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THEORY OF SHEARING

• Shearing is the method of cutting sheets or strips without forming chips.• The material is stressed in a section which lies parallel to the forces applied.• The forces are applied by means of shearing blades or punch and die.

Critical stages in shearing1. Plastic deformation.2. Penetration.3. Fracture.

1. Plastic deformation:

The pressure applied by the punch on the stock material tends to deform it into the die opening when the elastic limit is exceeded by further loading, a portion of the material will be forced into the die opening in the form of an embossed on the lower face of the material and will result in a corresponding depression on its upper face.

This stage imparts a radius on the lower edge of the punched out material. This is called the stage of “plastic deformation”.

2. Penetration stage:

As the load is further increased, the punch will penetrate the material to a certain depth and force an equally thick portion of metal into the die. This stage imparts a bright polished finish on both the strip and the blank or slug. This is “penetration stage”.

3. Fracture stage:

In this stage, fracture will starts from both upper and lower cutting edges. As the punch travels further, these fractures will extend towards each other and eventually meet, causing complete separation. This stage imparts a dull fractured edge. This is the “fracture stage”.

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1. Press Force calculation: The essential considerations are:

Cutting force Stripping force Ejection force

1. Cutting force “Cutting force is the force applied on the stock material in order to cut out the blank or slug”. This determines the capacity of the press to be used for particular tool. The area to be cut is found by multiplying the length of cut by stock thickness.

Cutting force (F) = L x S x T max

L = Length of periphery to be cut in ‘mm’. S = Sheet thickness in ‘mm’ T max = Shear strength in N/mm2

Shear and tensile strengths for most materials are not the same.Shear strength for:

Aluminum is approximately 50’% of its tensile strengthCold roll steel is approximately 80% of its tensile strengthStainless steel is approximately 90% of its tensile strength

2. Stripping forceThe main purpose of a stripper is to the part material from the ends of the punches. This function occurs at the

Withdrawal phase of the cutting process.Stripping force varies based on part material type and thickness as well as punch to die clearance. Most

applications do not exceed 10% of the cutting force. If the die has more than one punch the stripping force for that die is the sum of stripping forces required for each punch.

Striping force = 10% - 20% of cutting force (F)

Movement of stripperYstr = t + 2

Where Y sIr = Movement of stripper t= Thickness of stock

Spring deflection (Y) Y= (3 to 4) Y str= (3 to 4) (t+2)

WhereY = Total spring deflection at F max load

3. Ejection forceThe force required to eject the component from the punch.

Ejection force = 10% cutting force (F)

Press force = Cutting force + stripping force

The following table gives the shear strength (T max = 0.2 for tensile strength σ max ) of several materials.

Material T max in N/mm2

Steel with 0.1% carbon 240 - 300

Steel with 0.2% carbon content (deep draw steel) 320 - 400

Steel with 0.3% carbon 360 - 420

Steel with 0.4% carbon 450 - 560

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Steel with 0.6% carbon 550 - 700

Steel with 0.9% carbon 700 - 900

Silicon steel 450 - 550

Stainless steel 350 - 450

Copper 200 - 400

Brass 350 - 400

Bronze 360 - 450

German silver (2 - 20% Ni, 45 - 75% Cu) 300 - 20

Tin 30 - 40

Zinc 100 - 120

Lead 20 - 30

Alluminium 99% pure 20 - 120

Alluminium manganese alloy 150 - 320

Alluminium silicon alloy 120 - 250

Paper & card board 20 - 50

Hard board 70 - 90

Laminated paper or rosin impregnated paper 100 - 140

Laminated fabrics 90 - 120

Mica 50 - 20

Plywood 20 - 40

Leather 7

Soft rubber 7

Hard rubber 20 - 60

Celluloid 40 - 60

2. Cutting clearance:It is the small amount of gap maintained between the side of the punch and the corresponding die

opening on one side of the edge, when punch is entered in to the die opening. So the cutting clearance should expressed as the amount of clearance per side

Clearance for sheet thickness up to 3 mmc x s x T max

10 Clearance for sheet thickness above 3 mm

(1.5 x s) x (s-0.015) x T max 10

'C' constant = 0.005 or 0.01 as the case may be.T max, Shear strength 80% UTS. It is expressed in N/ mm2

If 'c' is 0.005 we get a clearance, which yields a better and cleanest work piece, but requires a higher cutting force and considerably more energy. If 'c' is 0.01, the cutting force energy as its minimum, but finish wil;l not b good. The usual practice 'c' will be conceded as 0.01

Ii is also expressed in terms of % of stock thickness (s) per side

C=c x t

Since the edge characteristics, dimensional accuracy and die life depends upon Clearance its value should be taken according to the requirements.

MaterialType of edge

I II III IV V

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Steel (SAE 102O) 21% 12% 9% 6 1/2% 2%

Steel (High carbon) 26 1/2% 18% 14 1/2% 12% 4.5%

Stainless steel 22 1/2% 12.5% 10 1/2% 4% 2%

Copper (1/2 hard) 25% 11% 8% 3 1/2% 2%

Copper (annealed) 26% 8.1/2% 6% 3% 1%

Brass (1/2 hard) 21% 9% 6% 3% 1%

Phosphors bronze 25% 13% 11.5% 4 1/2% 3 1/2%

Lead 22% 9% 7% 5% 2 '1/2%

Aluminum (Hard) 20% 14 1/2% 10% 6% 1%

Aluminum (250) 17% 9% 7% 3% 1%

Magnesium 16% 6% 4% 2 .5% 1%

Type I - large dished radius large burr - only for structural rough work.- Type II - large radius / Die roll. Normal burr Max, tool life for average sheet metal work. Type III - Normal Radius/die roll Burr free For Components to be formed later Type IV - Less radius Normal burr, Signs of secondary shear, for good quality components

to be shaved, reamed, polished and also for close tolerancesType V - Negligible radius Normal burr, complete secondary shear Recommended for accuracy for soft materials

And for hard materials the die life reduces considerably.

Recommended total shearing clearance, for precision stamping

Sheet thickness

Mild steel, Copper, Brass,

Aluminum

med. carbon steel

Duraluminium, Bronze

High carbon steel, High alloy steel

hard, Brass, and Bronze

Laminated plastics

Card board, leather, paper, rubber

magnesium alloys

S in mm Clearance on both sides in microns

0.10 5 6 7 4 2 --

0.20 10 12 14 5 3 --

0.30 15 +10 18 +10 21 +10 6 +5 4 +3 -- +10

0.40 20 24 28 8 5 --

0.50 25 30 35 10 6 17

0.60 30 36 42 12 8 20

0.70 35 42 49 14 9 25

0.80 40 +20 48 +20 56 +20 16 +10 10 +8 30 +10

0.90 45 54 63 18 12 34

1.0 50 60 70 20 15 35

1.2 70 +30 80 +30 100 +30 24 +15 10 +12 42 +15

1.5 80 110 120 30 22 52

1.8 110 130 140 36 27 62

2.0 120 140 160 40 30 70

2.2 160 +50 180 +50 200 +50 44 +25 40 +20 77 +25

2.5 180 200 230 50 45 90

2.8 200 220 250 56 48 98

3.0 210 240 270 60 53 105

3.5 280 320 350 70 60 122

4.0 320 +100 360 +100 400 +100 200 +50 60 +20 77 +25

4.5 360 450 540 90 60 157

5.0 400 500 600 100 60 175

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6.0 500 600 700 210 +50

7.0 700 +200 900 +200 1000 +200

8.0 800 1000 1100

9.0 1100 1300 1400

10.0 1200 1400 1600

11.0 1600 1800 2000

12.0 1700 +300 1900 +300 2200 +300

13.0 2100 2500 2800

14.0 2300 3000 3300

15.0 2700 3000 3300

16.0 2900 3200 3500

17.0 3400 +500 3800 +500 4100 +500

18.0 3600 4000 4300

19.0 4200 4600 5000

20.0 4400 4800 5200

Applying ClearanceGiven diagram illustrates how to apply clearance to obtain

correct size of hole and blank. When the metal is punched out from the functional part and the metal around the opening is scrap, the die is made to desired part size and the clearance is subtracted from (applied to) the punch size as shown in figure A. when the slug is discarded and the punched opening is functional, the required clearance is applied (added to) the die opening as shown in figure B. Determination of punch and die size

PiercingPiercing punch = Pierced hole sizeDie = Hole size + total clearance.

BlankingBlanking punch = Blank size-total clearanceDie = Blank size

Land and angular clearance.To avoid brakeage of cutting edge of the die plate die walls are

kept straight only to a certain amount from the cutting edge. The straight wall is called “The Land.” An amount of 3mm land for stock thickness up to 3mm and the thicker materials equal to their thickness has proved to be good practice.

The die wall below the land is relieved at an angle for the purpose of enabling the blanks or slugs to clear the die. Generally, soft materials require greater angular clearance than hard materials. Soft thicker materials above 3mm require more angular clearance. An angular clearance of 1.50 per side will meet the usual requirements

Pitch punches (side cutters) Allowance for stock cut off at the side of the strip

Stock thickness t (mm) <1.5 1.5-2 5 2.5-3

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Allowance for stock cut off f (mm) 1.5 2 2.5

Width of strip after cropping (W1) W1 = D + 2a

Width of strip before cropping (W2) T .

E2 = (0 + 2a + f + 2T)

Distance between the guides after cropping stage

81 = W, + g = 0 + 2a +g

Distance between the guides before cropping stage

Bt = W2 + X = D + 2a -I- f -I- 2T -I- X

where D = Governing dimension of the die opening 2T= Total tolerance of the strip a = Margin Allowance of stock cut-off g = gap for forwarding the strip x =Clearance 0.5 - 1 mm.

Stock thickness (t) mm Gap for forwarding (g)

<0.5 0.1-0.5

0.5-1.5 0.20.6

1.5-2.5 0.3-0.8

2.5-3.5 0.4-1.0

3. Scrap bridge:It may be appreciated for the economical production of blanks; the utilization of the strip should be of high,

say at least 75%. Generally for strips whose thickness exceeds 0.75 mm, following formulae used:

= 1.25 s, for C < 63 mm

= 1.50 s, for C > 63 mms = thickness of stripB = Clearance between successive blanks or clearance between the edge of the strip and blank

Here where C= L +B – lead or advance of the die

L = Blank length W= Width of the strip H = Blank width or height. For strips with thickness equal to or less than 0.625 mm, the above formulae are not to be used. Instead following Table is to be used.

Strip width W (mm) Dimensions B (mm)

0-75 1.25

75-150 2.30

150-300 3.00

300 3.75

So far the parameter for single- row single-pass layout have been explained, In case the layout is decided to be double – row double- pass, as shown in the bellow fig. the clearance B will follow the following rule:

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Single row double pass B = 1.50 t Double row Double pass with curved lines B=1.25 t Double row Double pass with straight and curved lines[ as in fig 4.1(c), B=1.25 t

The variants, namely, single-row double-pass or double-row double-pass are basically strip layout designed to improve the utilization factor. Utilization factor is the ratio of the blank area to the total area of me strip utilized to create a single blank. The same can be written in the form of equation:

a = LHA CW

whereL = length of blank H = height or width of blank C = advance or lead W = width of strip

Generally, the utilization factor is aimed at 70 – 75%

4. Economy factor:Stock material conservation being a decisive factor in press working, designer has to take every possible

means to attain this, with out satisfying the accuracy requirement of the component.

Economy factor = Area of blank x number of rows x 100 Width of strip x pitch

5. Buckling of Punches. When ever the punches are coming in to contact for shearing the sheet in the press tool, they will be

subjected to compression stresses. But if due to consideration of these stresses are over loaded during designing of the tool, then thin punches may tends to brake. Hence the max force, which a punch can withstand without buckling can be calculated by using the formula.

Fb = [ p ² × E × I ] Lp²

Fb= Maximum Force beyond which buckling occurs. E= Modulus of Elasticity (For steel Modulus of Elasticity varies from 200 to 220 GN /m²) I = Moment of Inertia in mm4 (different section details are given in last pages)  Lp = Length of punch in mm

 The ultimate condition is when,

 Buckling Force = Cutting Force required for the operation = Shear force on the punch.

Side-thrust or Lateral Forces

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Figure illustrates the shear, tensile, and compressive forces that occur during the cutting process. The amount of lateral force varies with the cutting clearance and material.

Effect of Die Clearance on Lateral ForcesBellow equation gives an approximation of the side thrust or lateral force generated when cutting or

shearing. When applying this equation, adjustments for the type of material and die conditions must be made.

C . = FH

T – V FV

where:C = clearance, in. (mm) F H = side thrust, lbf (kN)T = material thickness, in. (mm)P = penetration, typically 0.33 x T F v = cutting force, lbf (kN)

6. Shank LocationThe resultant force of all the cutting forces acting on different punches should pass through the shank

centre.

By applying the following two methods:

By calculation By graphical method (polygon of forces).

Centre point of shank location can be found by calculating the x and y coordinates for the point.The formula to be used for this calculation is given bellow. From the die plate references to the centroide of different split profiles of the die cutting area length of which is taken as l1,l2,l3.,,,,

X = (l1x1)+l(2x2)+(l3x3)……….+(ln xn) l1+l2+l3……………….,,,,,+ln

Y = (l1y1)+l(2y2)+(l3y3)……….+(ln yn) l1+l2+l3……………….,,,,,+ln

7. ShavingShaving is the secondary cutting operation. It is done by removing (shaving) a small amount of material

from the previously cut edge. The purpose of shaving is

To improve the dimensional accuracy of the piece part. To improve the cut edge characteristics of the piece part. To improve the flatness of the piece part.

The width of the scrap web removed by shaving operation is the shave allowance.Shave allowance for steel

A = C+0.04 s.Or minimum =0.08. A1= C/2 or min 0.04.

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Shaving allowance for brass, copper, German silver etc. A = C or min 0.08mm.A1 = C/2 or minimum 0.04.

C = Cutting clearance used for previous cutting operation (prior to shaving). A = Shave allowance for single shaving operation is employed. A1= Shave allowance for second shaving operation is employed.

Note:To improve the flatness of blank used to produce a better square cut edge, it is necessary to keep up side down in the

shaving. The striking force required for shaving operation is two to three times that of the stripping force required for the

blanking, piercing.

8. Fine blanking:Fine blanking is a unique metal forming process founded on the technology of metal stamping. Special

fine blanking presses and custom tooling produce parts that are too complex to make accurately by conventional stamping.

Features of fine blanking are: Components of very high accuracy are attainable tolerances of ±0.015mm are achievable. Holes with a dia. as small as 60% of the material thick can be pierced. Material up to 15mm thick can be fine blanked. Eliminates the need for secondary processes like reaming, shaving Components remain very flat. Compound nature tooling. This ensures superior positional accuracy between features. Tooling prices are competitive compared with conventional tooling. Virtually any metal can be fine blanked Components can have features such as countersinks, extrusions, semi-piercing; weld projections, coined chamfers, counter bores, and offsets.

Relation between Shear forces, Vee ring force & Counter force:The most important factor for determining the type of machine to be used is the shear force. In practice

the formula used is as follows:

F = L x S x T max

F = Blanking or shearing force (tones or kg) L =Total of outer and inner shear periphery lengths (in. or mm) s = Material thickness (in. or mm) T max =Tensile strength (t. /sq. in. or N/mm²)

If Shear force FS = ‘x’ tones then,

Vee ring pressure FR = 50% of ‘x’ (shear force)Or

FR= lr x h x TmaxFR = vee ring force. h = height of vee ring.

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Rm = Tensile strength. Lr = length of vee ring.

Counter pressure FG = 50% of Vee ring pressureOr

FG = As x QgFG= counter forceAs= part surface without inner forms and holesQg= Selected force (20-70N)

Total Press force F = FS + FR +FG tones

Note: Materials between 30-50N/mm² tensile ratio =30-50% of ‘x’ For harder materials FR= 100% of ‘x’ The common requirement of the Vee-ring must be implied on die and pressure plate, when the sheet thickness is

more than 4 mm. But in case of minimum die roll Vee may be adopted on both sides even though sheet thickness is less then 4 mm.

Vee ring indenter:On guide plate

Sl no. Material thickness a h r

1 1 -1.7 1 0.3 0.2

2 1.8- 2.2 1.4 0.4 0.2

3 2.3-2.7 1.6 0.5 0.2

4 2.5-3.2 1.8 0.6 0.2

5 3.3-3.7 2 0.7 0.4

6 3.8-4.5 2.2 0.8 0.4

On die plateSl no. Material thickness a h r

7 2.8-3.2 1.8 0.6 0.4

8 3.3-3.7 2 0.7 0.4

9 3.8-4.5 2.2 0.8 0.6

On guide plateSl no. Material thickness a h r

10 4.5-5.5 2.5 0.6 0.4

11 5.6-7 3 0.7 0.4

12 7.1-9 3.6 0.9 0.6

13 9.1-11 4.4 1.2 0.8

14 11.1-13 5.2 1.4 1

15 13.1-15 6.1 1.7 1.2

16 15.1-20 6.9 2 1.2

Cutting force:For punch diameter over 1.25 s clearance is 0.5% of sFor punch diameter 0.8 to 1.2 s clearance 1 % of

sFor punch diameter 0.6 to 0.8 s clearance is 1.2% of s.

Typical fine blanking tool.

1. Top plate 2. Bottom plate

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3. Guide plate 4. Top back-up block 5. Bottom back-up block 6. Guide pillor 7. Punch 8. Punch holder with adjusting plate 9. V-Ring plate10. Guide bushing11. Adjusting plate12. Punch retainer with adjusting plate13. Ejector14. Die block15. Piercing punch retainer16. Guide bushing

Bending:Bend allowance is a term which describes how much material is needed between two panels to

accommodate a given bend. Bend allowance, while being oftentimes tricky to determine for all cases, is fairly easy to predict and calculate for many standard circumstances. Determining bend allowance is commonly referred to as “Bend Development” or simply “Development”.

Bend development.Blank length = circumference at neutral axis + straight lengthsNeutral fiber:

L = 2 πα (Ri + k x s) 360

Ri = internal radiusS = sheet thicknessα = angle of bend.K = neutral axis offset (k factor)

For ri < 2t, k = 0.33t ri = 2 to 4t, k = 0.4t ri > 4t, k = 0.5t

Calculation for R max and R min. In order to obtain a permanent set the stress which occurs on bending must be higher than yield point of

the material. The above formula therefore gives the condition for R max. Radius which produces a permanent.R max could be calculated by following formula.Rmax

R max = SE 2sy

R min could be calculated by following formula.Rmin

R min = C 3 S

S = sheet thickness C = Constant referred to the following table.

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If ri is greater than the R max, no permanent deformation takes place.01. Mild steel 1.502. Deep drawing tool 0.503. Construction steel 2.0 04. Copper 0.27 05. German Silver 0.4506. Brass 0.407. Aluminum hard 0.408. Aluminum pure 0.709. Aluminum half hard 1.410. Gun Metal 1.211. Stainless Steel 0.512. Brass 0.3

Bending ForceBending force for Edge bending or Wiping die.

Bending force Fb: 0.33 x Su x W x t 2

L

W = width of stock

Su= ultimate tensile strength. (Kg/mm2)

L = Span = rd + rp + c C = Die clearance.rd= die radiusrp=punch radius.

Pad force:Fp = 0.5 x Fb

Total force:Fn = Fb + Fp

U - Bending or channel bending:

Force required Fs = 2 times force required for edge bending.

Bending force:

0.667 x Su x W x T2

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L

Pad force:FB = 0.4 x W x t x Su

Total load:

FN = 0.8 x W x t x Su

V - Bending Force:

FB = C x Su x W x t 2 L

C = 1 + 4 t L

L = Width of opening.The following formula is also frequently used for V- bending.

FB = 1.2 x Su x W x t 2 L

Curling:Force required for curling

Fc = 0.8 x Tmax x w x s 2 4 x Rc x (1 - µ)

Rc = radius of curling µ = co efficient of friction (0.05-0.1)

Off-setting or joggling:

Force required for off setting is 3 times the bending force (90º bend) if off setting is 6t and more, 8-10 times the V – bending force (90º bend) if offset is less then 6t

Spring Back

Degrees of spring back

MaterialDegrees of bend

5 10 20 30 40 50 60 70 80 90

Aluminium 3003-0 2.2 2.7 3.2 3.6 3.8 4.0 4.3 4.5 4.7 4.9

CRCA (SAE 1008) 3.0 3.5 4.0 4.2 4.6 4.7 4.8 5.0 5.1 5.3

BRASS (dead soft)70/30 3.5 4.0 5.0 5.4 6.0 6.3 7.0 7.3 7.8 8.2

Dead soft stain less steel 4.0 5.0 5.8 6.2 6.8 7.1 7.5 8.0 8.4 8.8

9. Forming:Flanging

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B = A + 5t for t < 1.2 mm 4 = A + t

H = t where t > 1.2 mm

H = 4t where t is 0.9 to 1.25 mm 5

H = 3t for t > 1.25 mm 5

R = t/4 for t < 1.20 mm = t/3 for t > 1.2 mm

Pre pierced hole size.d =

Force required for direct piercing and flanging (with single stepped punch)

Ff = (2-2, 5) π d t Ssh

Force required for hole flanging after pre-punching the hole:

Ff = (1,5-2) π d t Ssh

Embossing/Beading

Force for embossing Fe = Su t L

L = height of embossing or beadSu = uts

Bottoming forceFb=Sy A

A= plan area of bottoming zoneSy=yield of strength

Coining:Force of coining

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Fc=A Pc A = total area of deformed surface (mm²)Pc = surface pressure (Kg/mm²)

Coining pressure p in kg/mm2

MaterialUltimate

tensile stress Kg/mm²

Kind of coining

Letter and pattern

Both sidesLight

coining

Heavy coining

For depth mm

Pc

99% of Al 8-10 5-8 8-12 5-8Up to 0.40.4-0.7

1-126-10

Al alloy 18-32 15 35 14 -- 20

Brass 63% Cu

29-41 20-30 150-150 20-30Up to 0.40.4-0.7

100-12070-100

Soft copper 21-24 20-30 80-100 10-25Upto 0.40.4-0.7Over0.7

100-12070-10060-80

Hard copper

-- 30-50 100-150 -- -- --

Pure nickel 40-45 30-60 160-180 25-35Upto 0.40.4-0.7Over0.7

100-15070-9060-80

German silver

35-45 30-40 120-150 35-40Upto 0.40.4-0.7Over0.7

120-150100-12070-100

Steel 28-42 30-40 120-150 35-40Upto 0.40.4-0.7Over0.7

180-250125-160100-120

Stainless steel

-- 60-80 250-320 60-90Upto 0.40.4-0.7Over0.7

220-300160-200120-150

Silver -- -- 150-180 -- -- --

Gold -- -- 120-150 -- -- --

Note: Pressures for 0.4 over 0.7 are the excess pressures given up to 0.4

Flattening (planishing)Force required for flattening

Ff = A × PA = surface area of flattening portionP = surface pressure

Calculations for tool elements

Movement of stripperYstr = t + 2

Where Y sIr = Movement of stripper t= Thickness of stock

Spring deflection (Y) Y= (3 to 4) Y str

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= (3 to 4) (t+2)Where

Y = Total spring deflection at F max load

Sharpening allowance 'S' is provided on the tools

Y max = [(3 to 4) (t +- 2)] + SRubber blocks: Shore hardness recommended 65-68 Possible Max. Deflection =40% of it’s original height. Force developed under this deflection 25-35 kg/cm2 Expected life of rubber blocks =b 3 lakh cycles where rubber blocks are used. Space between blocks should be more than 1.6D to allow for bulging.

Press Tool design check list

Preliminary planning

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1. Has the blank been developed with due regard to best grain direction, to stresses and Strains, involved and to the press working equipment to be used?2. Are idle s stations needed in a planned-progressive die?3. Check for required dimensional accuracy be realized from the planned stock strip layout?4. Can the burr be so placed as to require no removal?5. Is the correct side of the blank up with respect to any shaved portions?6. Will any forming be done across the grain (optimum), or not to exceed 450

7. Is material utilization maximum?8. Have proper provisions been made for clamping the die set to press?9. Have the design feature been checked against the shut height of the closed die?10. Have unavoidable delicate projections been designed as inserts, for easy replacement?11. Has the centerline of pressure been properly established?12. Have any pilot-hole punches been suitably located?13. Has the final sequence of operations been thoroughly checked and established.

Punch planning

14. Have any notching punches been located and, if needed, provide with heel blocks or other backup support?15. Has it been determined whether shedder provision is needed on any forming punches?16. Where small pierce or blank punches are to be grouped closely together, are they stepped to reduce total

shearing pressure?17. If punches must be used having more than about 4-in. unguided length, have spacers or filler plates been

considered?18. Have heel punch fillets been made as large as possible?19. Have spanking punches, if any, been located at next-to-last station and, preferably, combined with bending or

forming?

Die plate and punch plate

20. Provided the intended service requires it, has the die block been Specified to be finished square on all sides21 Have edges of die openings been designed a minimum distance of 1 to 11/2 times block thickness from

outside edge of block22 Have the punches and dies been designed sectional, where feasible, for easy construction, hardening,

sharpening, and replacement?23. Are any finger stops so located as to avoid cutting on only one edge of the die?24. Will inserts and bushings be planned wherever needed to-facilitate die making, heat treatment, or easy

Replacement of worn or broken sections?25. Has a selected die set been checked for parallelism of mounting surfaces? For of guideposts in their

bushings?26. Have needed scrap cutters been suitably located?27. Have adequate provisions been made for scrap disposal?28. Has doweling been checked for sufficient size to withstand shearing action; for spacing far enough apart; for

means of removal from blind holes; for advisable staggering to prevent miss assembly?29. Is the punch plate sufficiently thick to support all punches adequately?30. Have any necessary clearance holes in die block or stripper been checked for transport of blanks or slugs?31. Have any hardened punches been designed to be mounted in a soft plug, rather than pressed directly into a

hardened punch plate?

General design details

32. If die setup are to be used, are they large enough for needed rigidity, and far enough apart?33. Have any needed release or vacuum pins been checked as to location and action?34. Have blank hole, scrap hole clearances been checked?35. Have the sizes of all springs been calculated?36. Have bushing decisions been checked as to need, location, and optimum length?37 Has the planned piloting practice been checked as to removability to facilitate punch grinding, for adjustability,

And to avoid miss feeds?38 Have bolt heads in die plates been set sufficiently below the top surface to permit maximum die sharpening?39 Have any necessary air vent holes been located?40 Are stop or bumper blocks needed anywhere?41 Has a thorough check been made to ensure safety to the operator, the die, and the press?

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Heat treatment.

Design is the sum total of many variables among which are geometry, mass, surface area, surface finish, material used, method of fabrication, and heat treatment.

Heat treatment is the most severe operation any tool or die must go through and it is necessary that ease or safety in heat treatment be given every possible consideration when designing tools and dies.

Some of the basic rules for design, directly related to heat treatment, are given in the following slides

1. Use sufficiently oversize stock to insure freedom from surface defects and decarburization after grade selection is made.

2. Generous fillets should be used whenever possible to minimize stress Concentration during heat treatment.

3. Avoid sharp re-entrant angles; also square inside corners.4. Avoid thin-walled areas. Increase cross section in such areas if possible.5. Avoid drastic changes in cross section. Use steps of taper whenever possible.6. Use sectional dies if the design is considered to be hazardous7. Avoid the use of blind holes when possible, because they tend to alter uniformity of cooling.8. Use fillets at base of keyways to minimize stress concentration.9. Avoid use of large masses. If design permits, incorporate a hole to facilitate

Spring Selection Steps

19

In determining the length of a spring, it should be remembered that maximum delivered spring load is obtained by selecting longer springs.

For best economy and saving of space, choose Light and Medium Load springs or the Heavy Load spring having a free length equal to six times the travel, or an Extra Heavy Load spring having a free length equal to eight times the travel. If ratios lower than these are used because of height limitations, the number of springs required will be substantially increased.

Step 1Estimate the level of production Required of the die - short run, constant production, etc.Step 2Determine compressed spring length “H” and operating travel “T” from the die layout.Step 3Determine free length “C” as follows:Decide which load classification the spring should be selected from -Light, Medium, Heavy, or Extra-Heavy Load. Then choose the figure nearestthe compressed length “H” required by the die design from the appropriate charts of spring supplier. Read corresponding free length.Step 4Estimate total initial spring load “L” required for all springs when springs are compressed “X” inches or millimeters.Step 5Determine “X” (initial compression) by using the following formula:

X = C-H-TStep 6Determine “R” (total rate for all springs in N/mm) by using the following formula:

R = L . X

Step 7Select springs as follows:1. The free length “C” must comply with the length determined in Step 3.2. Divide “R” in Step 6 by the number of springs to be used (if known) in order to get the rate per spring. Then refer to the spring supplier catalogs for springs having the desired rate. If the number of springs is not known, divide “R” from Step 6 by the rate of the spring you select for the correct number of springs.

Hardness conversion

Vickers ,HV Rockwell, c Brinell Vickers ,HV Rockwell, c Brinell

940 68 - 410 41 388

20

920 67 - 400 40 379

900 67 - 390 39 369

880 66 767 380 38 360

860 65 757 370 37 350

840 65 745 360 36 341

820 64 733 350 35 331

800 64 722 340 34 322

780 63 710 330 33 313

760 62 698 320 32 303

740 61 684 310 31 294

720 61 680 300 29 284

700 60 656 295 29 280

690 59 647 290 28 275

680 59 638 285 27 270

670 58 630 280 27 265

660 58 620 275 26 261

650 57 611 270 25 256

640 57 601 265 24 252

630 56 591 260 24 252

620 56 582 255 23 243

610 55 573 250 22 238

600 55 564 245 21 233

590 54 554 240 20 228

580 54 545 230 18 219

570 53 535 220 15 209

560 53 525 210 13 200

550 52 51 7 200 11 190

540 51 507 190 9 181

530 51 497 180 6 171

520 50 488 170 3 162

51 0 49 479 160 0 152

500 49 471 150 - 143

490 48 460 140 - 133

480 47 452 130 - 124

470 46 442 120 - 114

460 46 433 110 - 105

450 45 425 100 - 95

440 44 41 5 95 - 90

430 43 405 90 - 86

420 42 397 85 81