensile elongation of the
in pressworking operations. metal occur in bending.

• To produce a bend in a finished part, the yield (Max stress)

point of the material must be exceeded. (Zero stress)

• If the bending force does not exceed the yield (Max stress)

strength of the material, the part will return to

its original shape (on removal of the load).
• Elastic recovery or springback will occur when
• Residual stresses = stiffness of the material

47
f. Bending Methods

V-bending Edge-bending
48
g. Bending allowances and bending pressure
Bend Allowance
• It is used to determine the exact length of a bend (length of the true-
neutral axis of the bend).
• It is the arc length of the true-neutral axis of the bend.

 The neutral axis is 1/3-stock

thickness from the inside Bend allowance

radius of the bend for inside

radii of less than twice the
stock thickness (most of the
metal is stretched rather than
compressed). Bend angle

 The neutral axis is 1/2-stock

thickness from the inside
radius of the bend for inside
radii of greater than twice
the stock thickness.
49
Bend Allowance Formula
α
=B 2π ( R + K ba t )
360
where B = bend allowance in mm along natural axis;
α = bend angle, deg (this is usually the supplementary angle of the angle of bend);
R = bend radius in mm;
t = stock thickness in mm; and
Kba is factor to estimate stretching (ba stands for bend allowance)
If R < 2t, Kba = 0.33
If R ≥ 2t, Kba = 0.50

 Notice that the formula is written based on the fact that S = rө, &
ө = 2πα / 360 in radian.

50
Springback
• Increase in included angle of bent part relative to included angle of forming tool
after tool is removed.
• Because all materials have a finite modulus of elasticity, plastic deformation is
followed by elastic recovery upon removal of the load. In bending, the recovery is
known as springback.
• In other words the reason for springback:
• When bending pressure is removed, elastic energy remains in bent part,
causing it to recover partially toward its original shape

At this stage,
residual
stress
forces are
balanced
by the
material’s
stiffness.

51
Bending Force:

52
h. Percent reduction, depth of draw, drawing force

Drawing
Draw dies utilize a special
pressure-loaded plate
or ring called a draw
pad or blankholder to
control the metal's flow
into the cavity.
This plate prevents the
metal from wrinkling as
it flows into the cavity.
Increasing or
decreasing the
pressure exerted under
the pad also controls
how much metal feeds (a) Drawing of cup-shaped part: (1) before punch
contacts work, (2) near end of stroke; (b) workpart:
into the die. (1) starting blank, (2) drawn part.

53
Clearance in Drawing
Sides of punch and die separated by a clearance c given by:
c = 1.1 t
where t = stock thickness

In other words,
clearance c is about
10% greater than
stock thickness

54
Tests of Drawing Feasibility
• Drawing ratio
• Reduction
• Thickness-to-diameter ratio

Successful deep draw progression

55
Drawing Ratio DR
Most easily defined for cylindrical shape:
Db
DR =
Dp
• Db = blank diameter;
• Dp = punch diameter
• DR Indicates severity of a
given drawing operation
• Upper limit: DR ≤ 2.0
Db

Dp
Top view Usually Db =< 2Dp

56
t/Db and Reduction r
Thickness-to-Diameter Ratio = Thickness of starting
blank divided by blank diameter
• Desirable for t/Db ratio to be greater than 1%
• As t/Db decreases, tendency for wrinkling
increases

Reduction r = Defined for cylindrical shape:

Db − Dp
r =
Db
 Value of r should be less than 0.50

57
h. Percent reduction, depth of draw, drawing force

58
h. Percent reduction, depth of draw, drawing force
Example:
A cup is to be drawn in a deep drawing operation. The height of the cup is 75
mm and its inside diameter = 100 mm. The sheet metal thickness = 2 mm.
If the blank diameter = 225 mm, determine:
(a) drawing ratio,
(b) reduction, and
(c) thickness-to-diameter ratio.
(d) Does the operation seem feasible?

Solution:

59