r WBernias oven Chapter. 2 FUNOAMENTALS OF DIE DESIGN 2.1 Single Dies and Progressive Dies 2.1.1 Type of Single Dies fe required to be able to explain the type and characteristics of dies involved in the follosing single ate: (2) Blanking ate @ wing die (3) Bending and flanging dies cc) drawing ete (5) Miscellancous forming dics 2.1.2 Qutline of Progressive Dies es. Te necessary to knov the following advantages and Wisadvantages of progressive dies (2) Advantages @) sing speed is 1 (b) Die rigidity 12 improved (©) Extrene distortion does not occur in worked pisces (@) Suited to high-production (2) Disadvantages (2) Hot suitable for products of high dinenstonal accuracy because of Lint 14 Feed positioning accuracy () Distortion may be caused by partial different resistance due to carrier andics jmumoert oat 2 rene 6 IE Ssigk TS (e) Forming behavior is sometimes difficult, inaccurate oF impossible, depending on the product shape. (@) The thickness and wideh of works and che works to be used are Limited by different feeder specifications (@) High cost 2.2. Design of Single Dies 2.2.1 Blanking Dies (a) type of blanking ates Te fe necessary to know about the structure and characteristics of the following blanking dies (a) Blanking ate () Pheretng die (©) Shearing ate (a) Parting die (e) Notening die (f) shaving aie (2) Compound die (4) Fine blanking ate (2) Fondanentels of Blanking te ts necescary to have a basic Knowledge of blanking (@) Calculation method for blanking load ie ts necessary to have @ basic knowledge of the factors for calculation of blanking lead and to be able to pei © Calculation formulas (with and without shear sngle) ® Shear strength of various workswane weary josie STEAM ) ny apne 2 DET ete 5 @ Full Lengeh of sheared contour © sheet thickness Shear angle and penetration rate (with shear angle) © varie type, shearing speed, blanking teaperature, lubrication) correction values (punch-and-die clearance, atripper (®) calculation m hod for strtoping force It 4a requized to know the factors for calculation of stripping force and to be able to perform calculation. © Calculation formule @® Shear strength of various sheet metals @ Shact thickness @ Clearance between punch and die (©) Catculation method for lateral force Tt is required to know the factors for calculation of @ catevlation formula ® Maximum blanking Jad @® Correction factor for individuel work (@) calesiaeton method for shearing enersy Tt is necessary to know the factors for caleulation of shearing energy and £0 be able to perfora ca! @ Cateaiation formula © Maxtnun blanking load © sheet thicknesspenail aS mecei (e) Gut edge of worked pisces It is necessary to know the factors affecting the cut eige of worked pieces and conditions for making the cut edge required. © Maters property @® Clearance between punch and die © Contour to be blanked @ Shearing speed () Relation between clesrlance and dimensional accuracy Dimensional accuracy of blanked pieces depends on punch= and-die clearance. It is necessary to know the effect of clearance on dimensionsl accuracy under the following (Dinensionat accuracy involves hole and outer dianeter accuracies.) © Matersel property @® Effect by rolling direction of material ortion of worked piece It is necessary to kmoy the factore affecting the Afetortion of worked pieces. @ Clearlance between punch and die ® Presence or absence of blank-holder (m) cateulacs yn method for blanking load center Te is necessary to know the celculat on method for blanking load center,Cason 2 RONERTAS OF EHESTON 79 © flanking load center of parte of pattern shape (etrele, ere) | triangle, tetragon, sector form, etc.) | @ Discking load center of parts of complicated shape | @ saning toad center of perforated parte (D) determination of veb width (carrier and bridge) It de necessary to know the dtens to be considered in determining the width of web. © effective use of material (Increase in utilization) (ote: Minimun web wideh date should be considered) 7 @ Maceriel feeding accuracy 4) Position of pilot 44) Web width aynchronizing to working speed required Dinenstonal accuracy of products > 44) Residual otvese due to slitting of material © Mininws web width date i) Material property 44) Sheet chickness Et) Blank shape (efzete and rectangle) 4) Effect of deformation resistance distribution } ] G), Blanking Limit be Te ds necessary to know the following working Limite. imtoo (cutting-edge) dimension possible for pieveing ee is necessary to know the factors for determining che ‘inimun piercesble dimension and to be able to determine the dinension, (2) Materiel propertyED ChSe be OBE Le Cupar 2 ERs OF Eaten 8 4A) Presence or absence of stripper guide 4) Round or rectangle hole @ Miniaus disension of hole pitch As necessary to know the minimum digension of hole piteh © Working Matt dimension of blanking It ds necessary 0 know working Limits in blanking. Rectangular and tapered projection Limit dinensions 41) Rectangular and tapered notching Linit dimensions 114) Minimum distance betveen the edge to be blanked and round hole cireunference jy) Minimum distance between the edge to be blanked and rectangular hole eizcunference © Minimum distance between hole circumference and the edge of work Te ds required to be able to determine che sinimm distance to che edge of work in piercing. © Limit width dimension in parting and notching It Se required to know Laie dimensions, depending on parting and notching shape. (2) Fondanentals of blanking die design (a) Design consideration designing blanking dies. © Feononical blank layout ® hecurance of dimensional accuracyaces a Data 2 FOMENTAS OF IE esi 83 Te 4s required to know the {tent to be considered for the 4) Working sethod (cut-off, shaving, fine blanking, etc. 44) Proper clearance between punch and S41)dLe structure (rigidity, strength, surface roughness, etc.) tv) Selection of press machine (capacity, rigidity, horizontal and botton dead center accuracies, ete.) Wear condition of cutting edge © Press specification Tt ds necessary to know the press specification essential for designing. (cf. 1.1.5) © Selection of press for blanking It 4s necessary to know the factors essential for selecting 4 press for blanking {) Posesbie of suitable for blanking 41) Production quantity (production rate and total production ii)uaterial shape (coll strip, sketch blank, strip sheet, etc.) 4v) Supplying method of saterial and waloading method of worked pieces ¥) Blanking losd vt) Hecentese load and concen rated loa ‘vit)Disensional accuracy of worked pices Vid) Number of working processes aectingDam Ht Chster® RABEL OF IE BSN AS It de necessary to know the stone requived for setting @ die fon the bolster of press wachine. 4) Check alignsent of blanking load center with press center 44) Prevent concentrated load on the bolster. 441)Place the die 90° that worked pieces and si sp8 WiLL drop © Transfer method of worked pieces Te ds required to know the types and characterietics of the transfer method. 8) chute eype 44) Relt-conveyer type 44) Pan eype iv) Gylinder push type © Punch 2) Punch engeh Shape and ef ctive length of punch, presence or absence of punch guide and material property are ko be considered to prevent buckling. 44) Shear angle Apply shear angle, if necessary, considering pre capacity, sheet thickness and die inclination, 21)Panch hetght Jihen a nusber of holes are punched aimultancously, variegate punch heights so that blanking force 1a distributed. iv) Punch design considering dimensional accuracy of productsepee 2 RAGES OIE 887 @ me 1) Effective use of ate bushing 44) Prevention of sorap pulling 1141)Prevention of serap clogging Av) Die design considering dimensional accuracy of products and ® Prevention of scrap (or worked piece) pulling or Lifting It te necescary to know the preventive measures of scrap polling. 4) Bjecter pin Ejecter pin should be Located in such a manner that scraps (or worked pfeces)do not tneline 44) Ate blast 44)olearance between punch and die tv) Chanfering of die cutting edge (only for scraps) ¥) Atr suction (only for scraps) vi) Application of shear angle at punch nose point (oaty for scraps) vis)Deposited die @ Prevention of slug clogging in small holes Te ds necessary to know the preventive measures of elug logging in ens holes. 4) Stopped draft cavity for scrap dropping-through 44) Push-through eype draft cavity for preventing Jouning 11s)Uae of pipesBoke ome ape? ORES OF IE aIGK 89 4v) Inclination Litt of scrap deate cavity ¥) Ate efection vi) Clearance between punch and die vii)Use of slug breaker(for side hole) vist) Tapered draft for side hole ® Serap handling Te Se necessary to knoy the factors to be considered in scrap handling. Safety planning Prevention of scrap scattering and sharp edged scrape 44) Serap gravity-feed systen in each stroke, in principle 148)Use of scrap dropping assist Kicker pin, ejecter pin, ete: v) Preventive measure for scrap clogsing Size of eunnel A tunnel for 4 typ of scrap, in principle vt) Chute righasey viiProvision of storage place for scrap chute, if used visa) Fective use of roller carrier and conveyer @ Wigh-produetion planning Te is necessary to know the factors to be considered in high-producefon, 4) Selection of proper die-parts (punch, die, die set andapne 4 FRETS OF IE SLO 91 igcellaneous die cosponents) 44) Long Life punch and dle type say tote thangeable punch and die type 4v) Easy maintenance punch and die type v) Selection of proper dfe strveture (pplication of backing plate, ete.) (4) Blanking die-parts design (a) Fixing wethod of punch It is necessary to know the types and features of fixing method of punches. © shoulder type (Fig. 2-1-2) ) 1) Ponch perpendicularity # easy to obtain, 44) Conmercial punches are available ® ‘ole palt type (#ig.2.2.(2)) 41) Punch perpendicularity 42 easy to oben 44) Commercial punches available. 441) ¥asy punch removal @ setscrev-retained type (Pig-2-1.(3)) 4) Basy punch resoval © Side bolt-clanped type (Pig. 2.1.(4)) plate-fitting type (Fig. 2.1.(5)) 4) Baoy punch removal © Side bolt-retained type (Fig.2.1.(6))ope 2 RAB OF BE ESL 9B pall lock type (Fig.2-1-(7)) 4) Easy punch renoval 4) Sonetines difficult to obtain punch position accuracy and peectee punch perpendiculerity @ dowel pin & bolt-retained type (Pig. 2.1.(8)) 4) Used for Ekxing larger punch © Quit type (Fig. 2-1.0)) 4) Designed to prevent punch froa buckting () Preventing method of punch rotation It {s necessary to know the types and features of preventing method of punch rotation: © Use of dovel pin @ Uwe of key © Rotation-preventing face around pune (c) Preventing method of round button die rotation tt 4s necessary to know the types and features of preventing method of button die rotation © Wee of dovel pin uv © Rotation-praventing face around button die (a) Die eectioning Tt de necessary to know the itens to be considered in sectioning dies. © Bach die section mist be securely located and fastened.eter 2 FIBERS OF EHSL 95 eee i ach fe seetfon must have a shape easy for machining, parcievlarly For grinding. Dees t @ Each die section must have a shape possible to check j dinenstonal accsrazy. i | © Priscipally, a sectioning Line eust be normel tothe | eeecreetes’ | ; | © die insorts may be effectively used in concaverconver pat. | © sectioning most be performed considectag the presence 0 ) | (e) Fastening method of soctioned de blocke stocks Driving eype (Fig.2.2.(0) Shoulder type (Pig.2.2.(2)) Botton bolt-clasped type. (Fig.2.2.(3) ) ‘Top bolt-clanped type (Fig-2-2. (4)) © Segment shrinkage fit type (Fig.2.2.(5)) @ Wedge type (Fig-2-2. (6)) © Gross-key type (Fig.2.2.(7)) © Cross-volt type (Pig.2.2.(8)) © Dowel pin & bole-clanped type ( 5.2.2. (9)) (2D die plate design It 4s necessary to know the itens to be considered in designing die plates. Thickness of afe block Te ds necessary to know the itens nesded to determine the chteknese of aie blocks.—_—K—_—K—K—K—a—_v—=x=euoooe 4) Calculation foreula 44) Blanking oad {Various correction values (cutting edge contour Iength, aie block property) ® Minton slloveble dimension between cutting edge and aie peripheral edge It fs necessary to know the itens to be considered in determining the minimum allovable dinension. {) Calovlation formula 46) Thickness of die block Ls) Correction values according to the cutting edge shape Yintoun allovable dimension between tapped hole and die peripheral edge Jt is necessary co know che following items to be considered in calevlating the mininun allowable distance. 4) Catewlation formule 44) Bol dteneter s)Correction values depending on ate block dened of son-hardened © Minteus allowable dimension between tapped hole and dowel Ie 4s necessary to know eens required co calculate 4) Calewlation foraula 44) Bolt afsneter Lit)Correction values depending on hardened or age block snon-hardened90008 — @ Xe is necessary to know how to determine the ainimun allouable dinenaton, @ Relation between die. steel thickness and clanp screw dianerer Te 1s necessary to now the proper dle thtckness corresponding to the dianeter of clanp screw. (@) Design of plates Te 49 necessary to know the itens to be considered Sa designing plates. © Punch plate D Function ‘The punch plate helps to maintain accurate position Of punches at right angie. Determine plate thickness by punch dtamete © sacking plate 1) Fenetion The backing plate helps te provide @ backup for punches and die bushings, resulting in longer éte life. 44) Application standard Use backing plate when average surface presure exceeds a constant value. (Pa P/S vhere Ta te avarage surface Pressure, P blanking load, contact area) © stripper plate 4) Function The stripper plate serves to hold scraps doen clamp vorked pleces and guide punches. Clearance betwcen stripper plate and punch Proper clearance values should be chosen according to the ”Coupee 2 RUE 8 es TOL ) | Function of strippers. | i Ht)Metghe of punch nose point cee Te fs necessary to be able co determine the proper heights of stripper botton and punch nose potnt. | iv) Preventive seasure of stripper galling | short punch guide 1s recommended. | | (i) Retaining mothod of stripper | | Te ds necessary to know the types and characteristics of | stripper retaining sethod. . © Stripper bolt-retained type (Pig.2.3.(2)) ° 4) Low cost Re if) Longteudinal accuracy of stripper bolte directly affects the parallelisn of stripper @® Collar bole-retained type (Pig.2.3.(2)) ) 1) tow 60% ii) Parallelion of strippers is easy to obtain. @® Bolt-clamped type (Pig.2.3.(3)) 1) Low cost my 4) Parallel adjustment of stripper is required each time of Ateassenbling. ® knockout-pin-retained type (Fig.2.3.(4)) i) Parallelicn of stripper is easy to obtain. © Hanger plate fing type (Fig.2.3.(5)) 4) lsgh rigistty peraite high-speed blankingfl. am | Chote © RRO OF HIE SER 103 (4) Retaining nethod of spring lary to know the types and characteristics of It de neces inetallatéon method of apring. © sertpper bole saside of spring (Fig.2.4.(1)) ® Spring retaining pockets 4) Both-side counterbored spring retaining pockets (Fig.2.4. @) 11) One-side counterbored spring retaining pocket (Fig.2.4. (3)) 444)Bott located (Pig.2.4.(4)) fv) Gulde-pin located (Fig-2.4.(5)) @ Koockout pin used (Pig.2.4.(6)) (3) Design of pilot pin Te is necessary to know the tens to be considered in Te 49 ‘necessary to know the type and characteristics of pilot pin structur 4) Solid pilot pin (Fig.2.5.(1)) 46) Spring-backed pilot pin (Fig.2.3(2)) iit)center pilot pin (Fig-2-5.(3)) © Fesentials of pilot pin desten 1) Shape of pilot pin nose poing Te ds necessary co know the type and character pilot pin nose point in arance between pilot pin and guide holehowl Courter © ROMEO te ses 105 Tt is necessary to “be able to set the cloarance corresponding to dimensional accuracy requized 442)aLlovance pilot pin straight length it 4s necessary to know the protruding allowance of pilot pins raight from blanking die cutting edge and stripper plate botton face. (h) Becter pia Te ie necessary to know the type and characteristics of ejecter pins. ® ecter pin for punch (Pig.2.6.(2)) @® jecter pin for steipper (Fig.2.6. (2)) @® shecter pin for piloe pin (Fig.2.6.(3)) (5) Main blanking dfes and characterteties (@) Type and characteristics of blanking dies Te ds necessary to know the basic structure, type and characteristics of blanking dies. ® Basic structure of blanking die (Fig.2.7.(1)) ® Fixed stetyper type (Fig.2.7.(2)) 1) Low cost $8) Suited to high-speed blanking 444)Dish deformation aay occur in blanks. iv) Difticult to remove scraps at atss-punching ® Koockout-sctuated stripper type (2, with eub-guide (Pig. 2.70) 4) Migh-aceuracy production possible 44) High coster 2 ROWE 6 Eee 167 © ‘nockout-actuated stripper type (11) with common guide for upper & lower die holders and stripper plate (Fig.2.7.(6)) 1) High rigidity of striper plate ) Wigh-accuracy production possible {t)Lower cost compared te knockout: etuated stripper type (1) iv) High technique 46 required in spotting, © Compound type (Hg.2.7.(5)) 4) The same blanking surface between holes and blank edgo 48) High position accurecy between holes and blank edge st4)High cost © Pushback type (eig.2.7.(6)) 4) Blank ie held fairly flat. 44) Adjustment for secure push-back 4s atfr: () type oF ptoreing dies necessary to know the baste structure, type and characteristics of piercing dies. © Baste structure of piercing die (Pig.2.8.(1)) ® Fixed stripper eype (Fig.2.8. (2)) @ Inverted knockout-sctuated stripper type (Pig.2-8.(3)) © kockou Actuated stripper type with guide-pin Fig.2.8. ® Gutde-pose guiding Knockout-actusted stripper type ¥ig.2.8.(1)) © Worn-type (Pig-2.8.(5)) (©) Characteristics of shaving dieTe is necessary to know aboi D Relation between shaving allovance and material property @ Relation between shaving allowance and blanking clears the preceding operation @ Shaving direction @ Clearance between shaving punch and die @ The case where shaving is performed more than twice @ Pores necessary for shaving 2.2.2 Trimming Otes (2) Type of trinming dies Te {2 necessary to know’ the type and character © Pinch trinming die (Pig.2.9.(0)) 4) Draw-piach ertmmang a0 54) Posh-through pinch trimming die ® Plosh-teim die (Fig.2.9.(2)) © Wipe-dowm erin die (Fig-2-9.(3)) © Trim flange die (Fig.2.9.(4)) © orn-type tetaming die (Pig-2.9.(5)) © shinny ate © Camactuated trimtng de (2) Fundamentals of triaaing die desige (a) design consideration 109 sc8 ofecucway 1 4s necessary to know the items to be considered tn trimming ates. © om deration of de rigidity and selection of press achine of proper capacity ) Die for repeated redrava parts (with thickn & change and work hardening) 44) Die for products with vertical or inclined edge to be erinned @® Selection of erinming die on the basis of sheared edge and bare aide @ Ise of simvitaneous working operation (Drav-blanking,trim- pierce, trim-cut, etc.) 4) Consideration of operation tinting @ Sectioning method of shearing edge 4) Consideration of strength and orking method 14) Location of Joints of upper and lover shearing edge nt of rough trinaing ® Accompiistn @© orablishnent of die datua Line he 1) Consideration of other working operations © Trinming wothod of parts with inclined edge ® Trinning othod of parte with vertical edge Other itens are sistlar to those for blanking die design. 2.2.3 Bending and Flanging dies (Q) Type of dending and Flenging dies13 bending and flanging dies. (a) Baste structure of bending die (Pig.2.10.(1)) (&) Webending die (Fig.2.10.(2)) (6) Rage bending die (Fig.2.10.(3)) (2) Snap-lock bending die (Pg.2.10.(4)) (e) Hemming aie (F1g.2.10.(5)) (8) Woending die, Flanged U-bending die (F43.2.10.(1)) () Corting ate (Fig.2.0.(6)) (h) Pipo-and tube-forming dte (Fig.2-10.(7)) 10. (8)) (1) Corrugating end Reforming te (F: GG) Ribbed seaming até (Pig.2.10.(9)) (1) oFsset-box-forming die (F4g.2.20. (10)) ) @) counter pressured typ Special purpose bending die © Bolt bending © Bending by poly-urethane ate ) (2) vondas als of bending end flanging work Te is necessary to have s basic knowledge of bending and Flanging work. (@) Calculation method for bending pressure <, MEA Tk te necessary to know the factors required to calculate the bending pressure, and to be able to perform calculation,power Cater 2 RAGMEALS 6 HE esth TIS © ‘Type of bending ) Vebending (free bending and constrained bending) i) Wdending (Free bending and constreined bending) ALD L-righe-angle bending tv) Rending of nore than two aides at & tine @ Calevlation formulas Different calculations for different beading types wentioned above @ Tensile strength of various works © Sheet width (Bend Line Length) @ Sheet thickness © Die opening width (b) cateulation method for working energy oF power required for bending 1k ds necescary to know the factors required to calculate the working energy, and to be able to perform caleuletton, © type of bending 1) Vobending 18) U-bending ® cateutation formuleBRICK OT ptr 2 FMDMOHHS OF BLE SION 117 (e) Mininun bend radius Te ie necessary to know the factors to determine the ininimum bend radius, and to be able to provide the value. @ Macerial property @ Material characteristics Bending directfon and rolling direction @ Finteh condition of edge surface 0d (@) calculation ne blank development Length at bend Te 4s necessary to know the variovs calculation sethods for blank development. Approximate nethod Sun of neutral axial lengths of straight sides and bent pert (Fig.2.11.(1)) @ Stnplitted method the neutral axis is determined seperately for V-bending and bending (A = 1/3 snd A= 1/6 dn V-bending “and U-bending, respectively) @ Hethod of adding outside surface dimensions Metiod of adding all outside dimensions and svbetructing the elongation determined by sheet thickness and bend radius @ Method of adding inside eurface dinensions Method of adding all inside dimensions and adding Strict calculation (Fig.2.11.(2)) ® Coleslation formula fer curling dieDrwoOst ter 2 RACERS OF IE BSHCH 119 © Calculation foraula for henming die @® Celeulation foraula for shrink-flanging 4ie © Calculation foravla for stretch-flanging die (@) overcoming springback Tr de neces ary to kmow the factors affecting springhack, and the method of reducing springback. © Factors affecting on springback in V-bending 1) Maverial property 1) Ratio of bead radius to cheat thickness 144)D4e opening width iv) Bending pressure @ Factors affecting on epringback in U-bending 1) Material property 4) Punch shoulder radius and die shoulder radive LiDWith or without pressure pad, and its pad size fv) Troned or non-troned ¥) Depth of bend vi) Bonding pressure @ Reducing methods of springback in V-bending Providing ribs at bend area Punchs nose petat pressing (Zroning) Lt)Die shoulder pressing Av) Rending with eounter pressure v) Stretch bendingboxe voter 2 Faas oF sceN RL vi) Overbending by can (Overbending by using can die) 44)Use of rubber and apring ® Reducing sethods of epringback in U-bending 1) Rack pressuring method ( se of preseure pad) 14) Contrtvance of pad shape 141)Renedy ( Compression radius avea, slotting on inside or outside surface of radius area ) 7) Placing ribs on radiue area ¥) Making drafe angle at punch nose point vi) Providing projection on the punch where pressure pad © Redveing methods of springback sa Hanging work Adding ribs or beads it) Changing the bending tress into compressive s £3) Ironing 4v) Waking punch shoulder radius small ¥) Making dvafe angle at punch nose poine vi) Providing pusch radius stop on die side (© Countermeasure of faults Te 1 necessary to be able to provide designing wethod against the following faults fa bending and {langing work. © crack (Surface and edge)ote 2 NOMENA FO sas 1B © Inaccurate bending shape knese reduction © ad edge surface (g) Working Limitations and correction ¢ 1s necessary to know the following working linits and © winiaum height of Flange to be bent © Minimum distance of edge of hole to fold Line (3) Fundamentals of bending and Flanging die design (a) Design consideration @ selection of press machine euited to bending and flanging 4) Poseibte or suitable for bending and flanging 12) Curves for bending pressure and bending pres ALt)ocher itene are similar to those for blanking dies ® other design considerations are in accotdance vith those for blanking dies 2.2.4 Deep-Drawing Dies (1) type of deap-arawing ates Te te necessary to know the type and characteristic of deep-drawing dies. (@) Basse structure of doep-drawing die (Fig.2.12.(1)) (©) single fixse-draw ates ok holder (Pig.2-12.(2)) © Push-through drawing die withoutouter 2 rowers oF OE BIEL 12S © Listup draving die without blank holder (Fig.2-12.(3)) © Push-through draving die with solid black holder © Yornal push-ehrough drawing die vith blank holder (Fig.2. 2.)) @ Noraal List-up draving die with blank holder @ toverted bnockout-ejected drawing die with blank holder (#ig.2.12.€6)) () Single vedraw ales @ Push-through redraw die without blank holder (Pig.2.12.(5)) @ Kknockout-ejected redraw die with blank holder(Fig.2.12.(6)) (c) Single reverse redraw dies @ Pushethcough reverse redray dle without blank helder © Listeup reverse redraw die without blank holder @ Pash-chrough reverse redray die with blank holder vse redraw die with blank holder @ nackour-ejected re (eg. 2.12.) (a) Tandem Firat-deaw dfe (Pig.2-12.(8)) (e) Tandem redrae die redraw die (g) Special draving © rubber forming ® tydraulic forming © toca heating deep-arawing ® tocal cooling deep-drawing © spinning(2) Fundamentals of drawing Te 4s nocessary to have # basie knovledge of draving. (a) Fundamentals of planning for cupping operation ie necessary to know the fundanentels of planning for upping operation © determination of blank 4) Blank devetopment 44) Correction (trim altovance) @ determination of drawing rate @ determination of product diameter in each draving process © Planning of whole process procedures tncluding other tha drawing © determination of punch radius in each process @® hetermination of die radius in each process ® determination of depth of drawing 4 ® Calculation of blankholding force @ cateutation of draving force soning for rectangular drawing operation Te 1s necessary to know the fundamentals of planning for rectangular drawing operation. © blank devetopaent ® correction and determination of ¥ian @ determination of sectional shape in each process ® other teens are sintlar to those for cupping operation, (©) Caleutating method of surface area and blank diameter forreHae seme eylindeical-shaped dram product Tes necessary to know the calculation formla for the surface area and blank diameter: (2) determination of blank shape and dinensions for rectangular-shaped draym products Te 1s necessary to knoy the calculation formula for the blank shape and dimensions. (e) Limiting deaving ratio ( or Limiting draving rate ) Te ie necessary to know the factors affecting the Matting ratio, and to be able to deteraine the ratio. @ Yaterial property @ Natio of sheet thickness eo blank dianccer punch shoulder radius and dfe shoulder radius @ Labstestion @ Clearance between puoch and die @ Finish condition of die surface @ type of blank holder end holding pressure © Ddeaviag speed (©) Establishment of punch radius (y,) and die radius (rg) Xe fs necessary to know the factors to determine the proper values of yp and Yq. and to be able £0 determine then. ornula eB By First-drav or redray v9a Leet Couper 2 raawers oF 6 asIO BE © Relationship of yp and ¥q ( Generally, Yp $ Ya) © Gylindrical draw or rectangular draw (@) Betablishment of drew clearance is necessary to know the factors to determine the drav clearance, and to be able to determine it © Drawing conditions ) With or without blank bolder A) Plret-deaw or redraw 1L2)nough draw or Finish érav @ Material property © Sheet chickness © Cylindrical draw or rectangular draw (8) Depth of dravn products UE ds necessary to know the ealevlation formula for the depth of deavn products (2) tronteg, 4s necessary to know the factors required for des: for ironing work, and the effects of ironing. © Determination of droning rate Caleulation method for blask dimensions ©) Calewlation formula © calculation of force necessary for ironing 4) Coleutation formula © Calculation method of working energy requéred for ironingbemoan wT & Cowster 2 RAB 6 teeth 133, 4) Calewlation formule © Effects of sroning 4) Improverent of diuensionel accursey, surface roughness and wurtace appearance 41) Improvenent of draving performance(expressed by the dreving ratio or draving rate) due Co uniformity of shect thickness. Aca)Posstbility of thinning or tapering side walls G) Calculation method for drawing pressure Tt is necessary ro know the the drawing pressure, and to be able to deteraiae it @ Calculation formulae (for cylindrical draw and rectangular araw) © Matoriel property and tensile strength © Sheet ehtekness @ Punch diameter © Fir draw or redraw © Drawing ratio Ao of cheet thickness to blank dianeter @ Clearance between punch and die @ Punch shoulder redius and die shoulder radius ® Feietion and Lubrication condition betveen stenkholding surface or die top surface and blank shee (0) cateulation method of draving energy Te 4s necessary to know the factors required to calculatepina { t Carter 2 eUGRERS OF SK BEKON 135 i the draving energy, and to be able to perform calculation j © Caleviation formula t © braving preseure | © ® Depth of arauing @ conttsctents ( for cyl \drical draw and rectangular dea ) (Q) Calculation nethod of blankhoiding pressure Tt is necessary to know the factors required to calculate the blankholding pressure, and to be able to perform caleulation, © Calculation formias (for cylindrical grav and recteaguler arax) @® vatertal property and tensile strength ® Sheer thickness swing ratio © blenk diameter © Shoulder radius of punch and die @ Pivet-drav o redraw © eiceion and lubrication condition of flange su ) Countermeasure of Faults Te 4s necess: co be able to provide designing mecsure against the following faults in drawing work. © crack (#tg-2-1302)) 1) Drawing crack (at punch shouldee) 41) Wall breateageLb) ouster? RAMOS OE Sst IT s14)vertical crack 4y) Wall crack ® wesnkles (Pg.2.22.(2)) 4) Body wrinkles at punch bottom and wall caused by excessive etal Eloy 44) nuckding kes at punch boctox, all, ie shoulder and Flange © Dimensional inaccuracy 1) Springback (at punch bottom and wall) Af) Mlange defornacion A44)DLetortion © Visual defects (Pig.2. 4) Shock marks (3) Fundamentals of draving die design (a) Design consideration © Selection of press machine for drawing 4) Suitable for craving 1) Use of ate cushion ii)characteriatios of curves for vorking pressure, and stroke tv) Other items are similar co those for blanking dies.lomtee 2 ROMO OF OE OSE 139 @ orner considerations are similar to these for blanking (4) Process planning for draun products Te is necessary to know the pattern of process planning procedures for the following éravn products. © Flangeless cylingrical dr mn products 4) Drawn produce (Fig.2-16.(2)) £4) Deep-draun product © Flanged cylindrical drava products 4) Snall-flange cylindrical drawn product (Fig. 2.14. (2)) 44) Large-flange cylindrical drava product @ Truncaved-cone-shaped érav products 4) v6 haved product (P4g-2.14.(3)) 11) Pan-shaped product 4v) Lazge-Clange cone-shsped product © Nemtepherical-botton-shaped drawn products 5) Reflector-shaped product 8g. 2-14. (4) 44) Done-shaped product Rotational parabolic-chaped product © Stepped eylindricel dean products 4 4) Drawn product with little different dienet: i 44) Decp-dravn product with much different dianeters (Pig.2-14. oo)pie? aati o eset 141) Taper-stepped drawn product with much different dianeters iv) Curve-stepped dram product with auch different dianeters © Rectangular dram product (Fig. 2.14. (6)) @ teencated-pyranid-shaped draim products 4) Saoothly-sloped pyranid-shaped drava product 44) Severely-sloped pyramid-shaped draum product (Pig. 2-14. m igo of draving éie-pares It is necessary to know the function end application of © Guide type 1) ouide pose 42) Gutde bushing idouide plate ® Blank positioning parte Drawbead Die positioning block Hjecter pin and knockout pin © Litter pin 2.2.5. Miscellaneous Forming Dies () type of miscellaneous forniag dies Te 1s necessary to know the miscellaneous forming dies. (a) Bureing die ® Fundenontals) apie 2 TG FE esi ES 1) Calculation wethod for burr height i) Eotinace of reduction of sheat thickness Hi)fotinace of burring Liste @® type of burring dies 4) ureing de 41) Pleree-burring dfe (#g.2.15.(1)) 144)Pierce-enbossing die (Pig.2.15.(2)) (©) can ate wentals 4) Daleulation method for pressure required in cam die 44) Caleulacton method for vertical load applied on the wear plate $84)cam diagren £0) cam shape design v) Design of retura aystem vO) Design of can pad It fe te oe the type and structural characteristics of cam dies. ) Single can dle (Horizontal, upe d tnelined or down inclined setion) 41) Double cam die (Pig.2.16.(i)) Si)Upper sit cam die (Pig.2.16.(2)) 4) combination system cam dieotHatee mist oet ter © RROBOHTLS OF BE HESTON MS (e) Bulging aie (a) Necking ate (e) sexetch forming de 2.3 Design of Progressive Dies 2.3.1 Type of Progressive Dies It ds necessary £0 know the type and characteristics of progressive diss, and the design consideration. (a) Progressive blanking fe (Fig.2.17.(1)) (a) Relation between pilot position and pilot pin height (b) Alot pin size, nose point shape and pilot pin type(Direct or indirect) (©) Operation type at final stage ( Blanking, shearing © ing ) (2) Progressive eutting-forming die (Fig.2.17-(2)) cutting (blanking, shearing of parting) dnd 8 ‘coupleted at final stage. (a) Height of forming punch (ounted on lover dfe)and shearing ate cop (b) selection of upward or downward bending (e) Separate structure of bending punch and shearing punch, from maintenance consideration (2) Operation type at final stage (3) Progressive lancing-forming die (Fig.2.17-(3))syne 0) Rowe snogare ater 2 CHENTNS OF OE HON 7 Shearing and forming are performed at intermidiate stages, and operations are completed by shearing or parting bridge: (@) ending by mulefpie operations ( Overcoming of springback and inprovenent of dimensional accuracy) (®) Leation of carrier and bridge (Center, both aides or one side) (©) Relation between material rolling disection and shearing (a) Bteceive use of can slide ©) Effective use of Lifter pin, seripper and knockout £) Operation type at (W) Progressive drawing die (¥4g.2.17.(4)) (a) Selection of downward of upward drawing eype () shape and size of hour grass blanking Bffece to saterial stock width and feed pitch (©) Type of Lance elit Effect to aaterial stock width and co thick and hard matecial (@) Bifective use of Lifter pin, stripper and imoekout (3) Pushback ate (149.2.27.(5)) cked parts, pushed back to the strip of without dropping off stefp, are transferred co the next operacion (a) Doterminacion of contact amount of punch and die (©) Calculation of push-back forceSe CRA. ree ae asmane voter 2 FURIES OF ESIC 149 (©) Method of positioning pushed-back parts at the next stage 2.4 Die Design ané Orafting Techniques 2.4.1 Engineering Orawing () Te is necessary to have a knowledge for detersining the proper shape, geometrical and dimension¢] tolerance of produce (2) Te ts necessary to be able to make an enginecring drawing by using symbole of geometrical tolerance. () Te is necessary to know the nessur: seonetrical and dimensional tolerance of product. 2.4.2 Deformation Properties of Works Lt I required to know the deformation properties of works. (cr. 1.1.2 - a) 2.4.3. Layout Drawing () Te ie required to have a knowledge for making # layout satisfying the shape, geosetrfcal and dinensional colerance ecified on the engineering drawing (2) Te is necessary to imo the method of making a layout based on the Fteations. (a) Press spec: ations (Capacity, stroke, shut height, opening size) () calculation aethod of load center for layout (3) Te is required to know the method of making @ layoutRr, PEWSE Le Dia he | amp paces come Gunter © Moen oF ee te 154 (2) Inprovanent in stock utilization (®) Multiple-row arrangement 2.4.4 Assembling Drawing and Parts List Te ig required to know the For making assembly drawings and parts 2ists. (2) braving procedure of plan view of upper die (plan view from punch), plan vier of lover die (plan view from die), sectional view and side view of upper and lower dies, and principle of arranging then on a drawing (Pig.2-18.(1)) (2) Dimensions to be spect a) 4 on asseably draving (Fig.2.18. (2) Application and making of cross-sectional view of ond lower dies and partial sections (4) contents to be desersbed in parts List (Pig.2.18,(2)) 2.4.5 Ole-Parts Drawing ble to know the following tens necessary for making dis-parta drawings. (2) Reforonce plane Xe ie roquired co be sble to eseablish the proper reference plane suited to available press machine and dimensional accuracy of parts, and to specify the dimensions based on the reference plane. (2) Designation of surface roughness Fa necessary to know the method snd contents of designation using surface symbols and finish sinbols.fi FetRic mieo0co > | nosnes. newer’ (3) Indication of working process or wachine tools Ie ie necessary to know the method and contents for indicating working processes (or chine tools). (W) Attevence for aachining Tt i roquired to be able to determine a propar allowance for cutting or grinding work, depending on aachine type, material property, material size and shape. (5) Working tolerance Te ig advisable to have a baate knowledge for managing wuain parts by establishing the standards for the plant irself for based on comercial standard die-parts. 2.4.6 Material Selection of Main Die-Parts () Material selection points of main die-part Te is necessary to know the factors to be considered (2) Prodvetion quantity ( Monthly production, product change possibility, total production required) (b) Sheet property (©) Dimensional accuracy of product (@) Product shape (0) Size of parte (Relation to quench distortion) (©) Existing available working machine (2) Selection of material for die cutting edge (Fig.2.19) Te 4e required to know the uaterial properties ( vear 153>, FOE Coupee 2 FOUTS OF te est 157 (©) Backing plate Gatde pin and guide bushing (2) Pélot pin and pilot pin guide bushing ( Gutde plate for works (@) Scop pin for works (h) Guide Litter pin and atop Lifter pia (D Bjecter pia 2.5 Die Design for Safety 2.5.1 Baste Conditions for Die Design for Safety Te is required to know the designing conditions necessary for safe operations, aad to be able to instruct safety practices (2) Autonseson (2) covering (3) Movenent Linitation in movable parts (4) Relief tn novable ps (5) No or Less clearance between movable parts, for instance, guide poet and bushing (6) Rigtatey of parts (D) Prevention of aro (8) Prevention of loosing (9) Prevention of falling off (20) Prevention of breaking(LD Prevention of siépping out (12) Prevention of shank rotation (23) Chanfering of corners (14) Visual convenience (25) Indication of cautions and dée weight (26) cote coding of a: gerous die-parts (27) Safety precautions for die setting The arrangement of getting grooves and munber of setting bolts are to be considered. (48) Safety in eransferring dies 1g of upper and lower shoesWee for wain dieparts, and able to select che proper material. (2) Conented carbide () Ferro-tsc (e) Powder high speed tool steel (2) tigh speed tool stect (SKI, ete.) (©) Alloy tool steel (SKDL, SKDLL, SKS2, SKS3, ete.) £) Carbon tool ateel (SKS, ete.) (e) Batnive (8) tine alloy (3) Macerial selection for die see (Fig.2.29) Te 1s necessary to know the properties of the following saterials for die set and to able to select the proper material (2) Sphesoidur yeaphlte tron (F630, © (©) Caxbon steel for machine structural purposes (850C, etc.) (2) Rolted steel for general structural purposes (S841, ete-) (e) Aluminiua alley ‘ (P%.2.19) al selection f miscellaneous ain die-parte Te ta neces ry to know the type of materials to be used for the following aie-parts (Eig.2.19) 12 and die plate () stripper plate160 mre exutous 0) seem se SBRRD at () Shoulder eye (® Bolt pull type 3. Setsorowe retained Beas G77 ti ss isn fee Lidl YZ K sua rape aaame| vere] a ieomin|etn | ets [banat Teas euae Pate | | OLR | Sees [ss | ONT a ae ct the | &y |S. kage 3 all being nd ing 1 foe bead Se ser area. Bande —/ | shear deformation [2X Ax |e Seen Occurs when extersion Senate Sate tet ae Seemed Piet om eree|_~ __ ‘Beslage at ena Die ie ahoider Fads ld Se, pall"bending Sd benelg back eas. Bepal bending So Seong “backouter? owen FO EK 39H ae Ae cree ey omen wet dec eer RBIS 85s. , —s 7] = ==] emis [teed vse Il 1S mena ee a 7 sans | OF ow | ue | | want [a [5 A Ser, Bay wrines — r= ee aw | putine serine ction a — |r Fey a oh , eee) | [Be & emis anged dish type ae J Yo ACRE Spintec @ roasEoE, (Truncated. cone. shaved drown products 4) ames 4) Homiepherice!- bottom-shaned mau Fig. 214 (Continued)196 mtx emmnoxsCouper £m o IE est 197 ) CR mit @ anos 7 fee 2 amet 4 Cup craving 2 Cipiéraving 3 Py {peony OAT OaRMDS mare Ce Fig. 216 (Continued)198 wim auuetons Fig. 215 Miscellaneous forming die2m nen exaions {HHsat wanousno(ate 2 FUGRRIAL oF OIE est 207 5 Fig. 2.19 Die materials pee | Pa = BRS [Pine [toms [tahoe orotsion | pF Tov a0 aoa? [nm (gre aiegeecpe Joe nS ang [P| eve tit eG ot tater mt en Ane ena sq ose YT nannar [Spaeth apt [Di sed SST a E65 ernie (30 oe mer) Hes ecient (Re 38 aD ‘Treatment | Surface t reatment (TD-TIC ete.!| or more. = took | pgaterian | SKBS SKS SKS. $506 woe cating sr rn [at etme te 166)! a a = ease Se a 4 ouaa [BSR LSS, SKS, S50 ee | sernper Ist tenet The60~20) | yep 2s J io nc thes Hp, etme — Punch |atatenay | SKSB. Prebardened stent Sse cutng {Pinte | seam | Hit tenes Re c0~85) | o sets s fixing | Backing | Material /SKS3 SKS3. SKS eat treatment (Re ~60) | eat treatment (Re t0~| ste [eaten : NS en ee ee GE eo | eminent [Geemees etme) oF le SKS3.SK5. Issa sks. | f ste [Meroe B'S eye] a ] Steck [ote | Treatment The ebor'meretinear 1) [docs caine ete oe ~ Js SKD a, scott, sHS3 SeDIIor no ae |Meat etme ait Lae SP [tm [zane vst | Bp trstmen te Sop [otmene | 5658.SUI2, SRE SKS3, 8072, eS ‘ \ewatng x | eat treatment (R586) | ut sratnent fe 5- 1 | pa |e Bat — 4 - = —___| Die [atria SC SA or no we sess | 2 noise | treatmentSEY |. Vernr™! FATp= | ie — a mt CY? Ko | | - Sr WW