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doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Figure 2. A slug between the lower die shoe and the bolster: (A) before the run; (B) during production; (C) the damage remains after the next dieset. Smith & Associates.
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Figure 3. A slug under the die shoe forces the slide to tip out-of-parallel with the bolster. Smith & Associates For general presswork, the accepted maximum tolerance for slide to bolster parallelism is 0.001" (0.025 mm) per foot (305 mm). Precision dies for cutting silicon steel used in electrical motor production require an even more precise out-of-parallel tolerance. A single 0.030" (0.76 mm) slug under one end of a three-foot (914-mm) long die shoe will cause an out-of-parallel condition that will exceed the generally accepted tolerance by a factor of ten. Figure 3 is an exaggerated view of a slug under a die shoe.
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Figure 4. Example of damage to a cutting die caused by an out-of-parallel caused by a slug or other foreign object under the die shoe. Smith & Associates
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Figure 5. Close-up view of cutting edge damage shown in Figure 4. Smith & Associates
Figure 6 illustrates the damage that can occur. In (A) the set-up block is making normal contact with the upper die shoe. (B) Illustrates the block mushroomed out and literately imbedded into the upper die shoe. The lower shoe is damaged as well. The displaced metal in the shoes will spoil the precision fit of the guide pin and bushing holes.
Figure 6. Die damage caused by an out of parallel condition such as a slug under the die. Smith & Associates
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Setting dies on slugs and the resultant slug marks greatly accelerate bolster plate wear. Metal is displaced and worn away. Care in avoiding slug marks will greatly reduce the need to resurface bolster plates. In the event that a slug becomes embedded in the bolster plate, it should be picked out with a pointed tool. Next, the upset metal is peened down with a hammer. The spot is then finished flat with a file or oilstone. This procedure minimizes the amount of metal removed and the size of the remaining low spot.
Figure 7. The use of inserts to keep slugs and debris out of unused bolster T-slots. Smith & Associates
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Figure 8. Sheet metal shear and box brake used for press and die chute fabrication. Smith & Associates
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
Figure 8. An exaggerated view (A) of the press deflection that is a normal result of developing the tonnage needed to do presswork; the die offset to one side of the press (B) for operator or set-up convenience; unequal loading results in an out-of-parallel condition (C) when press deflection occurs; to correct off-center loading of a press, a simple production aid or stock guide (D) may be all that is required. Smith & Associates Off center loading actually results in an out-of-level condition much like that caused by setting a die on a slug. This is because the press must deflect in order to develop tonnage. If the load is centered the deflection is uniform and the slide remains parallel to the bolster. If the load is not centered, the greatest deflection occurs in the side of the press with the greatest load resulting in an out-of-parallel condition.
Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
In the case of cutting dies, too little clearance between the punch and die will result in excessive cutting pressures, which will break down the cutting edges quickly. Too much clearance will result in excessive burrs. Ram tipping will also result. This will cause rapid wear of the gib liners and other important press parts. Figure 8 (A) illustrates an exaggerated view of the press deflection that is a normal result of developing the tonnage. Just as a spring must change shape or deflect to develop pressure, a press must deflect to develop tonnage. The illustration shows a small die centered in a large straightside press. Not all of the press tonnage capacity is safely usable. As a rule, at least 70% of the press bed should be occupied with a centrally placed die shoe if full press tonnage is to be developed. Developing full tonnage with a small die can result in damage to the press slide and bed due to excessive localized deflection.
1. Is a smaller press available so the operator won't need to reach as far to place the blank? 2. Can a production aid be constructed to permit the part to slide into correct location by gravity or automatic movement?
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Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
3. Is it possible to operate two dies in the same press to correctly balance the loading? 4. Is the placement of nitrogen cylinders on one side of the press to balance the load a practical solution? 5. Is there a good reason for offset loading such as placing a progressive die to one side to balance the force? Figure 8 (D) illustrates a simple stock guide used to correct the problem.
Figure 9. Out-of-location stock can cause die damage: (A) out-of-location stock in a die; (B) a partial cut results in the stock being flanged into a die opening causing the die shoes to be displaced sideways; (C) the damage that results. Smith & Associates
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Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.
NOTES: _____________________________________________________
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