You are on page 1of 73

Press tooling.

GE24-060R /B
________________________________________
Stamping tools. Restamping tools Guide
Design basics ________________________________________

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 the stamping tools.

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 06/2006

© RENAULT 2006 Origin: PEGI - Renault Page: 1 / 73


GE24-060R /B

History of versions

Version Update Object of main modifications Author


A 01/2005 Creation (1) B.Nouhant
B 06/2006 Item 4.24 modifications, compensating blocks page 60 C.Laizé

Supersedes GE24-060R of 01/2005 version A

Availability Inside Renault, on the Intranet: http://gdxpegi.ava.tcr.renault.fr


Outside Renault, on the Internet: www.cnomo.com
Email: norminfo.moyens@renault.com

Documents cited Regulations :


International : ISO 3755.
European : EN 10025, EN 10293-2.
French : A 32-054.
CNOMO : E24.55.265.N.
Renault : EM24.01.100, EM24.02.032, EM24.02.035, EM24.03.304,
EM24.03.309, EM24.52.500, EM24.52.700, EM24.53.500,
EM24.54.300, EM24.54.500, EM24.54.700, EM24.55.100,
EM24.57.100, EM24.59.100, EM24.59.150, EM24.59.300,
EM24.59.500, GE24-010R, GE24-011R, GE24-012R, GE24-013R,
GE24-017R, GE24-040R.
Other internal doc :
Other external doc :

Coding ICS: 25.120.10; 03.120.20

Class E24

Key words emboutissage, équipement de presse, outillage de presse, fondamentaux, basic, press
tooling, pressing, press equipment

Language English

(1) Have participated in writing the document


Site Dept Name
FASA FASA MM.Maravert / Del-Cano
Valladolid /
Palencia
Velasco-Perez / Valencia
LHA 04734 MM.Pasquier / Roulier
TCR 65307 MM.Lambert P / Olivar / Hammoudi

© RENAULT 2006 Origin: PEGI - Renault Page: 2 / 73


GE24-060R /B

Contents
Page
Foreword ................................................................................................................................................... 4

1 SE panel (Simple Effect) ............................................................................................................ 5


1.1 SE panel, general..........................................................................................................................................5
1.2 SE panel with props ....................................................................................................................................10
1.3 Diagrams .....................................................................................................................................................16
1.4 SE panel with RG springs ...........................................................................................................................23
2 DE panel (double effect)........................................................................................................... 24
2.1 Typical DE panel .........................................................................................................................................24
2.2 DE panel with suspended plunger (called "floating") ..................................................................................25
3 SD (stretch-draw)...................................................................................................................... 27
3.1 Operating principle ......................................................................................................................................27
3.2 Calculations .................................................................................................................................................28
3.3 EE panel on DE press .................................................................................................................................28
3.4 EE panel on SE press with props................................................................................................................29
4 Common functions and elements ........................................................................................... 30
4.1 General........................................................................................................................................................30
4.2 Die 31
4.3 Plunger ........................................................................................................................................................35
4.4 Blank holder ................................................................................................................................................38
4.5 Frames ........................................................................................................................................................41
4.6 Handling ......................................................................................................................................................43
4.7 Guides / reactions / clearances / adjustment ..............................................................................................44
4.8 Blanks centring............................................................................................................................................47
4.9 Stops ...........................................................................................................................................................49
4.10 Blank holding ...............................................................................................................................................52
4.11 Blank retainers ............................................................................................................................................52
4.12 Blank stand..................................................................................................................................................52
4.13 Lifting ...........................................................................................................................................................53
4.14 Separators ...................................................................................................................................................53
4.15 Detection .....................................................................................................................................................54
4.16 Louvers........................................................................................................................................................55
4.17 Ranges for safety jack.................................................................................................................................56
4.18 Retainers / dampers ....................................................................................................................................56
4.19 Materials/grains ...........................................................................................................................................57
4.20 Adjustments.................................................................................................................................................57
4.21 Ranges ........................................................................................................................................................58
4.22 Air evacuation..............................................................................................................................................60
4.23 Strike marks ................................................................................................................................................60
4.24 Parallelism and compensating Blocks.........................................................................................................60
4.25 Details on suspended plunger.....................................................................................................................62
4.26 Details on die base......................................................................................................................................64

© RENAULT 2006 Origin: PEGI - Renault Page: 3 / 73


GE24-060R /B
4.27 Elastic spacers ............................................................................................................................................64
4.28 Protective shims ..........................................................................................................................................65
5 "Triple effect" tools .................................................................................................................. 66

6 Specificity for butt welded parts ............................................................................................. 67


6.1 Centring .......................................................................................................................................................67
6.2 Materials ......................................................................................................................................................68
7 Master Drawing ......................................................................................................................... 68

8 Restamping tools...................................................................................................................... 69
8.1 General........................................................................................................................................................69
8.2 Possible designs .........................................................................................................................................69
9 List of documents cited ........................................................................................................... 73

Foreword
This document is not a summary of "design rules".
It merely reminds a few basics and examples.
It cannot cover all particular cases. It is not complete.
It is an information complement to standard EM24.01.100 covering superficially the design of stamping
tools.
It must be enriched by:
 different user projects
 all manufacturing and maintenance sites by the intermediate of different DIVD.

Index / Translation abbreviation

ATFMR ramp up end activity agreement


ATLO Buy Off
DE Double action
EM Stamping die line
FGL Lamellate cast iron graphite
FTL Stamping line spec
GP Big Press
GP-DE Big Press – Double action
GPR Big reinforced Press
GSE Big Single action press
HOL Die height free
AR Rear
MAP Try out
PT Transfer press
RG Gas Spring
SD Stretch-draw
SE Single action
SF Blank holder
TGSE Very big single action press

© RENAULT 2006 Origin: PEGI - Renault Page: 4 / 73


GE24-060R /B

1 SE panel (Simple Effect)


Loads: Check that the loads are below the press capacities: refer to the FTL standards (press technical
sheets per line and per site) for the load graphs. When they exist, check compatibility with energy graphs.
Part: Check the part remains in good position repeatedly on the blank holder (in snap rings, keys, by
magnet or any other means). If impossible, implant timed gas springs (very costly solution to be used only
exceptionally).

1.1 SE panel, general


General rules:
2 cases to be considered:
A – The part has little risk of remaining stuck in the upper part
B- The part may remain stuck in the upper part

Case A

Separators

Punch

Linked and staged gas springs

Sole on lower frame


Shims if trimming lines located on the blank holder surface

Plan a sufficient number of separators in the die: Separators with metal springs or gas springs.
Beware compliance with the implantation guidelines for gas springs, more particularly concerning
the adjustment margin for safety. (see Renault standard EM24.54.700)

Case B
A die base must be implanted to separate the part and refit it using a spreader to prevent distorting
the part.
This spreader is not required if the panel is open at the ends to ensure the die base support on the
blank holder.

Dampers

Die
Spreader
Clipping props
Die base
Punch

Linked and staged gas springs Blank holder


Sole on lower frame
Shims if trimming line located on the blank holder surface

© RENAULT 2006 Origin: PEGI - Renault Page: 5 / 73


GE24-060R /B
Beware compliance with the implantation guidelines for gas springs, more particularly concerning
the adjustment margin for safety, (see Renault standard EM24.54.700).

If the panel must be clamped on the punch upon descent, implant a mobile shim system actuated
by jack or timed gas springs, prevent distorting the part upon lifting. See locking principle in
paragraph 1.1.4.
NOTE 1: for GSE and TGSE tools, do not implant this system, locking at "bottom dead" centre can
be ensured by the press cushion.
Note: this locking function does not exist on the cushion of the transfer press
PT 5400. (EM24.03.304 / EM24.03.309)
NOTE 2: by timed gas springs: cumbersome and costly solution.
Beware sizing of the spreader and clipping props.
 the spreader must be subject to a calculation note. (see standard EM24.01.100)
 clipping props: proposition

Lock screw
+ washer

© RENAULT 2006 Origin: PEGI - Renault Page: 6 / 73


GE24-060R /B
Example of locking with implantation of a roller:

A-A CROSS-SECTION

Roler bearing

Pneumatic jack

© RENAULT 2006 Origin: PEGI - Renault Page: 7 / 73


GE24-060R /B

Guidelines for implantation of blades on blank holder and die:


 blade parting lines must be skewed in respect of the "die entrance" line (5°min)
 upper parting lines must be offset in respect of the lower blade parting lines
 fasteners must be outside the blank and be accessible with tool open

Upper parting line


Upper part : Lock screw
+ washer

© RENAULT 2006 Origin: PEGI - Renault Page: 8 / 73


GE24-060R /B
Locking principle

Block

Gas springs
Moving shim actuated
or props
by jack

Upon attack: the


A l'attaque: blankest
le flan is At
Aa few mmmm
quelque fromdu bottom
bas de of Bas de course: la cale
Bottom stroke: the shim is
clamped between
serré entre the blank
le serre flan stroke,
course,the la shim
cale is
estonsurtheleverge
point s'intrepose sous l'effaceur.
inserted under the eraser
holder and the punch
et le poinçon. of penetrating
de pénétrer sousunder the eraser
l'effaceur du
of the de
fond die matrice.
base

Enthe
At finend
de remontée serrelifting:
of blank holder flan: Fin de
End dévêtissage.
of stripping Réarmement
Shim rearming de la cale.
le
thefond
baseest maintenu
is held in highenposition
position
by haute
the eraser andpar
thel'effaceur
shim
et la cale.

Note: implant a detector for each shim. As the shim is actuated by a jack, the latter will include a built-in
detector.

© RENAULT 2006 Origin: PEGI - Renault Page: 9 / 73


GE24-060R /B

1.2 SE panel with props

Props are used for SE panels fitted on presses featuring cushions:

GP - SE 4 000kN x 2,7 m* and all presses type GSE – SE 12 000kn x 2.7m,

TGSE – SE 20 000kN x 4.5m, station 1 PT5400.

* only those fitted: refer to the FTLs per site (press technical sheets per site and per line)

1.2.1 Tooling fitted on GP-SE presses

The blank holder must cover the surface of each


cushion properly; the props are distributed in order
to balance properly the loads over the press
cushions.

Cushion
Cushion

Press
axis
Refer to the FTL document (line technical sheets per

axis
axis
site) for the lengths of props which can be used.

Check that the thickness of platform +


cushion stroke is compatible with the
length of prop used.

If the length of the props is insufficient,


insert extensions between the latter and
the blank holder.

The prop extensions are standardised (see


standard EM24.57.100).
Indicate: prop length and height
Sole

protruding the platform

Or

© RENAULT 2006 Origin: PEGI - Renault Page: 10 / 73


GE24-060R /B

With symmetrical parts, or from the same


family, choose common locations

to
according to the production and backup
sites to reduce prop changing. This can
lead to drill holes in a punch to allow the
working prop displacement for another
part.

Sole
Before fitting the tool, the props are
recessed under the platform by a value
variable according to the type of press.

After fitting the tool, the props are raised Or


by a value variable according to the type of
press.

1.2.2 Tools type GSE, TGSE, station 1 PT 5400


Loading the blank(s) is performed: blank holder in the top stroke position. Extraction of the part(s) is
performed: blank holder lifted by 15mm (25 mm for TGSE Brazil).
Note: it is possible to extract the blank holder part(s) in the "top stroke" position (except PT 5400 presses
station 1).

SF position
for blank load
SF stroke

Part extraction
position
SF stroke

© RENAULT 2006 Origin: PEGI - Renault Page: 11 / 73


GE24-060R /B

Use of props on GSE, TGSE presses, Station I PT5400


All props remain in place in the press platform. They protrude by minimum 10 mm from the press
platform. If the working stroke < 300, the start position of the props is according to the tooling design.
Programming allows positioning the "stroke bottom" and "stroke top" points in the cushion adjustment
range.

Adjusting
range
10
Press platform

Recommendation: except in exceptional cases, do not use the extreme upper and lower positions.

Note: include the passages for props with the possibility of turning the tools flat by 180°, fitting 2 GSE
type tools either to the right, or to the left.
Transfer direction
Transfer direction

Assembly planned Assembly to plan

e.g. hood lining e.g. hood lining


Transfer direction

e.g. hood e.g. hood


Transfer direction

Assembly planned Assembly to plan

© RENAULT 2006 Origin: PEGI - Renault Page: 12 / 73


GE24-060R /B

1 - Prop extension
Prop extensions are part of the tooling. They are either offset or foundry single block with the blank
holder. Single block with blank holder, they must have a height < 150 mm. (to prevent problems upon
foundry, sand setting, and breakage when handling the blank holder)
For heights ≥ 150 mm, offset design according to Renault standard EM24.57.100.

H< 150 mm
Prop offset with Ø 80
rotation lock and
untightening system

Details on prop extensions:


For H ≥ 150 mm
see Renault standard EM24.57.100

Other principles:

Single block Screwed extension


extension with stop plate

© RENAULT 2006 Origin: PEGI - Renault Page: 13 / 73


GE24-060R /B
2 - Props stroke
It also equals the value of the panel depth:
 without pre-acceleration of cushion C = 300 mm max
 with pre-acceleration of cushion C = 300 mm max + 25 mm max
The stroke of the punch / blank holder retaining pins equals C + 20 mm.
NOTE: the possibility of pre-acceleration must be planned.

pre-acceleration +
D = panel depth +

20 mm
3- Pre-acceleration
According to the type of press, it can be either fixed with a value 25mm, or programmable from 0 to 25
mm.
Using pre-acceleration allows:
 reducing noise,
 preventing shock between die and blank holder, and hence optimise the press reliability (props
caulking, jack fatigue, etc.)
It must be planned systematically in studies. However, it is linked with stamping feasibility.
As the blank is supported only on the blank holder, it can "drop" and create attack folds (this problem can
sometimes be compensated by implementing blank support pads)
This phenomenon can be a possibility to "feed" the panel.
It is also possible to set the position of the blank holder at the blank attack.

Blank support pad


pre-acceleration

pre-acceleration

© RENAULT 2006 Origin: PEGI - Renault Page: 14 / 73


GE24-060R /B
4 – The choice of design of tooling depends on:

 the type of tool (GSE or TGSE),


 the type of backup (DE or SE version),
 the prop stroke.
See diagrams paragraph 1.3.

5 – Number of props
To determine this, consider:
 their distribution under the blank holder span
 the load balancing
Max loads per prop (see Renault standard EM24.57.100)

6 – Prop position in height


To determine this, consider:
 stroke C,
 min/max positions of props,
 fragility of the punch due to clearance
for prop passage
 the construction of the punch or lower frame.
The lower and upper positions can be
 chosen inside the adjustment range
 at any point.
NOTE: to prevent damaging the press, do not use the extreme positions of the props.

props Blank holder


Up position
310+25 theoretical max: Use 305+25 max

Open tool
pre-acceleration included

Course C
10 min theoretical: use 15 min

Course C
Course C

Stroke

Props
Low position closed tool

PMR

© RENAULT 2006 Origin: PEGI - Renault Page: 15 / 73


GE24-060R /B
6 - Clearances
The props (Ø 69) not used must be opposite a machined clearance Ø 80 mm, or rough Ø 90 mm, or at
least 10 mm from a rough face, with a depth equal to C + 30 mm.

30
acceleration
Stroke +
10 mini

Note: before delivering tools to the production, backup, MAP site, check passage of all props: practical
check indispensable.

1.3 Diagrams

1.3.1 GSE tools

1.3.1.1 GSE tool, GSE backup, TGSE in the axes

With prop extensions


HOF GSE 1180

according to the
value for stroke and
frame or sole
thickness

Principle with lower frame Principle with sole

Props: with or without extensions according to the value for stroke and frame or sole thickness.
Note: handling the entire tool, in the case of the offset sole is performed by the blank holder ⇒
privilege the principle with the lower frame.

© RENAULT 2006 Origin: PEGI - Renault Page: 16 / 73


GE24-060R /B

1.3.1.2 GSE backup tool PT 5400 (with riser)


- PT 5400 backup: prop extensions if C > 125 mm
Props supported in direct support if C = 125 mm max.
HOF 1650 PT5400

HOF 1180

HOF 1450
orOU
470

200
OU
or

Caution: handling the tool in the GSE position is performed with blank holder handling.

1.3.1.3 GSE tool, GP-DE press backup


GSE tool, fitted flipped.
GP DE

HOF 1180

GSE
HOF PL 1450

HOF SF 1300

200

Caution: handling the tool in the GSE position is performed with blank holder handling.

© RENAULT 2006 Origin: PEGI - Renault Page: 17 / 73


GE24-060R /B

1.3.1.4 GSE tool, fitted by 2 (side by side) on TGSE or PT5400 press station 1, backup by 1 on GSE
press

HOF GSE 1180

HOF 1380*
HOF 1650
Principle with
lower frame
Principle with
sole

Riser with prop step

200*
470
compensation spreader

* Case of fitting with riser without prop step compensation, compensation by


specific extensions

Note: for fitting on PT5400 station 1 the HOF must be 1650.

Outline sketch.

TGSE Press
GSE Press

GSE Tool GSE Tool GSE Tool

NOTE: riser plotted and available in "standard" section.

© RENAULT 2006 Origin: PEGI - Renault Page: 18 / 73


GE24-060R /B

1.3.2 TGSE tool, TGSE backup

AXE D'OUTIL
TOOL AXIS

Loads under blank holder, 2 possibilities:

- use press props.


- implant gas springs.
Beware compliance with the implantation guidelines for gas springs, more particularly
concerning the adjustment margin for safety. (see Renault standard EM24.54.700)

1.3.2.1 TGSE tool, TGP DE backup


Design identical to paragraph 1.3.1.5.
Note: linked gas springs are used only for possible backup on TGP DE press without flipping) or on TGP
SE press (if loads are compatible)
Caution ! When fitting on DE press (without flipping), the die must be integrated to the blank holder ram
opening, and no interference must occur during the press cycle.
(Check the positions of blank holder ram: see movement graphs in the FTLs).

© RENAULT 2006 Origin: PEGI - Renault Page: 19 / 73


GE24-060R /B

1.3.2.2 TGSE tool, TGP DE press backup (tool flipped)


Design with prop/blank holder direct support, handling entire tool by the blank holder, requires the
implantation of retaining pins between punch and blank holder.

HOF 1500

HOF 1650
Caution:
Design with prop extensions, handling entire tool by the blank holder, requires the implantation of
retaining pins between punch and blank holder.
HOF 1500

HOF 1650

Caution: handling the tool in the TGSE position is performed with blank holder handling.

© RENAULT 2006 Origin: PEGI - Renault Page: 20 / 73


GE24-060R /B

1.3.2.3 Specifics
A - Tools by 2, GSE type allocated on TGSE press: backup in degrouped on the GSE press must be
forbidden for parts with delicate stamping. (type lateral door caisson)
The difficulty comes from the difference in design of the TGSE and GSEcushions: "thrust points" are
located differently.
TGSE press

1125
Jack Tool axis type GSE

jack
TGSE axis

TGSE axis

Jack

GSE press

Jack

GSE axis
GSE axis

Jack

© RENAULT 2006 Origin: PEGI - Renault Page: 21 / 73


GE24-060R /B
Other GSE press

Jack

GSE axis

GSE axis
Jack

Other GSE press

Jack

GSE axis
GSE axis

Jack

B - TGSE or GSE tools with gas springs for backup on DE press (without flipping) or on SE press
(without props)
 very expensive solution (RG costs)
 Risks of MAP problems (behaviour different between a cushion (with programmable loads)
and RGs with loads increasing with crushing.

© RENAULT 2006 Origin: PEGI - Renault Page: 22 / 73


GE24-060R /B

1.4 SE panel with RG springs


Specifics in respect of design with props:
- loading the blank(s) is performed with the blank holder in top stroke position.
- Extraction of the part(s) is performed with the blank holder in top stroke position.
- The gas springs are linked* according to instructions mentioned in standard EM24.54.700. The filling
unit(s) must be accessible at front of press.
- The gas springs will be staged:
 1st stage = 4 to 6 RG
 2nd stage + 16 mm stroke = 4 additional RG
 3rd stage = + 17mm = all RGs enter in action.

Step 1 Step 2 Step 3

Note: plate thickness 3mm and 20mm are standardised.


See standard Em24.54.700

Step1: tool open with contacts of 4 to 6 RG

Step 2: intermediate phase with contact of 4


additional RG hence 8 to 10 RG activated
Step 3: all RGs are activated

* Gas springs linked to optimise loads and compensate potential failure of one spring.

© RENAULT 2006 Origin: PEGI - Renault Page: 23 / 73


GE24-060R /B

2 DE panel (double effect)


Loads: Check that the loads are below the press capacities: refer to FTL standards (press technical
sheets per line and per site) for load graphs. When they exist, check compatibility with energy graphs.

2.1 Typical DE panel


Foundry thickness
Cross-section: AA
With blades Without die base
and die base
B A

B
B- 10

B
B- 10

B
B
A

Cross-section: BB
B- 10

B*
B
B- 10
B

B* must be modulated
B

A
A according to cross-section:
B
see guide GE24-040R
paragraph 5

A B

Cast Steel Cast Steel


iron iron

TGSE 40 40 60 50

GSE 40 40 60 50

MP 30 30 50 40

GP 30 30 60 50

TGP 40 40 60 50

In practice, the values in the table are sufficient for thickness panels (e ≈ 0.7).

They must be modulated according to particular cases with high panel thickness notably or HLE panel.

Stamping loads: See Renault guide GE24-040R.

The design of the foundry (thickness, number and dimension of ribs) must take these loads into account,
more particularly the separation force of the die.

© RENAULT 2006 Origin: PEGI - Renault Page: 24 / 73


GE24-060R /B

2.2 DE panel with suspended plunger (called "floating")


This type of design is required in the following cases:
A - the outline of the "die entrance" line is not included in the press plunger ram outline.
B - plunger fitted from "below" (outline of the die entrance line very large and weakening the working
part of the blank holder)
C - fitting on TGP DE press (the plunger rams of these presses are not fitted with snap clamps)
D - tool with inner blank holder (e.g. body side)
E - for aspect parts and deep panels, to reduce air evacuation constraints. (air contained in the
volume defined by the clamped blank, between blank holder and die, and plunger shape with
major shrinkage: shrinkage due to press kinematics)
NOTE: this type of suspended fitting must be planned for all GP DE tools. The drawings for clamp
clearing, RGs or pneumatic springs will be in mixed line and the elements will mention: "do not launch".

Single block plunger:

Gas spring

Plunger with offset sole:


Solution mandatory in the B / D cases.

Gas spring

NOTE: beware fitting under GP DEpresses (opening in the posts): the stroke of RGs must = 80 mm. For
longer strokes, implant pneumatic springs "Harcross" type (See Renault standard EM24.54.700).

© RENAULT 2006 Origin: PEGI - Renault Page: 25 / 73


GE24-060R /B
Diagram with plunger connected to the press plunger ram: typical design

Plunger connected
to the press ram

Blank holder

Die

Position : blank holder contact


with panel and die High air volume

Diagram with suspended plunger:

Suspended plunger

Blank holder

Die

Position : blank holder contact Volume of air to limit


with panel and die

© RENAULT 2006 Origin: PEGI - Renault Page: 26 / 73


GE24-060R /B

3 SD (stretch-draw)
Note: This type of design remains exceptional, it is currently used for parts with shapes «lending well »
to this design. It was used to obtain a better tension of the panel, in the case of parts with little
curvature. Examples: hood panel, roof. The high consumption of material limits the cases of use.
Loads: check that the loads are below the press capacities: refer to the FTL standards (press technical
sheets per line and per site) for the load graphs. When they exist, check compatibility with energy graphs.

3.1 Operating principle


The different phases:

1 – The blank stands on the highest shape of the lower 2- Descent of upper blank holder to clamp
part the panel.

Upper blank holder Plunger

Lower frame

Lower blank holder Punch

3 – The part is clamped between the blank holder and 4- Stamping of counters by the plunger
stretching starts effect

Counters

© RENAULT 2006 Origin: PEGI - Renault Page: 27 / 73


GE24-060R /B

3.2 Calculations
See Renault guide GE24-040R.
It is imperative to check that for each phase in operation, the loads required are below those of the press,
refer to the FTL of the different production sites for press curves.

3.3 EE panel on DE press


Typical fitting;

Suspended fitting ("floating" die base)


Type A Type B

Type A: Traditional fitting on die base, with pneumatic springs or gas springs.
Type B: The die entrance line does not appear in the opening of the blank holder ram. The die base is
fitted from below and linked with an offset sole. The "suspended base" function is ensured either by
pneumatic springs or gas springs. The sole / die base link is ensured by M20 CHc screws and lock
washers. If the die base is suspended with gas springs, its locking must be planned with the upper blank
holder for fitting the sole.
Note: caution, the value of HOL equals: HOF + lower blank holder stroke (if RG) + upper blank holder
stroke (if RG). On GP-DE and GPR press, the total stroke must be below 80mm.
RG = gas springs
Check the passage in the post opening for lateral loading presses.

© RENAULT 2006 Origin: PEGI - Renault Page: 28 / 73


GE24-060R /B

3.4 EE panel on SE press with props


The gas springs in the lower part, under the lower blank holder, are replaced by the press props with or
without extensions.
Check by calculation that the loads applied by the props exceed:
F springs for upper blank holder + weight upper blank holder + weight lower blank holder.

Tool "TUNNEL" type

Blade holder
upper frame

Blades
4 retainer
pins Upper blank
holder

Lower blank
holder
Prop extension
Punch

Lower frame

Details of blank holder


dampening (4 damper
retainer systems) Details on blades

Details on retainers and


presser damper (2 systems)

Note: the retaining/dampening systems are either produced from Renault standard EM24.55.100 (retaining
rods with dampener), or an adaptation of the principle.

© RENAULT 2006 Origin: PEGI - Renault Page: 29 / 73


GE24-060R /B

4 Common functions and elements

4.1 General
4.1.1 For the design of foundries refer to Renault standard EM24.01.100 and Renault guide GE24-040R.
Important items:
- align the ribs on the foundry of the punch and/or plunger with the ribs on the die foundry.
- position the compensation shims opposite the ribs on the blank holder and dies, while taking into
account (when positions are known) of the press thrust points (rams and/or cushions)

4.1.2 To position the part, centre the outline of the die entrance line in the axes.

EM ( Die entrance )

X
1000

Start X

=
Z
700

l
=
Start Y

= L =

© RENAULT 2006 Origin: PEGI - Renault Page: 30 / 73


GE24-060R /B

4.2 Die

4.2.1 DE tool

- material (according to standard EM24.01.100 and specifics per project)


- fastenings on production and backup press platform by 4 notches (see reference frame drawings in
guides GE24-010R, GE24-011R, GE24-012R, GE24-013R)
- centring on production and backup press platform (see Renault FTL documents, Renault standard
EM24.02.032 and reference frame drawings cited previously)
- pneumatic, electric, or electro pneumatic fitting, electric cabinet. (See reference frame drawings
mentioned previously and Renault standard EM24.59.100 and EM24.59.150)
- handling of the element and overall tool
- holes for passing consolidation tie rods

Tie-rod fitte 80
d pre-stressed
63
Ø
80

- safety jack ranges (See paragraph 4.17/ 4.21)


- holes for contact tips according to Renault standard EM24.02.035.
- ranges for adjustment spacers located opposite ribs. (See Renault standard EM24.52.700)
- ranges for balancing shims with blank holder opposite ribs (see paragraph 4.25)
- guides with blank holder (see paragraph 4.7)
- blank centres (see paragraph 4.8)

© RENAULT 2006 Origin: PEGI - Renault Page: 31 / 73


GE24-060R /B
- blank detectors (see paragraph 4.15)
- blank support pads if required (see paragraph 4.12)
- separators (see paragraph 4.14)
- lifting system if required (for part extraction by "iron hand") (see paragraph 4.13)
- brushes, rollers if required (case ditto previous item)
- snap rings, keying according to Renault standard EM24.59.300)
- exploded view (see Renault standard EM24.53.500).
- die base or inserts (usually implanted for lining parts subject to modifications), Material (according to
standard EM24.01.100 and specific per project)

4.2.2 SE tooling

- material (according to standard EM24.01.100 and specifics per project)


- fastening by snap clamps + manual clamping on press ram
- pneumatic fitting or clearance for GSE and TGSE presses.
- element handling
- holes for passages of consolidation tie rods ditto paragraph 4.2.1
- safety jack ranges
- holes for contact tips
- ranges for adjustment spacers located opposite ribs
- ranges for balancing shims with blank holder opposite ribs
- guides with blank holder or with lower frame
- clearance of the centrers and detectors
- housings exploded according to Renault standard EM24.53.500.

© RENAULT 2006 Origin: PEGI - Renault Page: 32 / 73


GE24-060R /B

4.2.3 EE tools
In this case, the die is a die base. The design is:
 A single block with upper frame
 B offset on an upper frame
A single block

- Material (according to standard EM24.01.100 and specifics per project)


- Fastenings on press ram by fast and manual clamps
- Clearance of pneumatic fitting
- handling
if presser built-in:
- Carries the guides and presser retainers (see diagram paragraph 3.4)
- carries the pressure means of the presser
B offset

- material (according to standard EM24.01.100 and specifics per project).

4.2.4 "fuse" dies


Design, for parts thickness ≥1.25, regardless of the material grade, similar to a flanging function.
- with blades and/or keyed blade holder: the keys are calculated to withstand the loads resulting
from the stamping of a blank, and sheared for 2 blanks. Lateral reaction load (separation) (see
Renault guide GE24-040R for the load calculation)
30° Frame Frame

90°

Die blades
Die blade holder

© RENAULT 2006 Origin: PEGI - Renault Page: 33 / 73


-
Détecteur "double flan"- E15901051- édition 1
FONCTIONNEMENT CONSIGNES 10/02/04
D'IMPLANTATION
- situer ce système dans une zone plane

© RENAULT 2006
- zone ou le flan se "plaque" obligatoirement sur la portée
- zone de faible "avalement" de tôle
- à implanter dans le cas de tôles d'épaisseur à 1,2mm

th.24,3
Renault guide GE24-017R.

No
th. 36,3
int t tr
o an
En sl
gli ate
sh d

Origin: PEGI - Renault


th 36,3

Référence JOUCOMATIC
441 00 028
GE24-060R

Système détecteur " double flan "


/B

Page: 34 / 73
With 1 "double blank" specific detector according to guidelines and details in drawing E1590 1051 in
GE24-060R /B

4.3 Plunger

4.3.1 DE tool
2 designs:
A- Connected to the press ram: general case
B-1- suspended
B-2- suspended from below
A- Connected to the press ram

- Material (according to standard EM24.01.100 and specifics per project)


- fastenings on press ram by fast and manual clamps
- handling / flipping
- 3 holes for contact tips according to Renault standard EM24.02.035.
- Housings exploded according to Renault standard EM24.53.500.
- brackets for elastic spacers (between plunger and blank holder)
- linking ribs between plunger sole and body

B- Suspended
- material (according to standard EM24.01.100 and specifics per project)
- handling / flipping
- 3 holes for contact tips according to Renault standard EM24.02.035.
- Housings exploded according to Renault standard EM24.53.500.
- stands for suspensionsystems: pneumatic springs, RG (gas springs)
Note:-1 beware the value of HOL (tool free height) for certain lateral loading presses with low
passage height
-2 beware the determination of the number and type of pneumatic spring (see Renault standard
EM24.54.700.
- linking ribs between plunger sole and body
- Housing, implantation of dampening blocks according to Renault standard EM24.54.500.
- If required, according to the footprint, clear the snap clamp zones.

© RENAULT 2006 Origin: PEGI - Renault Page: 35 / 73


GE24-060R /B
C- Suspended with fitting by below

- fitting with steel plate


- material (according to standard EM24.01.100 and specifics per project)
- handling / flipping
- 3 holes for contact tips according to Renault standard EM24.02.035.
- Housings exploded according to Renault standard EM24.53.500.
- for plate:
Stands for suspension systems (pneumatic springs); if fitting is planned with gas springs,
implement retaining pins with lock between the blank holder and plunger for plate fitting.
Note: - 1 beware the value of HOL (tool free height) for certain lateral loading presses with low
passage height
- 2 beware the determination of the number and type of pneumatic spring (see Renault
standard EM24.54.700.
Housing, implantation of dampening blocks according to Renault standard EM24.54.500.
Fittings of the plate on the plunger by M20 CHc screws and locking washers.
if required, according to the footprint, clear the snap clamp zones.

© RENAULT 2006 Origin: PEGI - Renault Page: 36 / 73


GE24-060R /B

4.3.2 SE tooling
2 designs:
 A single block with lower frame
 B offset on a lower frame
With or without props, with or without gas springs.

A- single block with frame

TOOL AXIS

- material (according to standard EM24.01.100 and specifics per project)


- fastenings on press platform by 4 notches
- centring on press platform (visible and accessible)
- handling
- guides with blank holder
- retained housing of the blank holder
- housings of punches
- let all props pass without interference
- RG housings if tool with RG and without props
- electro pneumatic connection
- stamping 6 to 8 for references with blank holder (see paragraph 4.20)

B- offset on frame
TOOL AXIS
TOOL AXIS

- all previous items + (except direct links with the press platform)
- keying fastenings on frame
Lower frame: takes over the functions of direct links with the press platform.

© RENAULT 2006 Origin: PEGI - Renault Page: 37 / 73


GE24-060R /B

4.3.3 EE tools
2 designs:
 A single block with lower frame
 B offset on a lower frame

With or without props, with or without gas springs.


A- EE tool with lower blank holder on props
- Design identical to SE tool with props
B- EE tool with blank holder on gas springs
- Design identical to the previous without prop passage

4.4 Blank holder

4.4.1 DE tool

- Material (according to standard EM24.01.100 and specifics per project)


- fastenings on press blank holder ram by fast and manual clamps
- handling points
- safety jack ranges
- holes for contact tips
- ranges for adjustment spacers located opposite ribs
- guides with die
- guides with punch
- elastic spacers with plunger
- clearances for plunger handling
- guides with plunger
- plunger engaging protection shims
- ranges for balancing shims located opposite the rib according to die
- section to dimension properly (according to Renault guide GE24-040R)
- guarantee a passage of 50mm min with the plunger (see press kinematics in FTL standards)
50 min

© RENAULT 2006 Origin: PEGI - Renault Page: 38 / 73


GE24-060R /B
NOTE: specific case of tools with inner blank holder

A- Connected inner blank holder B- Moving inner blank holder in the plunger
of the outer blank holder

Specifics: Case A-
The blank holders are linked by a rolled steel plate (E295 according to standard
EN 10025) or from foundry (GE280, G20Mn5 + N or 270-480W standard A 32-054,
PR EN 10293-2, ISO 3755). Fasteners and keys of the blank holders on the plate by
M20 CHc screws with lock washers.
The plunger must be fitted "suspended" with offset plate.

Case B-
If the plunger is fitted "suspended", the inner blank holder is fitted on linked gas
springs. The control unit is fitted in the outer blank holder for accessibility.
Beware the deflection of the pipes.
If the plunger is linked to the press plunger, the control unit is implanted on the
plunger: holes must be planned in the outer blank holder for accessibility to this
control unit.
If required, the inner blank holder is reactioned with the inner part, retained by pins
according to CNOMO standard E24.55.265.N.

© RENAULT 2006 Origin: PEGI - Renault Page: 39 / 73


GE24-060R /B

4.4.2 SE tooling

- material (according to standard EM24.01.100 and specifics per project)


- handling points
- electro pneumatic fitting
- safety jack ranges (Note: preferential solution with implantation between the die and lower frame)
- holes for contact tips
- ranges for balancing shims located opposite the rib according to die
- guides with die
- guides with punch
- clearances for punch handling
- protection shims engaged on punch
- prop support ranges or housings for prop extensions or ranges with shims for tool with gas springs
- ranges for shimming with lower frame (or single block punch)
- retaining pins with punch or other retainer systems
- blank centrers
- blank holding system (DESTACO)
- blank detectors

4.4.3 EE tools
A- lower blank holder
Ditto identical to SE Tool paragraph 4.4.2

B- upper blank holder


Items identical to SE Tool (just replace punch by plunger)
Particularities: retained by pins and if required retaining rods according to Renault standard
EM24.55.100.

© RENAULT 2006 Origin: PEGI - Renault Page: 40 / 73


GE24-060R /B

4.5 Frames

4.5.1 Lower frame

4.5.1.1 DE tool
The frame is merely a bracket for working parts. It must provide for the following functions:
- support the blades
- material (according to standard EM24.01.100 and specifics per project)
- fasteners and centring on press plate
- handling of the element and overall tool
- pneumatic, electric or electro pneumatic connection
- electric box
- safety jack ranges
- contact tips
- adjustment spacers located opposite ribs
- blank holder guide stops

4.5.1.2 SE tooling
The frame is a punch bracket. . It must provide for the following functions:
- support the punch
- material (according to standard EM24.01.100 and specifics per project)
- fasteners and keying of the punch
- fasteners and centring on press plate
- passages of props or bracket for gas springs
- handling of the element and overall tool
- pneumatic, electric or electro pneumatic connection
- electric box
- safety jack ranges
- contact tips
- adjustment spacers located opposite ribs
- retaining of blank holder
- guide stops: with the blank holder and possibly the die

4.5.1.3 EE tools
The frame can be a punch bracket and must comply with the items cited in paragraph 4.5.1.2, i.e. a single
block punch frame and provide the functions of a punch, cited in paragraph 4.3, and those for a frame
cited in paragraph 4.5.1.2.

© RENAULT 2006 Origin: PEGI - Renault Page: 41 / 73


GE24-060R /B

4.5.2 Upper frame


Material: FGL 175 HB or A50 according to dimensions and structure.

4.5.2.1 DE tool
A- for plunger, it provides the following functions:
- fasteners and keys of working parts
- snap fitting notches and manual for press ram
- handling of the item alone and with the working parts
- ranges for supporting elastic spacers

B- for suspended plunger:


- plunger fasteners and keys, working part
- clearances for snap clamps of the press plunger ram
- handling of item alone and with plunger
- ranges for gas spring support or extensions for pneumatic jacks
- housings of dampers in contact with the press ram

C- for blank holder:


- required in the case of a tool with inner blank holder connected with the upper blank holder
- fasteners and keys of the blank holders
- notches for snap and manual clamping for press blank holder ram
- handling of item alone and with blank holders
- elastic spacers with plunger

4.5.2.2 SE tooling
Upper frame with die holder function (die blades)
- fasteners and keys of working parts
- snap fitting notches and manual for press ram
- clearances of pneumatic fitting for GSE and TGSE presses
- handling of the item alone and with the working parts

4.5.2.3 EE tooling on SE press


Upper frame with "die base" function.
- fasteners and keying of the "die base"
- snap fitting notches and manual for press ram
- clearances of pneumatic fitting for GSE and TGSE presses
- handling of the item alone and with the working parts
- upper blank holder guides
- retainers and dampers of upper blank holder
- possibly retainers of the presser in the "die base"
- carries the pressure elements of the blank holder and even the presser
- safety jack ranges

© RENAULT 2006 Origin: PEGI - Renault Page: 42 / 73


GE24-060R /B

4.5.2.4 EE tooling on DE press


Plunger:
Upper frame with "die base" function.
- fasteners and keying of the "die base"
- snap fitting notches and manual for press ram
- handling of the item alone and with the working parts
- ranges for supporting elastic spacers
Blank holder:
- fasteners and keys of the blank holders
- notches for snap and manual clamping for press blank holder ram
- handling of item alone and with working parts
- elastic spacers with plunger

4.6 Handling
- plunger / punch handling

- for other items, see mentions 4.1.1 and 4.1.3

© RENAULT 2006 Origin: PEGI - Renault Page: 43 / 73


GE24-060R /B

4.7 Guides / reactions / clearances / adjustment


Die guiding and clearance with SE tool blank holder: DE tool guides and clearance:
Clearance : 0.2
1 to 5 long and
narrow parts
4 to 5 for large parts

Machined

Guiding gap 0.1 Guiding gap : 0.2


constant

Note: the values of clearance between the plunger (punch) and blank holder depend on the value of the
"die input" radius.
Details of the blank holder guide with plunger:

Protection shim

Blank holder
Plunger

Die entrance line

Blank holder guides with die (DE tool) or die with lower frame (SE tool):

A-A CROSS-SECTION

© RENAULT 2006 Origin: PEGI - Renault Page: 44 / 73


GE24-060R /B

Die guide with blank holder ("small" SE tools): with "male and female sliders" (see standard EM24.52.500)

Blank holder guide with lower frame ("small SE tool"):

© RENAULT 2006 Origin: PEGI - Renault Page: 45 / 73


GE24-060R /B
Die reactions with blank holder:

To ensure and facilitate operator safety during loading/extraction operations (case with manual loading
and extraction), do not fit the reactions on the front and/or back sides of the press in the sweep and/or
access zone.
Sizing of the reactions is determined by evaluating the separation force while taking into account the load
on the blank holder and the slope.
Case requiring reactions:
- very large parts involving a small section of the blank holder.
- blank holder ranges with slope ≥ 20°.

© RENAULT 2006 Origin: PEGI - Renault Page: 46 / 73


GE24-060R /B

4.8 Blanks centring


Typical cylindrical centrer Oriented cylindrical centrer:

Anti-rotation
Th. 6 mm
Separation Blade depth 8 mm

On request

X to determine according
to the implementation
15 to 45°

Loctite locking
compound
45 on flat

70 or 130

Blading ∅ 51

Highest point of the curve

Centrer in "lunules":

Other types of "standard" centerings :


A- Sector shape

© RENAULT 2006 Origin: PEGI - Renault Page: 47 / 73


GE24-060R /B
B- hex stud shape

Ø50 XC 42 T7 or T8 HRC 54-58


45
35 on work face

A
R E 24-2

*80 min.(Without gusset)


**290 (Max. with gusset)
80 to 250 **
400 to 80 *

10
30°

H=
A=

About Blank holder


10

=61=

=
R2
25
5 = 5
E 24-2 Die
2

HEXAGON SIZE 30

5 MIN.
60
25 R
14
4
=40=

60
35

25
30

12.5

45 15
85
Edge 5 x 45° 2Ø12 for pin after MAP
if required

OBLONG IF
Section A
REQUIRED

Note: Adapt gusset mark « c » if A > 80


complete size H + gusset sizes

© RENAULT 2006 Origin: PEGI - Renault Page: 48 / 73


GE24-060R /B
Centrers/detectors:
Caution: this type of centrer provides simultaneous functions of centring and detection, and cannot be
applied in all cases.
It is best to separate the 2 functions to facilitate MAP and repeatability of the 2 functions.

4.9 Stops

4.9.1 RR moving stop


Clearance in upper part
Drilling lower part

See master drawing 1008 in Renault guide GE24-017R.


ish d
gl ate
En sl
o an
int ot tr
N

© RENAULT 2006 Origin: PEGI - Renault Page: 49 / 73


GE24-060R /B

4.9.2 Return stop

See master drawing 1018 in Renault guide GE24-017R.


ish d
gl ate
En sl
o an
int t tr
No

© RENAULT 2006 Origin: PEGI - Renault Page: 50 / 73


GE24-060R /B

Other "standard" element:

Other "blank rejogging" principle

* Cross out inappropriate


EXPLODED VIEW OF THE ASSEMBLY
choices

Unit load at attack


Total load at attack
Working
stroke

Unit Load end stroke


Tot. Load end stroke
compressed
Length

Quantity Spring

© RENAULT 2006 Origin: PEGI - Renault Page: 51 / 73


GE24-060R /B
4.10 Blank holding
Mainly used for "V" shaped EE stamping tools tight surface.
It can be implanted on SE tool blank holders with the same type of SF surface.

Pneumatique jack

4.11 Blank retainers


Snap rings
Refer to standard EM24.59.300.

Keying
Refer to standard EM24.59.300.

4.12 Blank stand


Use in DE tools:
- for aspect parts, with large die entrance, when the blank is likely to "drop" creating folds before attack.
- implantation outside zones formed by the die. (risks of marking)
Profile of blank removed Blank holder span

Use in SE tools (with props or RG):


- for aspect parts, with large die entrance, when the blank is likely to "drop" creating folds before attack.
- implantation outside zones formed by the punch. (risks of marking)

Zone at back or outside part

© RENAULT 2006 Origin: PEGI - Renault Page: 52 / 73


GE24-060R /B

4.13 Lifting
Refer to Renault standard EM24.57.100.

Recommendations:
In no case a hole for passage of lifting system
can be implanted in a zone
of counter-stamping.
Holes must be located at least at 20mm
from an "edge" line and 40mm from a zone
in back.

4.14 Separators
In the die of double effect tools without die base and simple effect tools, include spring or gas push rods,
in the part’s non visible zones.
For light parts, particularly in alu, include separators to hold the part in the lower section.
See standard EM24.54.300.

For Double Effect tools with die base, implant separators according to the following principle:

Die base

© RENAULT 2006 Origin: PEGI - Renault Page: 53 / 73


GE24-060R /B

4.15 Detection
See standard EM24.59.100.
Refer to paragraph 4.8 for the note on the detector/centrer element, in addition this type of detector
requires a counterweight adjustment.
Implant 2 detection systems per blank.
Implant 1 detector per axis: 1 longitudinal and 1 transversal.
Implant them in zones where the blank is either standing on the range or very close to the range.
Make the link between the detector and its cable accessible.

LONGITUDINAL AXIS
AXE LONGITUDINAL

AXIS
AXE TRANSVERSAL
TRANSVERSAL

Other non standard detection system:

Upper frame clearance


FT axis
FT axis

© RENAULT 2006 Origin: PEGI - Renault Page: 54 / 73


GE24-060R /B

Double blank detector system:


See guide GE24-017R drawing E1590 1051, with implantation instructions.

ish d
gl ate
En sl
Détecteur "double flan"- E15901051- édition 1
FON CTIONNEMENT CONSIGNES

o an
10/02/04
D'IMPLANTATION

int ot tr
- situer ce système dans une zone plane
- zone ou le flan se "plaque" obligatoirement sur la portée
- zone de faible "avalement" de tôle
- à implanter dans le cas de tôles d'épaisseur à 1,2mm

N
th.24,3

th. 36,3

th 36,3

Référence JOUCOMATIC
441 00 028

Système détecteur " double flan "

4.16 Louvers
See Renault standard EM24.53.500.
For aspect parts with coating, implant the type of louver on polyurethane: it allows limiting metal tearing,
and hence pollution of the tool and part.
Drawbacks: - large housing for polyurethane.
- the dimension of the polyurethane separates the cutting line from the zone requiring
panel sliding.

The type of louver on steel block can be implanted on "non aspect" and non coated parts.

© RENAULT 2006 Origin: PEGI - Renault Page: 55 / 73


GE24-060R /B

4.17 Ranges for safety jack

Possibility of « rough cast »


supporting surfaces
The ranges are implanted for the tooling:
- DE between die and blank holder.
- SE between the lower frame (or frame/punch) and the die.*
- EE between the lower frame (or frame/punch) and the upper frame. **

* SE particular case: in certain cases, the ranges are implanted between the blank holder (lower part) and
the die (upper part)
** Particular case EE: in certain cases, the ranges are implanted between the lower blank holder and the
upper blank holder.
NOTE: these particular cases require approval from the production and backup site

Other particularity:
The fitting of "safety jacks" in automatic (on certain presses GP type) imposes a position in space, see
standard EM24.01.100 and the as-built drawings.

4.18 Retainers / dampers


- See CNOMO standard E24.55.265.N, standard EM24.55.100.
- With plates:
Principle diagram
Shim 10 mm

Detail
+1
Stroke

© RENAULT 2006 Origin: PEGI - Renault Page: 56 / 73


GE24-060R /B

4.19 Materials/grains

See EM24.01.100 standard and other specific standards per project.

Grains: in expansion zones, plan grains in X153CrMo4V12 - T6 (54-56 HRC)


The grain seams must not be parallel with the material sliding lines, the fasteners must be implanted
outside range zones.

Theoretical blank

Die entrance line

4.20 Adjustments

If size H must be ensured (trimming line


on blank holder), the blank holder must be grounded with
the sole: implant a shim
Trimming

Block

If size H is not required (trimming line Trimming


fully on punch), leave a clearance between blank holder
and the sole. No shim.

© RENAULT 2006 Origin: PEGI - Renault Page: 57 / 73


GE24-060R /B

Adjusting spacer (or HOF stop) at the 4 ends of the tool:


- between die and blank holder for DE tools
- between lower frame (or frame/punch) and blank holder for SE tools
- between lower frame (or frame/punch) and upper frame for EE tools
Implant 4 spacers according to Renault standard EM24.52.700.

4.21 Ranges

4.21.1 Blank holder / die range or lower blank holder / upper blank holder range

blank limit
Theoretical

To reduce machining of die and blank holder ranges, include a rough cast clearance at ~ 15mm constant
beyond theoretical blank. (blank flat on range).

4.21.2 Clearances between plunger, punch, die, and die base


Reminder:
The surfaces, convex in one direction, concave in the other, require full range of the die or die base,
plunger, punch.

© RENAULT 2006 Origin: PEGI - Renault Page: 58 / 73


GE24-060R /B

- Clearances for plunger, punch


Example for door panel:
No clearance is admitted except in
window openings. The range has a width of
50mm min. (value in projection), at
periphery and clearance of 2mm deep.

The panel is tightened on points a-b-c

The panel would be tensioned along the a-b lines

- Die or die base clearances


Except in counter-stamped zones, clear
the die or die base over a depth
of 10mm and at 50mm constant from the outer outline.
A band of the same value around the counter-stamped,
on either side of the "edge" lines and in the
parts to open.

- Clearances between plunger and die


Case of convex plunger Case of concave plunger
and concave die and convex die

The plunger must be The die must be shaped


shaped as the part as the part

© RENAULT 2006 Origin: PEGI - Renault Page: 59 / 73


GE24-060R /B

4.22 Air evacuation


Plan in construction in concave zones
the position and number of holes required
for air evacuation while taking into account the speed
of the press.

4.23 Strike marks


Implant the strike marks at the positions mentioned in the manufacturing sheet, and according to Renault
standard EM24.59.500.

Trimming

Part finished

Die
Die base

4.24 Parallelism and compensating Blocks

4.24.1 Parallelism Blocks


Have to be fixed between Die and Blank holder on fourth corners. Try out activities is done on those
parallelism blocks for a parallelism grinding activity. Parallelism block details are mentioned on rule
EM24.52.700

Parallelism
Blocks
Ø100

Compensating
Blocks
Ø50

© RENAULT 2006 Origin: PEGI - Renault Page: 60 / 73


GE24-060R /B

4.24.2 Compensating blocks

Have to be fixed between Die and Blank holder, at the nearest position of die spotting surfaces for big
parts.
On Narrow parts:
 space them from die axis for effort balancing,
 Locate them in front of ribs (on die and blank holder) and in front of application forces
 Quantity of blocks link with perimeter

After blank holder die spotting activity, install compensating blocks within 0,5 mm gap compare to die
design studies for no rectifying activities on them, After, adjustment compensation blocks is done

Adjustment with calibrated steel


lead

Ø 50

After stamping part good quality results, realize compensating blocks final fixing using calibrated steels.
Calibrated steel height result from lead piece usage

Compensating block

Within this methodology compensating blocks


adjusted by die maker, are re adjusted during first try
out in plant. Re adjustment is done to come back to
stamping quality part obtained during By Off activities
(block spotting without hard point)
Block marking is done during ATFMR (see Try out
section / stamping department 65307 procedure)

Calibrated steel fixing on die

© RENAULT 2006 Origin: PEGI - Renault Page: 61 / 73


GE24-060R /B

4.25 Details on suspended plunger

4.25.1 Jack extensions


These extensions prevent the jack rods from protruding in respect of the base of the blank holder, their
function is to protect the rods.
The springs (pneumatic or nitrogen) are fastened on the blank holder, the rods of these springs transmit
the loads and movement to the plunger through extensions linked to the plunger.

Self-locking washer

60
Plunger sole

60
CHc M20-60

45
100
Jack extension

Ø 20
L

Ø90
S.F. sole
Ø120

4.25.2 Snap clamp clearance


The snap clamp passage zones must be cleared to allow clamping travel.
Snap clamp

Fixed sole or plunger


axes

Plunger
Clearance on
plunger according
to sole profile

Section A

4.25.3 Recommendations
Design diagrams:

Vissage du clinquant sur l’outil


Adjustment block
Adjustment block
Rib on the axis of
gas spring

© RENAULT 2006 Origin: PEGI - Renault Page: 62 / 73


GE24-060R /B

4.25.4 Dampers
Do not implant elastic spacer dampers on tools with plunger suspended with gas springs.
In the case of tools converted into suspended plunger, these spacers must be removed.

Recommendations for fitting dampers:

Tool open

Plunger ram

Blank holder ram

Tool closed

Table defining the number of dampers according to the weight and stroke of the plunger.

Weight of floating Stroke of floating plunger


plunger (kg) 50 70 90 110 130
500 *5 *6 *8 4 5
1 000 4 5 6 7 9
2 000 8 10 12 14 17
3 000 11 15 18 21 25
4 000 15 20 24 28 33
5 000 18 25 30 35 41

* Use of dampers cut in halves.

© RENAULT 2006 Origin: PEGI - Renault Page: 63 / 73


GE24-060R /B

4.26 Details on die base


In the case of die base implantation (design rarely used), the die/die base parting line must be outside the
functional zones of the base. For aspect parts, do not run this paring line in a visible zone.
Cylindrical on die base, clearance between die and die base, instructions if slope:

Gap : 1 Gap : 0.2

- if no reaction:
the height of the cylindrical is 30 to 40mm.
Clearance between die and die base is 1mm
Index the base using pins.
- if reaction:
with a slope ≥ 10° adjust the die base in the reaction zone over a height of 60mm
the parting line must be as close as possible to the die entrance, in case of "needle" shorten the
die base and in case of "step", use the following principle:

Recess about 10
Die

Die base

4.27 Elastic spacers


Elastic spacers must be implanted between the blank holder and the plunger, exclusively on DE tools
with plunger linked to the press plunger ram, and tools with suspended plunger fitted with pneumatic
springs. See Renault standard EM24.52.700.

Lower cup
M 231 265 101
Elastic spacer
X 346 556 306
Spacer
95

M 222 130 501


Stroke plot
X 346 557 803
Washer
95

M 213 139 214


CHc screw M20-140

Storage spacer assembly


10

R100 157 453

Ø50

© RENAULT 2006 Origin: PEGI - Renault Page: 64 / 73


GE24-060R /B

4.28 Protective shims


Implant opposite the blank holder guides with plunger or punch, shims in polyurethane to protect the
plunger or punch outline during assembly.
See Renault standard EM24.54.500.

Protection shim

Blank holder

Plunger

Die entrance line

© RENAULT 2006 Origin: PEGI - Renault Page: 65 / 73


GE24-060R /B

5 "Triple effect" tools


Loads: Check that loads are below press capacities: refer to the FTL standards (press technical sheets
per line and per site) for the load graphs. When they exist, check compatibility with energy graphs.

Design allowing to construct a "counter" zone.


Diagram of the operating principle

RG

CH

This principle can be applied to a DE stamping tool, beware however the loads under die, which when
rising "push" the blank holder. The moving die must be locked at "bottom dead centre" either
mechanically or with retarded gas springs.

© RENAULT 2006 Origin: PEGI - Renault Page: 66 / 73


GE24-060R /B

6 Specificity for butt welded parts


The butt welding line must be located in a zone not subject to panel displacement perpendicular to this
line.

To date, butt welding lines are straight lines

6.1 Centring
It must be performed with centrers located on the butt welding line, otherwise in notches constructed at
blank cutting, notches as close as possible to the butt welding line.
In the case of butt welded parts, centring must be performed on the high thickness side.
To ensure repeatability of centring, the blank must be pushed against these centrers by blank return
stops. (see guide GE24-017R, drawing E1590 010 18)

Examples of centring:

Blank return Butt welding line Pre-centrers


stops

Pre-centrers Butt welding line Blank return


stops

© RENAULT 2006 Origin: PEGI - Renault Page: 67 / 73


GE24-060R /B

6.2 Materials
Additions of grains in X153CrMoV10 with adjusting shims, on the butt welding line, in the die part.

Die

Offset grains

Offset grains

Adjusting according to radius


Butt welding line

7 Master Drawing

Available in Renault guides GE24-010R, GE24-011R, GE24-012R, GE24-013R, GE24-017R.


CAUTION: the implementation of the reference frames, in 3D, involves a ban on using 2D definitions.
(These are no longer updated upon creation of the 3D equivalent)

© RENAULT 2006 Origin: PEGI - Renault Page: 68 / 73


GE24-060R /B

8 Restamping tools

8.1 General
This operation consists in increasing the stamping height locally.
Example: Type of part with restamping operation lateral door caisson.
This operation is usually multi-function:
The restamping function is often associated with trimming, punching, opening functions.
According to the type of press and part dimensions

8.2 Possible designs


2 designs can be considered:
- presser and blank holder separated: diagram type I
- presser and blank holder single block: diagram type II

8.2.1 Presser / BH separated


Other damper retainer system
Retainer + damper rod
SCHEME TYPE 1
EM24.55.100

Ext. presser
central
(E24.54.700)

Int. presser central


(E24.54.700)
Retainer hook
Em24.55.100

Int. presser

External pressure
External pressure Blade Blade
Range for balancing
with lower part

© RENAULT 2006 Origin: PEGI – Renault Page: 69 / 73


GE24-060R /B

Design - independent inner presser


- outer blank holder
- gas spring connected with presser unit
- blank holder loads: use the calculation formula valid for the panel, see GE24-040R
- presserloads: use the calculation formula for a pick-up tool, see GE24-040R.
- material (according to standard EM24.01.100 and specifics per project)
- dampening retaining: Independent for presser and SF
- locking according to calculations
• according to calculations with closed tool RG loads (considering the multiplier
ratio) + element weight
- SF guide per plate (plates on plates if reaction)
- presser guiding per columns or plates (plates on plates if reaction)
Note: upper frame / lower frame guides by stops with insert in cupro plates on cast iron.
(no columns except if punching, trimming functions)

Benefits / Drawbacks of this type of design

BENEFITS DRAWBACKS

- Loads adjustable separately for the presser and blank - Dimensions of the tool + RG implanted for outer SF
holder functions ⇒ MAP facilitated
- Difficulties for implantation of inner presser retainer
- Light maintenance: no need to remove the tool
completely • access without pins difficult, even impossible
⇒ * retainer / damper system by rod
* fitting / removal difficult
access -upper frame side
- presser side
⇒ heavy maintenance
- Beware the cross-section of the blank holder (ring
shaped)
- Difficulties for implantation of inner presser guides

© RENAULT 2005 Origin: PEGI – Renault Page: 70 / 73


GE24-060R /B

8.2.2 Presser / S. monoblock

SCHEME TYPE 2

Upper frame

Retainer hook
Em24.55.100

Presser Presser

Presser Presser
Blade Blade

Range for balancing


with lower part

Section a (version 1) Section a (version 2)

© RENAULT 2006 Origin: PEGI – Renault Page: 71 / 73


GE24-060R /B

Design - presser / BH linked by "suspenders"


- blades implanted in "bridge"
- suspender section (see EM24.01.100)
- linked gas springs
- beware the distance between suspenders and blades (see EM24.01.100)
Note: value "d" take damper crushing into consideration
- loads: ditto previous design principle
- retainers / dampers
! according to kinetic energy calculations
! to reduce "d" it is recommended to use dampers of the "rod" type,
! considering the difficulty of fitting / removing this type of dampers, this solution
must be validated with the production site (maintenance sector)
- locking
! according to calculations with closed tool RG loads (considering the multiplier ratio)
+ element weight
- guiding: presser / BH
! by plate (plate / plate if reaction)
- material (according to standard EM24.01.100 and specifics per project)

Note: upper frame / lower frame guides by stops with insert cupro plates on cast iron. (no
columns except if punching, trimming functions).

Benefits / Drawbacks of this type of design

BENEFITS DRAWBACKS
- Delicate inner/outer links
- Design for reduced dimension tools
- Material steel imperative
- Implantation retained / dampers without difficulties ⇒ cost higher
⇒ longer foundry time
- Reduction in the number of guides

- Removing a foundry mobile element - Cannot adjust the presser and blank holder loads
separately (MAP)
(pressers / BH grouping by 1 element only) - Difficulties of R6 implantation for blank holder
function
- Blades in «bridge »
⇒ * fragility of blade sector
• for maintenance removal obligation of using
certain blades
• multiplicity of parting lines of the blades
- Modelling audit mandatory to check presser/BH
solidity

© RENAULT 2006 Origin: PEGI – Renault Page: 72 / 73


GE24-060R /B

9 List of documents cited


NOTE : For non dated documents, the latest version is applicable.

ISO 3755 : Carbon steel moulded for general use mechanical construction.
EN 10025 : Hot laminated products in non allied construction steel. Technical delivery
conditions.
PR EN 10293-2 : Construction and general use cast steel. Section 2: Construction cast steel.
A 32-054 : Foundry products. General use cast steel in mechanical construction.
E24.55.265.N : Press tooling. Retaining and locking pins. General specifications.
EM24.01.100 : Presentation of the basic offer and free offer in press tooling design
EM24.02.032 : Implementing stamping tools under presses, Assembly FOP.
EM24.02.035 : Geometrical inspection contact tips for pressing tools
EM24.03.304 : Press technical sheets per line. Douai plant (being written)
EM24.03.309 : Press technical sheets per line. MCA plant.
EM24.52.500 : Press tooling. Plates and sliders for cam stations.
EM24.52.700 : Closed tool height (H.O.F) stops Elastic storage spacer for press tooling
EM24.53.500 : Press tooling. Louvers on polyurethane and louvers on steel block
EM24.54.300 : Compression spring in elastomere – Flexible stripper in elastomere. Spring push-
rods for press tooling.
EM24.54.500 : Press tooling: Damper blocks. Dampers. Protection shims.
EM24.54.700 : Gas springs. Pneumatic springs for press tooling.
EM24.55.100 : Press tooling. Retaining and locking pins. Retaining/guiding rods with damper.
EM24.57.100 : Press tooling. Prop and prop extension. Compensation prop. Lifting system.
EM24.59.100 : Proximity sensors and accessories for press tooling
EM24.59.150 : Pneumatic connecting plates and accessories in press tooling
EM24.59.300 : Offset locking pins, single block locking pins for press tooling.
EM24.59.500 : Punch checking punches, elements identification punches, marking elements for
press tooling
GE24-010R : Press tooling Master drawing for GP presses
GE24-011R : Press tooling Master drawing for GP presses DO NOT USE THESE 2D DRAWINGS
FOR X91, X61.
GE24-012R : Press tooling Master drawing for TGP presses. "DO NOT USE THESE 2D
DRAWINGS FOR X91, X61 EXEPTION FOR VACUOUS STATION"
GE24-013R : Press tooling Master drawing for OYAK.
GE24-017R : Press tooling. Miscellaneous master.
GE24-040R : Press tooling. General design guidelines.

© RENAULT 2006 Origin: PEGI – Renault Page: 73 / 73

You might also like