PROCEDURES OF CALC ULATING A PROGRESSIVE DIE

Step 1: Part Specification

Step 2: Scrap-Strip Development
Step 3: Differentiation between Blanking and Piercing
Step 4: Punch and Die Radial Clearances
Step 5: Angular Clearances
Step 6: Maximum and Actual Shearing Forces and penetration to fracture: Strip Shear Strength
Step 7: Force Reduction: a. Angular Shear andb. Off-setting
Step 8: Calculation of the Centre of Pressure
Step 9: Die and Die-Block Calculations: a. Thickness, b. Margin, c. Land Height
Step10: Punch Calculations: Forces, Strength, and Buckling
Step11: Min. Piercing Diameter.
Step 12: Stripper Calculations: a. Force, b. Type c. Dimensions
Step 13: The Distance between Nests
Step 14: Springs or any other mean of applying Forces
Step 15: Selection of Pilot
Step 16: Selection of Finger Stop locations
Step 17: Selection of Automatic Stop type and location
Step 18: Shanks
Step 19: Full-Dimensions of Punches and Dies: a. Nominal dimensions, b. Radial Clearances,
c. Angular Clearances d. Tolerances
Step 20: Selection of Bushes.
Step 21: Die-Set Selection According to Accuracy and the Part Dimensions
Step 22: Tool Materials Selection and the Bill of Materials
Step 23: Special Tools.
Step 2 Scrap-Strip Development
 Step 4: Radial Clearance
(Clearance between. Shearing Punch & Die)
Transformer Steel
Steel sheet in Steel Brass sheet Copper AICuM g-
Sheet
Sheet stamping sheet, Pure alloy, i.e.
hard,
thickness quality normal with low Si with high aluminumduralumin
soft Half hard soft half -
(hard) (half hard) content Sicontent soft
hard
0,25 0,02 0,05 0,015 0,01 0,01 0,015 0,015 0,02 0,008 0,02
0,04
0,50 0,035 0,03 0,03 0,02 0,025 0,03 0,03 0,025 0,01
(0.05)
0,06
0,75 0,05 0,045 0,04 0,03 0,03 0,04 0,04 0,05 0,015
(0,07)
0,05 0,08
1,00 0,07 0,05 0,04 0,04 0,05 0,05 0,07 0,02
0,06 (0,10)
0,06 ,
1,25 0,09 0,075 0,06 0,05 0,05 0,06 0,06 0,09 0,03
(0,12)
0,075 0,12
1,50 0,10 0,05 0,06 0,06 0,075 0,075 0,11 0,04
0,09 (0,15)
0,09 0,14
1,75 0,12 0,09 0,07 0,07 0,09 0,09 0,13 0,05
, (0,17)
0,13 0,105 0,16
2,00 0,105 0,08 0,08 0,105 0,105 0,15 0,06
0,14 0,12 (0,20)
2,25 0,16 0,14 0,11 0,22
0,16 0,13 0,19
2,50 0,13 0,11 0,11 0,13 0,13 0,17 0,08
0,18 0,15 0,25
2,80 0,2 0,17 0,14 0,28
3,00 0,21 0,18 0,16 0,14 0,14 0,16 0,16 0,20 0.1 . 0,22
 , 0
0,23 0,20 0,17
0,25
3,50 0,25 0,18 0,20 0,22 0,25 0,35
0,21
3.80 0,27 0,23 0,19 0,38
0,30 0,21 0.40
4,00 0,24 . 0,28 0,30
(0,28) 0,325 (0,20)
(0;24)
4,30 0,30 0,26 0,22 0,43
0,37 0,41 0,27
4,50 0,30 0,34 0,37 0,45
(0,32) (0,27) (0,23)
4,80 0,34 0,29 0,24 0,48
0,45 0,50 0,325
5,00 0,36 0,42 0,45 0,50
(0,36) (0,30) (0,25)
5.50 0,53 0,62 0,40 0,43 0,50 0,53
6.00 0,62 0,75 0,48 0,51 0,60 0,62

s ab
Table 2. Guiding values for the cutting edge clearance p , and Sp2, in relation to strip th ckness and
shear resistance

Shear resistance τB (N/mm2)

Up to >250 to >400 to >400 to
>600 Up to 250 >250 to 400 >600
250 400 600 600
Strip
thickness
in mm

0,1 0,002 0,003 0,004 0,005 0,003 0,004 0,005 0,006

0,2 0,003 0,005 0,007 0,01 0,006 0,008 0,010 0,012
0,3 0,005 0,008 0,011 0,015 0,009 0,012 0,015 0,018
0,4
0,5 0,01 0,015 0,02 0,025 0,015 0,02 0,025 0,03
0,6
0,7
0,015 0,02 0,03 0,04 0,025 0,03 0,04 . 0,05
0,8
0,9
0,02 0,03 0,04 0,05 0,03 0,04 0,05 0,06
1,0
0,03 0,04 0,05 0,07 0,05 0,06i 0,08 0,09
2,0 0',05 0,07 0,09 0,08 0,10 0,12
2,5 0,04 0,06 0,09 0,11 0,08 0,10 0,13 0,15
3,0 0,07 0,10 0,13 0,12 0,15 0,18
3,5 0,05 0,08 0,11 0,15 0,10 0,14 0,18 0,21
4,0 0,06 0,09 0,13 0,17 0,12 0,16i 0,20 0,24
4,5 0,07 0,11 0,15 0,19 0,14 0,18 0,22 0,27
5,0 0,08 0,13 0,17 0,21 0,16 0,20 0,2 5 0,30
 Shearing through different die blocks
Material Thickness Land height Δ Angle α
Type of die Applications
(mm ) h, (mm ) ( ' ) ( ° )

≤ 0.5 h=3-5 10

For blanking with

0.5 - 5.0 h = 5 - 10 20 3-5
higher accuracy
5 - 10 h = 10 - 15 30

0.1 - 0.5 10 - 15
For blanking small 0.5 - 1.0 15 - 20
parts with medium 1.0 - 2.0 0.0 20 - 30
accuracy 2.0 - 4.0 30 - 45
4.0 - 6.0 45 - 60

Used for blanking

great parts and the
- --- --- ---
parts that are
ejected in the punch

≤ 0.5 h=3-5 10
For piercing small
diameters up to 5 0.5 - 5.0 h = 5 - 10 20 ----
mm
5 - 10 h = 10 - 15 30
 Ste p 6: Shearing Forces

Max. shearing force = L. s . W

The max. force for rectangular form = ( 2a+2b) s. W
The max. force for round form = Π d s W

L = cutting perimeter (mm), W strip shear strength (N/mm2), s= strip thickness (mm)
Table 1 The percentage Penetration (p) for several materials and thicknesses

Material thickness [mm]

Material
< 1.0 1.0- 2.0 2.0- 4.0 >4
Soft steel
W = 250 - 350 N/mm2
0.75- 0.70 0.70 - 0.65 0.65- 0.55 0.50- 0.40
W = 300 - 400 N/mm2
Half Hard Steel
W =350 - 500 N/mm2
0.65- 0.60 0.60 - 0.55 0.55- 0.48 0.45- 0.35
W = 400 - 550 N/mm2
Hard steel
W =500 - 700 N/mm2
0.50- 0.45 0.45 - 0.40 0.40- 0.35 0.35- 0.20
W = 550 - 750 N/mm2
Aluminium
0.8 - 0.75 0.75 - 0.70 0.70- 0.60 0.65- 0.50
Kupfer (annealed)
 Tensile and Shear Strength o f Sheets
Ferrous Metals

Material DesignationMaterial no. Tensile strength σ l (N/mm2) Shear strength τ (N/m m2)

Steel for chains USt 35-2 1.0208.5 350...420 280...340

USt 38-1 1.0217 380...450 300...360
Steel for bolts
USt 36-1 1.0201 340...420 270...340
USt10 1.0022.5 280...500 220...400
USt12 1.0330.5 280...420 220...340
Light sheet
USt13 1.0333.5 280...400 220...320
USt14 1.0336.5 280...380 220...300
St 37 1.0120 370...450 300...360
St 42 1.0140 420...500 340...400
Structurat steel St 50 1.0531 500...600 400...480
St 60-2 1.0543 600...720 480...580
St 70-2 1.0633 700...850 560...680
Ck10 1.1121 340...400 270...320
Case-hardening steel
Ck15 1.1141 370...450 300...360
Ck22 1.1151 420...500 340...400
Ck35 1.1181 500...600 400...480
Heat-treatable steel
Ck45 1.1191 600...720 480...580
Ck60 1.1221 700...850 560...680
16 MnCr 5 1.7131 550...700 440...560
Case-hardening steel 20 MnCr5 1.7147 600...750 480...600
15 CrNi 6 1.5919 600...750 480...600
25 CrMo 4 1.7218 600...750 480...600

Heat-treatable steel 34 CrMo 4 1.7220 600...750 480...600

34 CrNiMo 6 1.6582 650...800 520...640
30 CrNiMo 8 1.6580 700...850 560...680
 Non-Ferrous Metals
ile strength σl ear strength τ
Material Designation Material no.
(N/m m2) (N/m m2)
Aluminium AI 99,5 AI 99 soft 3.0205.26 70...100 60...80
AI 99,5 AI 99 semi-hard 3.0205.30 100...150 80... 100
AIMo 3 soft - 180...250 150...200
AlMg 3 sem i-hard 3.3535.26 220...270 180...220
AlMg 5 soft 3.3555.10 230...260 190...210
AlMg 5 sem i-hard 3.3555.26 250...300 2Q0...240
AlMg 7 soft 3.3575.10 300...350 240...280
AlMg 7 sem i-hard 3.3575.26 350...400 280...320
AlMg 9 soft - 320...380 260...300
AlMg 9 sem i-hard - 400...450 320...360
AlMgSi soft 3.2315.10 110... 130 90...100
AIMgSi age hardened 3.2315.72 280...350 220...240
Aluminium alloys
AISi 5 3.2345 120... 150 100... 120
AISi 12 3.2584 150...200 120...160
AIMn soft 3.0515.10 100...150 80...120
AIMn sem i-hard 3.0516.26 120...180 100...140
AlCu soft - 160...220 130... 170
AlCu sem i-hard - 380...450 300...350
AlCuMg soft 3.1325.10 170...250 140...200
AlCuMg age hardened 3.1325.51 400...480 320...380
AlCuNi anneale d - 180...220 140...180
AlCuNi unannealed - 380...420 300...330
MgM n - 190...230 170...210
Magnesium alloys
MgAI 6 - 280...320 250...290
Copper Cu - 210...240 200...230
Copper Alloys Tin bronze SnBz 6 2.1020.10 450...560 350...450
 Alu bronze AIB z4 - 300...400 240...330
CuZn 10 F 24 2.0320.10 290...350 240...300
CuZn 10 F 30 2.0320.26 350...430 300...370
CuZn 28 F 28 2.0260.10 250...300 200...250
ZnCu 1 - 200...300 160...250
ZnAI 1 - 180...250 150...210
i Sn - 35...40 30...35
Zinc Zn - 120...140 120...140
Nickel Ni soft - 400...450 32...36
Lead Pb - 200...300 20...30

Non-metallic materials

Material Shear strength τ (N/mm2) Material Shear strength τ (N/mm2)

Paper and cardboard 20... 50 Birch particle board 20...30
Resin board 70...90 Wood 10...30
Klingerit and similar 40...60 Celluloid 40...60
Synthetic resin laminated paper 100...140 Leather 7
Resin-bonded fabric 90...120 Soft rubber 7
Synthetic resin, pure 20...30 Hard rubber 20...60
Mica 50...80
Penetration to Fractu re
 Step 7: How to reduce the Forces
a) Using angular shear for the punch or the die

The shearing force (using shear) == S in (mm) * max.S̃hearing˜F̃orce

Shear + S in mm
 Step 8: Center of Pressure
The transfer of force from the ram to the workpiece should take place with no leverage and thus no
pullout torque
A torque effect of this kind would subject the press guides and the workpiece to further stresses and
lower the precision of the stamped parts. For this reason it is important that the punch holder is in the
correct position, in the central point (centre of gravity) of the force
As the force is calculated from the circumference and the material thickness, the central point of the
force is in the centre of gravity of the circumference line. This is why it is called the centroid.

Determining the centroid using the separate lines

 Determining the centro id
The circumference lines are divided into segments with known centroids. Then the product of the
segment distances and the segment lengths is found, these products are added together and this sum
is divided by the sum of all the segment lengths.
For all figures, a circumference line is always made up of the same basic elements. These basic
elements are: circles, arcs and straight lines.
The centroids of these basic elements must be known (see Table 18.3).

When piercing symmetric openings, the centroid is not determined from the centroids of the individual
lines, but from the circumferences of the symmetrical figures and the centroid of the area.
 Example:
Where: tooling arranged as in the sketch (Figure 18.4). Find: force centroid
 Step 9: Die-block Calculations
Table 1 Table 2 Table 3

Die block thicknesses for Die block thicknesses based Die block sizes
mild steel stock on blanking perimeter

Stock Die block Blanking Die block Stock Die thickness for 1 MPa
thickness thickness perimeter thickness thickness of shear strength
mm mm mm mm mm mm

Up to 1.50 22 - 25 Up to 75 20 0.25 0.05

1.5 - 3.0 25 - 30 76 - 250 25 0.50 0.10

3.0 - 4.5 30 -35 Over 250 30 0.75 0.14

4.5 - 6.0 35 - 40 1.00 0.18

Over 6.0 40 - 50 1.25 0.21

1.50 0.24

1.75 0.27

2.00 0.29

2.25 0.31

2.50 0.32
Example: Design a die block for blanking an 80 mm Table 4
diameter in 1 mm thick cold rolled C20 steel.
Expansion factors for die thickness
The shear strength for that steel = 390 MP a
Shearing load = 390*π*80*1 = 98.018 K N Cutting perimeter Expansion factor
mm
Case i: from Table 1,
Die thickness = 22 mm, Up to 50 1.00
Die opening to edge = 1.75*22 = 38.5 51 - 75 1.25
= 40 mm
76 - 150 1.50
Hence, die block is to be 160*160*22 m m
Case ii: from Table 2, 151 - 300 1.75
Perimeter of cut = 80*π = 251.327 m m 301 - 500 2.00
Die thickness = 30 m m
Die opening to edge = 55m m
Hence, die block is to be 190*190*30 mm
Case iii: from Table 3,
Die thickness = 0.18 * 390 = 70.2 m m
Expansion factor from Table 4 is 1.75
Die opening to edge = 1.75*70.2 =122.85 m m = 125 mm
70*330*330
 Another Meth od

9.2 DIE BLOCK S

A die block is a construction component that houses the opening and receives punches. These die
openings may be machined from a solid block of tool steel or may be made in sections. . The die
block is predrilled,tapped, and reamed, before being fastened to the die shoe.
9.2.1 Die Opening Profile
i opening profiles depend on the purpose and required tolerance of the workpiece. Four opening
profiles are shown in Fig. 9.1. The profile in Fig. 9. la gives the highest quality workpiece, but its
machining is the most expensive. Die blocks must frequently be resharpened to maintain their edge;
to allow a die block to be sharpened more times, the height of the die block h, needs to be greater
than the thickness of the workpiece. The value of h is given in Table 9.1. This kind of die opening is
used for blanking parts having complex contours with greater accuracy.
The die opening profile in Fig. 9.lb is used for making small parts with low accuracy. The angle of the
cone, a = 10’ to 20’ for material of thickness T< 1 mm, and a = 25’ to 45‘ for material of thickness T 2
(1 to 5)mm . For the angle to be correctly derived, the following relationship must be satisfied:
a ≤ tan-1 (A/2H)
where:
A = tolerance of workpiece,
H = height of die block.
The simplest die opening profile is the cylinder, as shown in Fig. 9.1~T.h is type of profile is used for
making relatively large parts. With this profile, after the part is cut out, it is pushed up and away from
the die
Thetwo-cylinder die opening profile, shown in Fig. 9. Id, is used to punch small-diameter (d ≤ 5 mm)
holes. The value of h can be taken from Table 9.1. The diameter of the larger cylinder needs to be
D = d +3 mm.
+3 mm.

Fig. 9.1 Types of die opening profile.

Table 9.1 Value of Dimension h Depends on Material Thickness T
Material thickness T (mm) < 0.5 0.50 5.1 - 10.0
Height h (mm) 3.0 - 5.0 5.10 - 10.0 10.1 - 15.0
9.2.4 Calculation of Die Block Dimensio ns
A die block for blanking and punching operations is loaded at force Z? About 40 percent of this force
isexerted in a way that would fracture the die block in the radial plane. However, the die block is
additionally loaded with the friction force produced when the b lanked or punched material is pushed
through the opening of the die. The calculations for the die block dimensions are very often simplified,
making use of two empirical formulas calculating only the thickness of the die block H, and the width
of the wall e (Fig.9.5). The height (thickness) H of the die block is calculated by the formula:

where: 𝐻 = 10 + 5𝑇 + 𝑎 + 𝑏 𝐶
T = material thickness,
c = constant whose value depends on the mechanical properties of the workpiece material andi
a , b = opening die dimensions, given in Table 9.2.
The wall thickness e is given by the formula:
e = (10 + 12T)+ 0.8H
UTS (MPa) 117 245 392 784
c 0.6 0.8 1.0 1.3
 ( a) ( b)
Fig. 9.5 Schematics for calculation of die block dimensions
Step 10 : Punch Calculations
 Step 11 : min. Piercing Diameter
The punch should have sufficient compressive strength so that it can apply necessary force required
during punching.
Let d = min. diameter of the hole (mm)
t = workpiece material thickness (mm)
τ = ultimate shear strength of the work material (N/mm2)
σy = yield compressive strength of the punch material (N/mm2)
P = Shearing force = ᴨ d t τ
Fc= compressive force of the punch = π d2 σy /4

π d2 σy /4 = π d t τ
d = 4 t τ / σy
The table below indicates the strength of some common materials:
Yield strength Ultimate Yield strength Ultimate strength
Material Material
(MPa) strength (MPa) (MPa) (MPa)
Steel Cast steel 400-850 500-850
Plain carbon 200-400 300-700 Aluminum 150-200 200-400
Free cutting 400-700 Brass 300-600
Spring steel 1500-1800 1700-2400 Bakelite 40-80
Low alloy 420-550 600-850 Rubber 10-70
High alloy 240-440 550-900 Copper 120-180 220-350
 min. Piercing Diameter

Normal Piercin g Piercing with guided

punc h
Materia l
Punch form

cylindrica l rectangular cylindrical rectangular

Steel sheet (high strength 1.3 s 1.0 s 0.5 s 0.4 s

Soft steel, brass 1.0 s 0.7 s 0.35 s 0.3 s

Aluminu m 0.8 s 0.5 s 0.3 s 0.28 s

Textolit and Pertinax 0.4 s 0.35 s 0.3 s 0.25 s

 Step 12 : Stripper Design
Strippers are of two types, fixed or spring-operated. The primary function of either type is to strip the
workpiece from a cutting or noncutting punch or die. A stripper that forces a part out of a die may also
be called a knockout, an inside stripper, or an ejector. Besides its primary function, a stripper may also
hold down or clamp, position, or guide the sheet, strip, or workpiece.
The stripper is usually of the same width and length as the die block. In the simpler dies, the stripper
may be fastened with the same screws and dowels that fasten the die block, and the screwheads will
be counterbored into the stripper. In more complex tools and with sectional die blocks the die block
screws will usually be inverted, and the stripper fastener will be independent.
The stripper thickness must be sufficient to withstand the force required to strip the stock from the
punch, plus whatever is required for the stock strip channel. Except for very heavy tools or large blank
areas, the thickness required for screwhead counterbores, in the range of 9.5 to 16 mm, will be
sufficient.
The height of the stock strip channel should be at least 1 % times the stock thickness. This height
should be increased if the stock is to be lifted over a fixed pin stop. The channel width should be the
width of the stock strip, plus adequate clearance to allow for variations in the width of the strip as cut,
as follows:
Stock thickness, mm. Add to strip width, mm
up to 0.040 2.00
0.040 to 0.080 2.40
0.081 to 0.120 2.77
over 0.120 3.175
If the stripper length has been extended on the feed end for better stock guidance, a sheet metal plate
should be fastened to the underside of the projecting stripper to support the stock This plate should
extend slightly in for convenience in inserting the strip. The entry edges of the channel should be
beveled for the same reason.
Where spring-operated strippers are used, the force required for stripping is 3500 times cut perimeter
times the stock thickness. It may be as high as 20 per cent of the blanking force, w hich will determine
the number and type of springs required. The highest of these values should be used.
Die springs are designed to resist fatigue failure under severe service conditions. They are available
in medium, medium-heavy, and heavy-duty grades, with corresponding permissible deflections
ranging from 50 to 30 per cent of free length. The number of springs for which space is available and
the total required force will determine which grade is required. The required travel plus the preload
deflection will be the total deflection, and will, determine the length of spring required to stay within
allowable percentage of deflection limits. As the punch is resharpened, deflections will increase, and
should also be allowed for.
STRIPPING FORC E
When spring strippers are used it is necessary to
calculate the amount of force required to effect stripping.
Stripping force is found by the formula:
Pstrippin g = L * T * 3.80 kN

where: L = Length of cut. In piercing operations this is

the sum of the cutting perimeter,
T = Thickness of stock, mm.
P = Force, in kN, to effect stripping
[1] Stripper Force
PStripper =kba* P
Where : P = Total shearing Forces, kg
Kab = factor from the following Table:
Strip thickness, Type of Shearin g
s Blanking or Piercing Piercing following Piercing with multi-
(mm) using one punch Blankin g dies
Up to 1 0.02 - 0.06 0.06 - 0.08 0.10 - 0.12
1 to 5 0.06 - 0.08 0.10 - 0.12 0.12 - 0.15
Over 5 0.08 - 0.10 0.12 - 0.15 0.15 - 0.20

[2] S tripper Force: When spring strippers are used it is necessary to calculate the amount of
force required to effect stripping. Stripping force is found by the formula :
P = L x T x 855 lb
Where : L = Length of cut. In piercing operations this is the the sum of the perimeters of all
perforator faces.
T = Thickness of stock
P = Force, in pounds, to effect stripping.
[3] M inimal Thickness of Stripper Plates: The thickness of a stripper plate can be calculated
by using the formula
 h =W+ 2t
3
where h = minimum stripper plate thickness, inch
W = stock width, inch
t = stripped material thickness
The result should be rounded up to the nearest fractional dimension in the eighths range,
such as 0.375 in., 0.50 in., 0.625 in., 0.750 in., and so on.
[4] Stripper Width:
B=W+C

Strip width (mm) Up to 1 1-2 2-3 Over 3

C (mm) 2.0 2.5
 STRIPPE RS

Descriptio n Drawing Description Drawing

The stripper plate has two

counterbored holes, usually 6
mm. deep. The punch holder
counterboring is deeper in
In this piercing die, the upper
ordert-apply the correct
portions of the springs are
initial spring deflection. Hole
retained in holes bored
edges are chamfered25x
through the punch plate. The
45°. In machining the
spring ends bear against the
counterbored holes, the
ground underside of the
stripper plate and the punch
punch holder.
holder are clamped together,
and the holes A are drilled.
These holes are then used as
pilots when counterboring.

Here, the springs are placed

around stripper bolts.
The pilots shown here
Although this method is
provide an excellent means
widely used, it is not
of locating the springs.
recommended for high-grade
dies.
 Standard "Stripper" spring
units allow removal of the
Standard rubber springs can
stripper plate- without
provide sufficient stripping
disturbing the springs. The
pressure, are low in cost, and
left-hand stripper is so
are easily applied. However,
installed as to prevent
they are adversely affected
sidewise movement of the
by pressworking compounds,
lower portion of the unit. The
and are indicated for short
right- hand unit is used to
runs only
hold the locating plug of the
unit to the stripper plate

This shows application of

springs to a blank-and-draw
i, where the pressure pad
bottoms in such a way that
This shows a bending die
the springs are entirely
used to form a flat part to
confined. In this case, the
channel shape. Shoulder
counterbored holes are
bolts limit stripper plate
chamfered at least 3.2 mm. x
travel, and the springs are
45°. Safety pins A are
placed around them. The
pressed into the dieholder. If
stripper bolts will hold the coil
a spring should break, these
if spring breakage occurs.
pins hold the fractured coil
and prevent it from getting
between the pressure pad
and the face of the die holder.
 An inverted compound die
Here, the stripper platei employs a spring-actuated
actuated by four pins A knockout in the upper die.
through one large die spring. The spring is confined in a
A springholder stud threads counterbored hole in the
into the dieholder unit, and is punch shank, and applies
adjustable pressure to the knockout
through pins.

This shows a method of

holding springs below the
dieholder, if there is
insufficient room for them
within the diesel. A housing is
screwed into a tapped hole,
and the confined spring
actuates the knockout.
 Step 13 : The width of the nest

Fig. 1 Calculation of the distance between nests with:

a ) spring guidance b) rigid guidance
B = actual strip width,
A = distance between guidance (nests) on the die,
D = dimension of the cut perpendicular to the nests,
b = min. dimension of the bridge between blanks,
z = max. dimensions between strip width and guidance,
ΔB = one sided min. tolerance of the strip width
 Table 1 calculated relationships of the strip width
Strip guidance Actual Strip width Distance between guiding nests
A = B+ z
With spring guidance (Fig.1a) B = D + 2b + ΔB
= D+- 2 b +- ΔB + z
A = B+ z
With rigid guidance (Fig. 1b B = D + 2 ( b+ ΔB -) +z
=D+ - 2 ( b +- ΔB + z )

Table 2 Strip width (mm) for rigid guidance (higher values are for thicker strips)
Strip width [mm] One row offset
Up to 100 0,5 - 1,0 1,5 - 2 2
over 100 1,0 - 1,5 2-3

Table3 Width tolerance ΔB (mm) for low carbon steel strip

Material thickness Normal accuracy Higher accuracy
[mm]
Strip up to 100 Strip over 100 Strip up to 100 Strip over 100
[mm] [mm] [mm] [mm]
0,05 - 0,5 -0,3 -0,5 -0,15 -0,25
0,55 - 1,0 -0,4 -0,6 -0,3 -0,4
over 1,0 -0,6 —0,8 -0,4 -0,6

spring guidance nest can not be used with strip thickness lower than 0.3 [mm].
Step 14: Sprin gs
Step 15: Pilot
Step 16: Finger Sto ps, Shape and Locations
 STEP 17 : AUTOMATIC STOPS
When feeding the stock strip from one stage to another, some method must be used to correctly locate and stop
the strip
Automatic stops (trigger stops) register the strip at the final die station. They differ from finger stops in that they
stop the strip automatically, the operator having only to keep the strip pushed against the stop in its travel through
the die
e3-20 shows automatic stop designs ranging from simple pin to escapement type mechanisms.

View C. If no scrap is left between

View A illustrates a pin stop suitable View B shows the method of blanks, as in a double-action blank-
for low- to medium-production dies. locating the pin stop so that it bears and-draw die, a bent pin stop is
When the ram ascends, the strip against the blank opening upon an suitable. The sharpened point of the
clings to the punch, is stripped, and angular edge, so that the strip is stop faces the incoming strip, thus
then is fed until the pin hits the edge crowded against the back stop and thrusting the fins aside and stopping
of the hole accurate piloting is obtained the strip when contact is made at the
opposite side of the hole.
View D presents a design in which
a combination stop and backup block
View F. Overhanging stops are
locates the strip and prevents View E shows another solid stop.
useful when the press cannot bei-
deflection of the cutoff punch of this The part, after cutoff, can drop
clined, or when the size of the die or
two-station die. The part, a flat through a hole in the die set to a box press will not allow partremoval
spring, drops to the punchholder and directly beneath through the bolster plate.
slides by gravity to the rear of an
inclined press.
View G. If the strip must be cut to
View H. A notching strip is ideal for
accurate width, a trimming stop can View I. Double trimming stops
automatic stopping of the strip when
be used against the shoulder formed reduce the extent of the waste end.
the first operation partially blanks the
by the trimming punch. The length of Stop A and punch B are used during
sides. When the strip is advanced, it
the trimming punch is made equal to starting and normal running of the
is automatically positioned by the
the feed distance for part length. The strip. Stop C and punch D cut the
left edge of the punch overlaps the shoulder left by the blanking punch. last two parts when the end of the
previous cut to prevent leaving a fin The only extra cost is that for the strip is reached
on the strip stop.
 View L. Commercial trigger stops
are widely used for high-speed
View K. Punch stops are applicable operations. The design shown
View J. A latch stop, like a pin stop,
to many types of cutting dies. A consists of gage pin A which fits
is ideal for low-production jobs, but
round eccentric protrusion on a loosely in a hole in the stripper, and
should not be used on a high-speed
round or square punch body spring B that normally holds up lever
press. The latch pivots on a pin and
is held down by a spring. In use,the contacts the scrap bridge. The ram C. The strip advance crowds the
strip is moved until the scrap bridge descent causes the punch body to gage pin to the slanted position
has lifted the latch and it drops into cut out a portion of the scrap strip. shown. Ram descent causes pin D
the hole. Then the strip is pulled Upon ram ascent the strip is to push the lever down, and the gage
advanced, the eccentric passing pin is lifted above the. strip. Spring E
back until the bridge is against the
through the gap until contact is made now pushes the gage pin on top of
latch
with the next scrap bridge. the scrap bridge. Upon forward
movement of the strip, the gage pin
falls inside the hole just blanked
 View O. Spring torsion and
compression combine to operate a
stop. Ends of spring A are entered in
drilled holes in stop plunger B and
Views M and N. Web trigger stops can be applied to simple blanking dies
cap plug C. At assembly the plug is
or to compound dies. At ram descent, stop A is lifted out of the strip by
rotated to apply sufficient torque so
actuating pin B. Spring D rocks sideways so that it will fall onto the scrap at
that stop D is kept firmly in contact
ram ascent. This permits the strip to be advanced until the cut edge resets
with the die block. Strip advance
the stop.
slightly compresses the spring. At
ram descent, pin E trips the stop and
spring A pushes it forward to drop
on the scrap bridge.
View P. An escapement stop View R. A notch in the strip edge
View Q, Long, high-speed runs on
eliminates misfeeds if the stock is serves for strip location in a tw o-
heavy stock often require an auto-
fed forward to the stop every time. stage piercing and blanking die. At
matic toe stop. Lever A pivots on pin
Rocker arm A lifts the square toe the first station a small notch is cut in
B to rock toe C, on pin D, above the
stop B above the strip, when struck the strip edge. At the second station,
strip surface, when the ram
by actuator C attached to the punch actuator A enters the cam hole in
holder. •Now spring-operated detent descends. Spring F, acting through
stop B to retract the toe from the
D holds the stop up, until the plunger G, pushes the toe until the
notch. Spring C swings the toe
advancing scrap bridge strikes the heel on top rests on the lever. When
the ram goes up, the toe falls on the counterclockwise so that it comes to
cam surface H on the rocker arm. rest on the strip edge. Upon strip
Thereupon, the toe is dropped in scrap bridge. It eventually contacts
the cut edge, when the strip is advance, the toe springs into the
front of the cut edge, just as the next notch just cut and stops the material
ram descent commences. advanced, thereby resetting the stop.
in the correct position
 STEP 18 : SHANKS
A B C

All types of ordinary tools intended

for cutting operations use standard
shouldered shanks. Such a shank
is press-fitted into a specially
Threaded shanks are used in
bored hole of the upper shoe. In In large-size tools the shanks are
drawing and bending tools with
cases where accurate alignment of threaded and shouldered.
guide posts.
the tool is of special importance,
the shank forced in the shoe is
given additional polishing after
assembly.
 D E F

When blanking out small-size

In large-size dies with guide posts, accurate parts from thin sheets
where the shank serves for A shank for screwing the punch of and when using tools with
centering, or in dies whose design a drawing die (the punch cemented-carbide punches and
allows no other shanks, use is installed directly into the shan k) dies or with ball-bearing guides,
made of shanks of the type shown is shown above. use is made of self-aligning
above. ("floating") shanks and spherical
inserts
 G H I

For heavy-duty work in bending Adapter Shanks

tools, fork-type shanks of the
If the tool shank does not fit in Split adapter bushings
design shown above are
applied the press slide hole,
Step 19: Tolerances
 Manufactured Manufactured
Process and the type of the part dimension of th e diedimension of the punch
Blankin g:
δ
dimensions of the finished Dd=(D-Δ) Dp = (D-Δ-C)-δp
Parts that are part: D-Δ
touching and
Piercin g:
tolerated δ
dimensions of the finished
Dd=(d+Δ+C) dp= (d + Δ)-δp
part: d+Δ
Blankin g:
dimensions of the finished Ddfe = D+ '
Dpfe =(D-C)-δ'p
Parts that are not part: D
touching tolerated Piercin g:
dimensions of the finished ddfe =(d+C) +δ'd dpfe = d-δ'p
part: d
where:
Dd ; Dp; dm; dp Manufacturing dimensions for die and punch with the given tolerance
(D+Δ) or + for the finished parts,
D Dimension of the finished part,
δd; δp; ' ; δp Manufacturing tolerance for the die and punch respectively,
C Clearance between die and punch,
A Tolerance of the finished part,
d Dimension of the pierced hole,
Ddf e ; Ddfree e
ddf e ; dpf e Manufacturing dimensions for die and punch without.
Because of wear of cutting die and punch, the manufacturing
tolerance for blanking should be selected as: δd(ratio) = Δ - δd. For
piercing, the amount of tolerance should be: -δp(ratio) = Δ - δp It is,
therefore, advisable, if the mass production of shearing die and
punch with respect to the tolerance of the finished part Δ fully
exploited.
Manufacturing tolerances [mm] for replaceable round cut
and piercing punch and cutting dies
Min.both sides Manufacturing tolerance
Material
clearance bet.punch
thickness i + δd Punch -δp
and die
[mm] µm µm
[mm]
, 0,02 0,015 0,01
, 0,03 0,02 0,01
, 0,05 0,02 0,012
, 0,06 0,025 0,015
, 0,10 0,03 0,02
, 0,14 0,04 0,02
, 0,20 0,05 0,03
, 0,24 0,06 0,03
, 0,40 0,08 0,04
, 0,60 0,10 0,05
, 0,80 0,12 0,06
, 1,30 0,16 0,08
1 , 1,80 0,20 0,10
1 , 2,40 0,24 0,12
The specified tolerances refer to the diameter to 50 mm or material
thicknesses that are not listed in the table, must be interpolated.
Step 20 : Selection of Bushes
Step 21 : Selection of Die-set
 Step 22: Tool Materials Selection
Tool Materials
The tool material should be selected carefully in respect of the following properties
1) Wear resistance
2) Toughness
3) Resistance to compression and tension
4) Ability to get hardened.
Usually punches, die plates, and pressure plates are hardened between HRC 55 to HRC 62.
 The percentage composition of some of the to ol Steels
STEE L C Mn Si Cr V W Mo Co
W1 1.0
W2 1.0 0.25
S1 0.5 1.5 2.5
S2 0.5 1.0 0.5
O1 0.9 1.0 0.5 0.5
O2 0.9 1.6
D1 1.0 12.0 1.0
D2 2.25 12.0 1.0
M1 0.8 4.0 1.0 1.5 8.5
M2 1.3 4.0 4.0 5.5 4.5
T1 0.7 4.0 1.0 18.0
T2 0.85 4.0 2.0 18.0
W = Water hardened steels S = Shock resisting tool steels
O = Oil hardened steels D = High carbon high chromium steels

They combine high wear resistance with deep hardening properties.

M,T=These are general purpose grades of high speed steel.
 CONSIDERATION IN P RESS TOOL DESIGN
The various points to be considered during press tool design are as follows:
x All parts which have to withstand heavy forces and repeated blows should be of proper strength.
x Tolerances on each part of press tool should be accurate.
x There should be safety and ease of use for both operator and setter.
x Sufficient space should be available for feeding devices and auxiliary stock devices.
x Die sets should be made of proper materials.
x Thickness of punch-holder and thickness of 'die shoe should be in line with the strength
requirement aid allowable press shut height.
x Length of guide posts or pins should be specified.
x Shank diameter should be specified.

A properly designed punch-die set have the following advantages

1. A lignment of punch and die members.
2.Improved quality of the part produced.
3. M inimum set up time.
4. G ood positioning and fastening of work piece.
5.Increased life of punch-die set.
6. Less maintenance.
Design Procedure for Blanking Die
The various steps involved in design of blanking die are as follows:
1. P repare a sketch incorporating all elements of die to be used.
2. D etermine punch, and die opening diameters considering whether the operation is blanking or
piercing
3. D esign the die block and select proper die set.
4. P rovide arrangement for fixing the punch in the punch retainer.
5. P rovide stock stop.
6. P repare following drawings.
a) Sectional front view of punch in position.
b) Bottom view of punch showing position and method of securing punch, dowels, and screws
to the punch plate through the back up plate and retainer.
c) Plan of lower portion showing die block, die shoe, stripper, stop pin positions and method of
securing each.
d) Side sectional elevation of punch and die assembly.
7. S tate type of press and capacity of press.