flange die

© RENAULT 2005 Origin: PEGI - Renault Page: 1 / 38

Press tooling. Flanging down, flanging up, calibration tools. Basics on design

GE24-080R /C ________________________________________

Guide ________________________________________

Status Enforceable

Importante Note : This document has been translated from the french. In the event of any dispute, only th

french version is referred to as the reference text and is binding on the parties. Object Define the recommendations for designing flanging down, flanging up, and calibration. Scope of application Renault group Issued by 65307 - Stamping Process Industrialisation Confidentiality Non confidential Approved by Function Signature Application date

D.COURATIN Head of department 65307 01/2005

GE24-080R /B


History of versions

Version Update Object of main modifications Author A 02/2004 Creation (1) B. Nouhant C 10/2005 Addition of the paragraph 3.2.8 flanging up with rocker. C. Laizé Dept 65307

Supersedes GE24-080R of 01/2005 version B Availability Inside Renault, on the Intranet: http://gdxpegi.ava.tcr.renault.fr

Outside Renault, on the Internet: www.cnomo.com E.mail: [email protected]

Documents cited Regulations : International : ISO 3755, ISO 4957. European : EN 10083-1. French : CNOMO : E01.14.220.N, E01.33.211.N, E01.41.050.N, E01.45.030.N. Renault : EM24.01.100, EM24.15.050, EM24.15.100, GE24-017R, GE24-

040R, GE24-060R, GE24-120R. Other internal doc : Other external doc : Coding ICS: 25.120.10; 03.120.20 Class E24 Key words emboutissage, outillage de presse, outil de presse, dessin, fondamentaux, tombage,

relevage, calibrage, conception, pressing, press tooling, press tool, design, basics, bending, flanging down, restrike

Language French (1) Have participated in writing the document Site Dept Name Site Dept Name LHA 09610 Mme LEREVEREND

MM. BEAUFOUR / DELAFENESTRE / DELAHAYE LECHEVALIER / LOISEL / MORVAN / TERRIER

TCR 65307 64140

MM. BRUNDU / FERRANDON / GUYOMARCH / HAMMOUDI / LEBOEUF PRESA / TRADOTTI

M. GOURDET

LHA 04734 MM. BAUBE / PASQUIER ROULIER

FLINS 09410 MM. CHAPPE /

GE24-080R /B


Contents

Page 1 General ........................................................................................................................................ 4 1.1 Different types of tooling................................................................................................................................4 1.2 Different functions .........................................................................................................................................4 1.3 Foundries design...........................................................................................................................................5 1.4 Frame guides ................................................................................................................................................6 1.5 Storage ..........................................................................................................................................................6 1.6 Calculations...................................................................................................................................................7 1.7 Aluminium parts.............................................................................................................................................7 1.8 Butt welded parts...........................................................................................................................................7 1.9 Narrow parts, thick parts, HLE, THLE panels ...............................................................................................7 2 Flanging down / flanging down-calibration tool .................................................................... 11 2.1 General on design .......................................................................................................................................11 2.2 Tool composition .........................................................................................................................................13 3 Flanging up tool........................................................................................................................ 16 3.1 General on design .......................................................................................................................................16 3.2 Tool composition .........................................................................................................................................16 4 Flanging down / Flanging up / Calibration tool...................................................................... 19 4.1 Operation.....................................................................................................................................................19 4.2 Tool composition .........................................................................................................................................20 5 Working parts............................................................................................................................ 20 5.1 Blades..........................................................................................................................................................20 5.2 Punch and presser range............................................................................................................................26 5.3 Pullers / Separators.....................................................................................................................................30 5.4 Presser ........................................................................................................................................................32 5.5 Part centring ................................................................................................................................................33 6 Materials .................................................................................................................................... 35 7 Cambering................................................................................................................................. 36 8 Normative references for metallic materials cited in this document................................... 37 9 List of documents cited ........................................................................................................... 38

Foreword This guide is not:

A collection of "design rules". Exhaustive in propositions.

This guide is a reminder of a few basics and examples, and must be enriched with: The different user projects. All manufacturing sites by the intermediate of different DIVDs.

NOTE: All the information concerning the materials are indexed by an asterisk (*): this means that the type of material is cited for information, and is defined by the EM24.01.100 standard and specific project standards.

GE24-080R /B


1 General

1.1 Different types of tooling Flanging down tool Flanging down / calibration tool Flanging up tool Multiple tool:

flanging down / flanging up / calibrating or flanging up / flanging down / calibrating

designated as "double pressure tool".

1.2 Different functions • Conformance

A stamped radius is reduced to meet the value in the part drawing

• Calibration A surface is struck, e.g. to ensure proper mating with a neighbouring part.

• Shrinkage

The part is flattened to reduce a radius. Requires the part to be mobile in the tool.

• Fitting the aspect line An aspect line is marked with a small radius. It must be obtained from the stamped OP. To prevent the panel from being pushed back in the aspect zone, the finished part must be as vertical as possible.

• Fold According a straight line intersecting 2 planes.

• Flanging down According to a curved line in 3 dimensions.

• Edge flanging up

According to a curved line in 3 dimensions.

• Edge striking According to a curved line in 3 dimensions.

• Overfolding See paragraph 7 Along a straight line

Calibrated zone(Hashed in a top view ofthe part in themanufacturing sheet)

GE24-080R /B


1.3 Foundries design See Renault standards EM24.01.100 and Renault guide GE24-040R.

Guiding gap – 0.1 +-0.01 in GP(lower frame/upper frame) – 0.15 +-0.01 in TGP

if frame/frame columnsguiding constant

guiding constant

Offset punch

PresserUpper frame

Gap between presser and blade: 0.4 to 0.6 to reduce to 0.1 min in major shrinkage zones

(or more according to result of flexion calculations

under reaction load)

Dropping bladeblade parting line: gap ≤ 0.03

Guiding gap – 0.1 +-0.01 in GP(lower frame/upper frame) – 0.15 +-0.01 in TGP

if frame/frame columnsguiding constant

guiding constant

Offset punch

PresserUpper frame

Gap between presser and blade: 0.4 to 0.6 to reduce to 0.1 min in major shrinkage zones

(or more according to result of flexion calculations

under reaction load)

Dropping bladeblade parting line: gap ≤ 0.03

GE24-080R /B


1.4 Frame guides The general guides must be located on the same level as working parts. The 2D and 3D master drawings must hence be modified to meet these conditions.

1.5 Storage

50 m

in b

efor

e co

lum

n en

gagi

ng50

min

bef

ore

colu

mn

enga

ging

Tool

axis

Range of working parts

Tool

axis

Range of working parts

Inse

rtio

n in t

he

pla

tes

= 4

0m

m

Tool tip viewFree tool position ( HOL )

Too

lan

dpr

ess

axis

Inse

rtio

n in t

he

pla

tes

= 4

0m

m

Tool tip viewFree tool position ( HOL )

Too

lan

dpr

ess

axis

GE24-080R /B


1.6 Calculations See Renault guide GE24-040R.

1.7 Aluminium parts The design is identical, except for materials specifications: refer to Renault guide GE24-120R.

1.8 Butt welded parts If the butt welding line is located in a zone to calibrate, include blades to ensure the time, aspect, and geometry.

1.9 Narrow parts, thick parts, HLE, THLE panels

1.9.1 Particularities of design of narrow parts Implement compensators between presser and lower working part. The presser, mobile base elements must be in cast steel 270-480W* or G50CrMo4 M* The blades must be in steel with specific treatment (X153 CrMoV12* T6 special) implanted in blade holders

Presser guides per plate at the ends

GE24-080R /B


fitting from top of presser

Rib above blade parting lines

Other frame shape

HAN

DLI

NG

Blades

Stro

ke

Frame


Other frame shape

HAN

DLI

NG

Blades

Stro

ke

Frame


Other frame shape

HAN

DLI

NG

Blades

Wor

king

stro

ke

Frame

X = nominal stroke of spring – working stroke


Other frame shape

HAN

DLI

NG

Blades

Wor

king

stro

ke

Frame

X = nominal stroke of spring – working stroke

GE24-080R /B


other particularities

Extension of the internal presser by an outside zone. Caution: the sizing and number of linking suspenders space "P" between the suspenders and blades implanted in "overhang" consider max crushing of presser dampers positioning the suspenders according to the blades the gaskets of blades to remove balancing loads, retainers, and guides.

Note: drawbacks of this design = maintenance penalised by removing the blades before presser access.

1.9.2 Design specifics for thick parts High thickness parts are panels thickness ≥ 1,2 mm. They are usually narrow parts. The foundry thickness of cast elements must be increased The presser, mobile base elements must be in cast steel 270-480W* or G50CrMo4* The blades must be in steel with specific treatment, X153 CrMoV12* T6 special (56 to 58 HRC), implanted in the blade holders

The blade holders must be of a "fuse" design Include sized reference holes to facilitate refitting.

Compensationbloks

P

Blades

Compensationbloks

P

Blades

Tie-rod axis

Tie-rod axis

Holes Ø H7 for reference

Blade holder270-480W

Tie-rod axis

Tie-rod axis



Tie-rod axis

Tie-rod axis



GE24-080R /B


Other examples: The blades must be implanted in blade holders with a "fuse" system: e.g. tie rods, keys.

GE24-080R /B


2 Flanging down / flanging down-calibration tool

2.1 General on design 2.1.1 Tool with offset punch

TOOL WITH STRIKE TOOL WITHOUT STRIKE A B C D A B C D Cast

iron Steel Cast

iron Steel Cast

iron Steel Cast

iron Steel

TGP 40 50 40 40 40 40 40 50 40 30 30 20 GP 40 50 40 40 40 40 40 50 40 20 30 20 MP 30 40 30 30 30 30 30 40 30 20 30 20

1) Lower frame: FGL 215 HB* 2) Lower punch.: G50CrMo4* T3 + T7 hardness ≥ 54 HRC (if rate ≥ 500 p/day) or FGS 600 3A* (if rate < 500 p/day) 3) Upper frame.: FGL 215 HB* 4) Presser: FGL 240 HB*, FGS 600 3A*, 270-480W* 5) Calibration blades: X153CrMoV12* T6 hardness 54-56 HRC or 42CrMo4* or G50CrMo4* T3+T7

hardness ≥ 54 HRC 5bis) Location of the calibration blades to be planned. X153CrMoV1*2 - T6 (54-56 HRC) + TiN or

G50CrMo4* T3+T7 (≥ 54 HRC) or pre-treated steel* T4 (>52HRC) 6) Flanging down blades: X153CrMoV12* - T6 Special (56-58 HRC) + TiN or 42CrMo4* or

G50CrMo4**T3+T7 (≥ 54 HRC) or pre-treated steel* T4 ( ≥ 52 HRC) 7) Gas springs in upper part (type of springs according to calculations) 8) separators: Stroke < 80 mm, outside purchases from Renault certified suppliers Stroke ≥ outline drawing 01 016 in Renault guide GE24-017R. 9) Retaining/locking pins (if compatibility with loads) 10) Probe (do not implant in a span zone) 11) Span balancing of the presser (supports).

GE24-080R /B


2.1.2 Tool with lower frame / Single book cage

TOOL WITH STRIKE TOOL WITHOUT STRIKE A B C D A B C D Cast

iron Steel Cast

iron Steel Cast

iron Steel Cast

iron Steel

TGP 40 50 40 40 40 40 40 50 40 30 30 20 GP 40 50 40 40 40 40 40 50 40 20 30 20 MP 30 40 30 30 30 30 30 40 30 20 30 20

1) Lower frame single block in FGL 240 HB* 2) Upper frame: FGL 215 HB* 3) Presser: FGL 240 HB*, FGS 600 3A*, 270-480W* 4) Calibration blades: G50CrMo4* T3 + T7 hardness ≥ 54 HRC 4bis) Location of the calibration blades to be planned: X153CrMoV12* - T6 (54-56 HRC) + TiN or

G50CrMo4* or 42 CrMo4* T3 + T7 ( ≥ 54 HRC) or pre-treated steel* T4 (>52HRC) 5) Flanging down blades: X153CrMoV12* - T6 Special (56-58 HRC) + TiN or 42CrMo4* or G50CrMo4

* T3+T7 (≥ 54 HRC) or pre-treated steel* T4 ( ≥ 52 HRC) 6) Gas springs in upper part (choice of type of springs according to calculations); spring distribution

ensuring proper load balance. 7) Separators: Stroke < 80 mm, outside purchases from Renault certified suppliers.

Stroke ≥ outline drawing 010 16 in Renault guide GE24-017R. 8) Retaining/locking pins (if compatibility with loads) 9) Part presence detectors 10) Span balancing of the presser (supports).

GE24-080R /B


2.2 Tool composition Functions to be provided The general functions of all tooling must be met (handling, storage, fitting under press, part loading and extraction...). In addition, beware more particularly the points in the following table:

FUNCTION OBJECTIVE COMMENTS

PART CENTRING

Machine ability ratio, CAM ≥ 1.3 tolerance interval CAM = dispersion

Within this objective, plan effective centring in the important zones of

the part. This centring must be durable (paragraph 5.5).

WORKING PARTS GUIDE Compensate press guiding faults.

TIGHT CLAMPING OF PART Prevent parasite distortion and strip the part in respect of working blades.

Calculation of clamping loads. The moving parts must be lockable at bottom dead centre position for unseizing

REACTION Compensate horizontal roller loads due to working on sloped shapes.

Fit the reaction plates as close as possible to the loads to

compensate to reduce distortion of the tooling frames.

WORKING PARTS STURDINESS

Withstand shock, high superficial loads and intense friction.

Seizing between panel and working blades is highly detrimental, as it

results in press stoppage and requires grinding the blades, hence

a drift in geometry.

SEPARATORS AND PULLERS

Prevent the part from adhering to the lower part or struck onto the upper

part.

Separators and pullers must not distort the part. In order to do this,

they must not exert any flexion loads on the part, when the upper

part of the tool is in contact with the part.

PART SUPPORT Apply the geometry and prevent creating aspect faults.

The punch span must be sufficient next to the working lines, and prevent the part’s collapse.

Locking: it must be included provided calculations allow it for parts with rolled edges likely to cause seizing. The locking decision must be validated during drawing reviews with all players. (Project, plant, provider)

Clearance see paragraph 1.3Clearance see paragraph 1.3

GE24-080R /B


2.2.1 Lower frame FGL 215 HB* or upper frame single block punch FGL 240 HB* Carries the fasteners and centrers on production and backup press platform Pneumatic and/or electric connecting plates Handling by slings and/or clamps Storage spacers (elastic, RG, storage set over 3 heights) Safety jack plates Holes for contact tips Adjusting spacers (on ribs) Guide: Columns if collar flanging down punch Guide stop with cupro plate including cast iron inserts

Reaction: if required, cupro plate with inserts on steel plate Punch fastening and keying Separators / pullers / centrers For aspect parts: presser supports (prevent marking, protection of edge lines, after contact, during press cycles without part or/and loads too high between presser and punch)

For single block tools: any grains in major shrinkage zones For single block tool: part presence detectors 2 detectors per part For single block tool: part centring on shape, centrers-separators (see paragraph 5.2) Include passage of punch support studs (see Renault guide GE24-040R)

2.2.2 G50CrMo4* or FGS 600 3A* punch Fastening / keying on lower frame Carry the separators / centrers / pullers For aspect parts: presser supports (prevent marking, protection of edge lines, after contact, during press cycles without part or/and loads too high between presser and punch)

Possible grains (e.g. collar flanging down) Part presence detectors 2 detectors per part (ex working zones)

Part centring: on shape, by centrers / separators: See paragraph 5.2 Snap connection plate for detector

Electric link between lower frame and connecting plate or KHEOPS socket with detector cable on punch

Studs (supporting studs of free punch to protect detector and cable or/and separators) (see Renault guide GE24-040R)

2.2.3 Upper frame FGL 215 HB* Clamping under production and backup press ram (snap and manual clamping) Handling by slings and/or clamps Clearance for link with press ram pneumatic connection block Ranges for safety jacks with contact tip holes Ranges for adjustment spacer, fitted on ribs Range for storage spacer Guides – bushes (consistent with lower frame) plates (consistent with lower frame)

Reaction (consistent with lower frame) Presser guides Pressure means Carry the blades Separator stands Retaining pins with or without locking (according to calculations) Pneumatic link with lower frame if start up

GE24-080R /B


2.2.4 Presser FGL 240 H*B or FGS 600 3*A or in case of fragility cast steel 270-480W* Pressure means stand (metal, polyurethane springs)

Note: springs must be balanced RG / work loads / guiding Housing for retaining and/or locking pins Part clamping (see paragraph 5.2) For aspect parts: presser supports (prevent marking, protection of edge lines, after contact, during press cycles without part or/and loads too high between presser and punch)

2.2.5 Blades See paragraph 5.1

2.2.6 Pressure means Metal springs Polyurethane springs Non linked gas springs.

Choice of type of springs according to load calculation Pressure means and loads impact the choice of storage spacers

2.2.7 Separators See paragraph 5.3

2.2.8 Detection 2 detectors per part

2.2.9 Reaction Compensate horizontal loads due to:

the work slope the outline shape (beware open outline)

Place the reaction place as close as possible to the loads to compensate to reduce distortion of the various tool elements.

2.2.10 Calibration blades Calibration must be performed with blades fitted onto the upper frame. Exceptionally calibration of coining can be performed by the presser.

• Calibration blades X153CrMoV12* - T6 (54-56 HRC) or G50CrMo4* or 42CrMo4* - T3 + T7 (≥ 54 HRC) or pre-treated steel* T4 + T7 ( ≥ 54 HRC)

Punch: plan the foundry for possible implantation of blades.

GE24-080R /B


3 Flanging up tool

3.1 General on design 1) Punch in G50CrMo4* T3+T7 hardness ≥ 54 HRC. 2) Lower frame FGL215 HB*. 3) Mobile base FGL240 HB* or G50CrMo4* T3+T7 (≥ 54 HRC) 4) Gas spring (no prop)

Avoid using polyurethane springs (rebound effect upon press flanging up, detrimental to part extraction).

1) No shim under mobile base.

3.2 Tool composition

3.2.1 Lower frame FGL 215 HB* Carries the fasteners and centrers on production and backup press platform Pneumatic and electric connecting plate Handling by slings and/or clamps Storage spacers (elastic, RG, stop over 3 heights) Safety jack ranges Holes for contact tips Adjusting spacer (on ribs) Guide: Stops with cupro plates including inserts on foundry or male/female slider Columns if collar flanging up

Reaction if required by cupro plates with inserts on steel plate Mobile base guide Carry pressure means Mobile base retainers with or without locking Flanging up and fitting blade holder

GE24-080R /B


3.2.2 Moving base FGL 240 HB*, FGS 600 3A*, G50CrMo4* M T3+T7 hardness ≥ 54 HRC if fragility Supports for pressure means Handling (anchor point balance) Guide with frame Passage of retainer Possible grains 2 detectors per part If steel reaction plate (cupro with inserts on frame) Location of the columns to be planned.

3.2.3 Upper frame FGL 215 HB* Clamping under production and backup press ram

Snap and manual clamping Handling by slings and/or clamps Clearance for link with press ram pneumatic connection block Pneumatic link with lower frame if start up Ranges for safety jacks and contact tips Ranges for adjustment spacers fitted on ribs Ranges for storage spacer Guide with lower frame / consistent with lower frame Reactions if required Fastening, punch keying Passage or stand for separators

3.2.4 Punch FGL 240 HB* or FGS 600 3A* or G50CrMo4 M* T3+T7 hardness ≥ 54 HRC Fasteners, keying with upper frame Separator stand

3.2.5 Blades See paragraph 5.1

3.2.6 Pressure means Metal springs Polyurethane springs Gas springs Choice according to load calculation Pressure means and loads impact the choice of storage spacers

3.2.7 Separators See paragraph 5.3

GE24-080R /B


3.2.8 Flanging up with rocker Note: this type of construction can avoid the realization of a mobile bottom. Principal plan

Lower frame

Upper frame presser

insert

springsupport

grain

Punch of de rising

Guiding ring

punch

rocker

Retention pin

Shim of reaction

Adjustment shim

support

spring

Control rod

Shim in polyamide

Lower frame

Upper frame presser

insert

springsupport

grain

Punch of de rising

Guiding ring

punch

rocker

Retention pin

Shim of reaction

Adjustment shim

support

spring

Control rod

Shim in polyamide

GE24-080R /B


4 Flanging down / Flanging up / Calibration tool

4.1 Operation In this tooling, also called "double pressure tools", the part is mobile, and the upper part includes a presser. However, flanging down and lifting operations cannot be simultaneous. The decision to perform first a flanging down or first a flanging up depends on the working loads and also the capacities (in footprint) to receive the number of springs required. Flanging down is performed first if the load is lighter than the lifting load. We then have:

Lower clamping load > Presser load + presser weight + flanging down load + Weight of the lower moving base. If lifting is lower than the flanging down load, lifting is performed first.

Upper clamping load > Clamping load + Lifting load + Weight of the presser + Weight of the lower moving base.

If the load to lock exceeds the load capacity of 4 pins diameter 63, do not install a locking (only use retaining).

Column to be planned, but do not launch.For possible implantation of punch or/and flanging

No stroke shimRetainer-locking pin

Columns required if reference flange lifted

Springs (no props).

Stroke shim, superior size

Column to be planned, but do not launch.For possible implantation of punch or/and flanging

No stroke shimRetainer-locking pin

Columns required if reference flange lifted

Springs (no props).

Stroke shim, superior size

GE24-080R /B


4.2 Tool composition All elements cited below use the functions described in paragraphs 2 and 3.

Lower frame Moving base Upper frame Presser Blades

Flanging down Flanging up Calibration

5 Working parts

5.1 Blades When working the panel, the active part of the tool is subject to friction, whereas the item supporting the part (here the punch) is less solicited, as the sheet is wound on it. Usually, the active item is made of blades which are offset, embedded, screwed into the frames. The presser cannot be used to calibrate the part. If a lower zone must be picked up, a punch will be fitted on the frame inside a recess in the presser or mobile base. Prevent the presser from "rubbing". For single block punches in G50 CrMo4 *- T3+T7 (HRC ≥ 54) the foundry must be of capacity for the implantation of the blades in the zones to be calibrated; (e.g. crimping zone). NOTE: in the case of parts with off-centred tolerances, shims must be implanted behind the blades on the punch, and in the upper parts. These shims must be linked to the blade stand element.

Presser

Upper frame

Punch

Presser

Upper frame

Punch

No stroke shimNo stroke shim

2 CHc screws M12 + 1 pin Ø12 (plan but do not launch)

Presser

BladePunch

Upper part

Blade (to be planned, but do not launch)

Do not source from foundry

2 CHc screws M12 + 1 pin Ø12 (plan but do not launch)

Presser

BladePunch

Upper part

Blade (to be planned, but do not launch)

Do not source from foundry

GE24-080R /B


Calibration of a stringer in HLE panel Calibration of a small edge and one mating face

Angle to be determinedpractically

Radius stroke requested upon calibration

AVOIDIn safety parts

(material fibre breakage)

Angle to be determinedpractically

Radius stroke requested upon calibration

AVOIDIn safety parts

(material fibre breakage)

R according to partdrawing

Calibration blade without vertical cylindrical part

Presser

Punch

Upper frame

R according to partdrawing

Calibration blade without vertical cylindrical part

Presser

Punch

Upper frame

GE24-080R /B


Expanding edges Very large shrunk edges Implant a presser with balancing shims to prevent the formation of folds.

Pan

el th

ickn

ess

Offset blades if required

Lower presser

Pan

el th

ickn

ess

Offset blades if required

Lower presser

Outer view of blades

PenetrationPenetration

Outline sketch of the work line outline

The blade parting lines must be symmetrical in respect of the part’s axis of symmetry

Work line profile

Outer view of blades

PenetrationPenetration

Outline sketch of the work line outline

The blade parting lines must be symmetrical in respect of the part’s axis of symmetry

Work line profile

GE24-080R /B


Blade materials

Blades in X153CrMoV12* - T6

The blades are cut in commercial rolled steel X153CrMoV12* preferably pre-machined, in order to reduce machining and guarantee the working zone will not be decarbided, or rough rolled, but with sufficient descaling ( -5 mm).

In case of strong lamination and after development in the plant, apply ionic nitriding or a titanium nitride coating (TiN) on blades in X153CrMoV12* Special T6 treated according to the range indicated in EM24.15.100.

Final development of the blades. T8.2: Ionic nitriding (thickness 0.1 to 0.2 mm), or T9: TiN.

In case of complex shapes, it may prove interesting to cast blades in X153CrMoV12*, while ensuring the foundry overthickness is sufficient beside the working zone to ensure the blade has the hardness required.

Blades in G50CrMo4* or 42 CrMo4* T3+T7 hardness ≥ 54 HRC or pre-treated steel T4+T7 (≥54 HRC)

Torch treatment (T7) must be performed on the entire working section.

Zone impacted by T7

Dire

ctio

n of

fla

me

T7

Zone impacted by T7

Dire

ctio

n of

fla

me

T7

GE24-080R /B


FLANGING DOWN BLADE STRIKING BLADE

RESTAMPING RADIUS CONFORMANCE See Renault guide GE24-060R. SHRINKAGE BLADE CALIBRATION OF THE CRIMPING ZONE

OR CALIBRATION WITH VARIATION OF PART DEPTH Note: For blocks cast in G50CrMo4*, plan handling means.

For blades in hot reduced steel, do not exceed 15 kg To select the materials, refer to paragraph 2.

Presser

Punch

Upper frame

Dropping blade

For rising, flip the flanging section

R = panel thickness on bladebefore MAP)

Reaction indispensable for stroke on unbalanced sloped edges and flanging> or = 1 m

1 GT 12 pin per blade

2 Chc screw M12

Punch blade

Presser

Punch

Upper frame

Dropping blade

For rising, flip the flanging section

R = panel thickness on bladebefore MAP)

Reaction indispensable for stroke on unbalanced sloped edges and flanging> or = 1 m


2 Chc screw M12

Punch blade

2 Chc screw M12

Between panel beforecalibration and span limit


Restampingblade

G50 CrM04 * T3+T7Hardness ≥ 54 HRCX153CrMoV12 * T6

54-56 HRC if th ≥ 0.8 mm

G50 CrM04 * T3+T7Hardness ≥ 54 HRC if th ≤ 0.8 mm

2 Chc screw M12

Between panel beforecalibration and span limit


Restampingblade

G50 CrM04 * T3+T7Hardness ≥ 54 HRCX153CrMoV12 * T6

54-56 HRC if th ≥ 0.8 mm

G50 CrM04 * T3+T7Hardness ≥ 54 HRC if th ≤ 0.8 mm

G50 CrM04 * or 42CrMo4 * T3+T7Hardness ≥ 54 HRC


X153CrMoV12 * T654-56 HRC

Cast steel punchBlade location planned, but do not

launch

Cast iron punchBlade location planned, launch this

blade in case of rework on part depth


Upper frame

2 Chc scew M12

Mov

ing

base

st

roke G50 CrM04 * or

42CrMo4 * T3+T7Hardness ≥ 54 HRC


X153CrMoV12 * T654-56 HRC

Cast steel punchBlade location planned, but do not

launch

Cast iron punchBlade location planned, launch this

blade in case of rework on part depth


Upper frame

2 Chc scew M12

Mov

ing

base

st

roke

GE24-080R /B


Blade design Max weight = 15 kg (machined)

DETAIL OF A FLANGING DOWN BLADE AND ITS MARKING Note: To facilitate the development of parts with a symmetry plane, study blades symmetrical with this

plane (MANDATORY).

Front view(extraction)

(extraction)

Rat

e

Top viewIf pulled blade

Comercial rate (preferencepre-machined

Example of markingbefore thermal treatment

Nature materialMark

Rat

e

If pinned bladeRate

Marking of hardnessafter thermal treatment

Mark 56

Grinding wheel radius 20 to 30

(Mus

t be

size

don

bla

dedr

aw)Front view

(extraction)(extraction)

Rat

e




Nature materialMark

Rat

e

If pinned bladeRate


Mark 56


Front view(extraction)

(extraction)

Rat

e




Nature materialMark

Rat

e

If pinned bladeRate


Mark 56


(Mus

t be

size

don

bla

dedr

aw)

GE24-080R /B


5.2 Punch and presser range

5.2.1 Aspect parts a) The punch must be on span along the working lines over a width of 160 min. b) The punch must support the part properly, without risk of marking the edge lines: The recesses in the

punch span must never be at less than 40 mm from the edge lines. Note: Recesses must never intersect an edge line. c) No hole nor blading nor probe housing must end in the punch span. d) The punch span recesses must be contained in a square dimensions 200 x200. e) The presser must never have a range contained in the punch span (5 to 100 mm recess) and must

never press a panel not supported in the lower part. f) In the particular case of concave zones on the punch and convex on the spans, the presser and

punch must be extended beyond the peripheral 120 mm by protruding the punch’s concave zone by 40 mm.

5.2.2 Other parts General principle for structure part a) The punch must be on span along the working lines over a width of 160 mm. b) The mating zones must be on punch and presser span. c) The punch span recesses must be contained in a square dimensions 300 x 300. d) The presser must have a span contained in the punch span (5 to 10 recess). e) Avoid screws, pins, probes at less than 40mm from the working lines.

Blade

Uper frame

Convex punch Concave punch Convex punch

PresserEdge line supportedwithout interrution

ProbePinScrew

Punch

Wor

klin

e

No sharpedges

Blade

Uper frame

Convex punch Concave punch Convex punch

PresserEdge line supportedwithout interrution

ProbePinScrew

Punch

Wor

klin

e

No sharpedges

GE24-080R /B


5.2.3 Diagrams FLANGING DOWN OF HOOD FR, RR & LAT EDGE

FLANGING DOWN FOR GENERAL CALIBRATION OF FENDER

DOOR CAISSON RESTAMPING DETAIL: Hinged panel restamping The "restamping" is treated in the Renault guide GE24-060R.

PunchPresser

Cross-section A Extractor

Presser clearance

Fulley supportededge line

PunchPresser

Cross-section A Extractor

Presser clearance

Fulley supportededge line

Cross-section B

Full punchPresser cleared

Cross-section B

Full punchPresser cleared

Full punchPresser cleared locally

Punch(blade)

Detail A

Separation

Detail A

Presser

PunchBlank holder

Upper frame

Full punchPresser cleared locally

Punch(blade)

Detail A

Separation

Detail A

Presser

PunchBlank holder

Upper frame

GE24-080R /B


CALIBRATION EDGE FLANGING DOWN FOR FR DOOR PANEL

CALIBRATION EDGE FLANGING DOWN OF THE LATERAL PANEL

Beware the "edge" lines

CALIBRATION EDGE FLANGING DOWN FOR RR DOOR PANEL Beware the "edge" lines

C cross-sectionC cross-section

D cross-section

Punch clearedpresser cleared

Probe in not visible zone

D cross-section

Punch clearedpresser cleared

Probe in not visible zone

E cross-section Full punch (except window framePresser cleared

E cross-section Full punch (except window framePresser cleared

GE24-080R /B


GENERAL CALIBRATION EDGE FLANGING DOWN OF THE ROOF

Note: Eliminate all these recesses on the punch if the rear gutter is restamped. In this case, the upper presser must be in span in the concave zones of the punch and over the entire periphery. Beware the "edge" lines

TUNNEL: CALIBRATION EDGE FLANGING UP

F cross-section

G cross-sectionUpper presser

Upper blades

G cross-sectionPresser / punch contact

G cross-sectionUpper presser

Upper blades

G cross-sectionPresser / punch contact

GE24-080R /B


BODY SIDE Beware the "edge" lines

5.3 Pullers / Separators If the part is likely to remain clamped on the tool, the punch or the upper frame are fitted with pullers or separators (pullers for skin parts, separators for structure parts) Pullers are required in the following cases:

One flanging down or flanging up line completely closed. Edges flanged or risen in expansion (e.g. wheel entrance edges on fender or lateral panel). Edged holes or openings.

Pullers in an edged hole

Punch clearedPresser clearedPunch clearedPresser cleared

Spring

∅ Of pre-hole

Spring

∅ Of pre-hole

GE24-080R /B


Outer pullers Centrer-Extractor master drawing Stroke 0 to ≤ 63 Stroke 63 to ≤ 80 Stroke 80 to ≤ 140

}

External purchasing from suppliers approved by Renault Outline drawing 01016 in Renault guide GE24-017R

H = height of the max flanged edge Presser stroke = H+35 = EXTRACTOR STROKE = 2H+43 Y1 = height of the floating face of the puller E = cylindrical height of profile templates E ≥ H + 9 + 5

Size the punch cylindrical (edge height + 25 mm) outside pullers, represent the supporting surface of the pullers and size the cylindrical height on punch X > 2H + 43 + Y1 beside the pullers.

Centring of the part (Tool at top stroke)

Panel holder at contactFlanged edge(Tool at botton strocke)

Pre

sser

cr

ushi

ng=

0

Pul

lers

trock

e=

= 0

Pul

lers

trock

e=

H +

6

Pul

lers

trock

e

Centring of the part (Tool at top stroke)

Panel holder at contactFlanged edge(Tool at botton strocke)

Pre

sser

cr

ushi

ng=

0

Pul

lers

trock

e=

= 0

Pul

lers

trock

e=

H +

6

Pul

lers

trock

e

End stroke ofpanel holder

End stroke ofpullers

Dam

ping

crus

hing

8 m

ax

Pul

lers

trock

e=

0

Pre

sser

cru

shin

g=

0

GE24-080R /B


In the case of very large edges leading to spring strokes > 120-160 mm or edges primed at α < 30° which fragilize pullers, it is best to separate the puller and centrer functions and actuate pullers using a double effect jack.

the puller is actuated upwards from the bottom dead centre. the puller must return to its low position before the arrival of the new part.

5.4 Presser Hold the panel using the presser with a ribbed plate. Principle forbidden for aspect parts.

a<30°

Center

Extractor

Pre

sser

stro

cke

+ 11

a<30°a<30°

Center

Extractor

Pre

sser

stro

cke

+ 11

If marking the part by the ribbed section is not admissible, change the process or product

Simultaneous attack of the edges

Highpressure

The panel isswallowedby the bladeRibbed plate

If marking the part by the ribbed section is not admissible, change the process or product

Simultaneous attack of the edges

Highpressure

The panel isswallowedby the bladeRibbed plate

GE24-080R /B


Presser stroke and load The stroke must be sufficient to ensure the presser holds the panel at 10 mm minimum before the blades touch the part, 25 mm if centrers - pullers. The clamping load must be sufficient to prevent the panel from sliding or buckling close to the working blades. The value of the load is determined preferably based on existing tools for a similar part. a) Refer to the tooling study of the reference tool. b) Determine in the plant whether pressure on the presser is considered correct and actually the one

studied. In the absence of references, the load will be determined according to chapter 1. Presser recentring with lower part (see paragraph 2.2.4)

5.5 Part centring For most parts, the punch shape is sufficient to centre the part. In this case, install additional centrers: NOTE: for certain parts, it may be required to add profile templates for precentring (process

individually) Fixed pilot in punching or opening ∅ ≥ 12 mm

Fixed profile template on edge already risen or trimmed "hole" type formed upon stamping the risen edge

GE24-080R /B


Mobile centrer on flanged edge Principle to be used exceptionally: prefer fixed centring on edge tip

Mobile centrer on puller (see § 5.3) Caution! Centring must be ensured until the part is clamped.

"Y" must exceed the distance travelled by pullers before presser contact.

GE24-080R /B


Centrer for part with a shape not ensuring centring: Two tabs, with a triangular punch are created upon trimming. Part centring is performed by the pilot (adjustable) and then the tab is cut by the flanging down blade.

6 Materials NOTE: All the information concerning the materials is indexed by an asterisk (*): this means

that the type of material is cited for information, and is defined by the EM24.01.100 standard and specific project standards.

NOTE: If the materials do not result from European standards, use materials with a quality exceeding that required. Beware compatibility with treatment and recharging, see Renault standard EM24.15.050 and EM24.15.100.

Adjustable pilot

Surface to adjust

Cross-section A

Cutting rework profile

Cutting or flanging lineHave the hole andtab sorced fromthe trimming OP

Adjustable pilot

Surface to adjust

Cross-section A

Cutting rework profile

Cutting or flanging lineHave the hole andtab sorced fromthe trimming OP

GE24-080R /B


7 Cambering Particular function of flanging down = DANLY principle (Contact the brand representative to validate

particular cases) Short edge

Folding is required when the height of the edge is too low to be primed by the roller jaw.

Overfold

Folding has an angle between 90° and 120°. It is achieved by modifying the standard roller. The radius of the folding jaw remains constant with respect of the new angle tangent to this radius. Overfolding is ideal for spring or high hardness panels, and for preparing folds dropped at 180°.

CLAMPING

FOLD

OVERFOLDING

Holding ensured

Lesser load

Up to 120°

GE24-080R /B


Z at 90°

Folds frequent for DANLY cambering blades. For Z folds, the panel’s thickness and height determine the diameter of the roller. A "pad" will sometimes be required to prevent the panel from buckling. We recommend a double-section anvil. Panel clamps or pilots can maintain the part’s stability during folding.

U

U and Omega folds are implemented with two DANLY cambering blades in a single press stroke.

Omega

Omega folds can be achieved in a single operation with two Z fold elements.

Large radius

Large radius folds, larger overfolding is required to compensate panel return. A larger roller diameter is required to roll the radius. Refer to DANLY to determine the anvil blank angle.

8 Normative references for metallic materials cited in this document Designation Reference document 270-480W standard ISO 3755 42 CrMo4 standard EN 10083-1

T4 pre-treated steel CNOMO standard E01.14.220.N FGL 215HB CNOMO standard E01.41.050.N FGL 240HB CNOMO standard E01.41.050.N FGS 600-3A CNOMO standard E01.45.030.N G 50CrMo4 CNOMO standard E01.33.211.N

X 153CrMoV12 standard ISO 4957

GE24-080R /B


9 List of documents cited NOTE : For non dated documents, the latest version is applicable. ISO 3755 : Tempered steel. Section 1: Technical delivery conditions for special steel. ISO 4957 : Tool steel EN 10083-1 : Tempered steel. Section 1: Technical delivery conditions for special steel. E01.14.220.N : Bars in T4 pre-treated steel. Technical specifications. E01.33.211.N : Moulded steel G50CrMo4. Technical specifications. E01.41.050.N : Lamellar graphite cast iron. FGL 175HB. FGL 215HB. FGL 240HB. Technical

specifications E01.45.030.N : Spheroid graphite cast iron FGS 400-18A and FGS 600-3A. Technical

specifications. EM24.01.100 : Presentation of the basic offer and free offer in press tooling design EM24.15.050 : Materials used and associated surface treatment for press tooling. EM24.15.100 : Procedure for chrome-plating press tooling. GE24-017R : Press tooling. Miscellaneous master GE24-040R : Press tooling. General design guidelines GE24-060R : Press tooling. Stamping tools. Basics on design (Being written) GE24-120R : Design rules for press tooling for aluminium stamping