3 forming tool concepts pvp
DESCRIPTION
TRANSCRIPT
INCREASE EFFICIENCY AND EXPAND YOUR OPERATIONS WITH FORMING
MATE SOLUTIONS TRAINING
AGENDA
• Why use forming?
• Forming basics
• Ways to use forming in your operation
• Summary
WHY USE FORMING?
• Increase efficiency
• Expand your capabilities
• Eliminate of secondary operations
• Increase machine time
• Reduce tool wear
• Secondary processing of machined countersinks is non value-added time
• Make them on the turrets, forming up or down, as required
EXAMPLE: ADDED COST AND PROCESSING TIME
• The ribs in this pane were nibbled, increasing machine time and tool wear
• Use a forming tool on the turret is a much better way
EXAMPLE: INCREASED TIME AND TOOL WEAR
FORMING VS. PUNCHING
• Punching– Makes a hole– Requires stripping– Stroke may not be critical– High speed
• Forming– Changes work from 2D to 3D– Stroke length critical to achieve
correct results– Lower ram speed– Station ranges are usually
reduced
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Definitions
Special Assembly-
•Any tool that transforms the material to 3D
•Any tool that requires multiple holes in a single hit.
•Any tool that requires multiple forms in a single hit.
•Any tool that punches a non-standard shape or size hole.
FORMING BASICS
MATE SOLUTIONS TRAINING
WHAT LIMITS FORM HEIGHT?
• Machine Limitations– Maximum forming height is about 6.0mm
– Calculation:Maximum Form Height = (Turret gap/2) – Material Thickness – 1.0mm safety
– Forming should always be done last
• Not necessary with machines with forming cylinder
– Adjacent stations to the forming tool should not be used
• Sheet marking, bending, risk of tool breakage could occur
• Material Limitations– Emboss stretches material
– Some forms bend material like lance and form
– Material ductility
– Form geometry
MATERIAL TERMINOLOGY
• Ductility– Ability to be elongated in one dimension while becoming
thin in another dimension
• Elastic Limit– Point at which material will not return to original shape
• Plastic Deformation– Stretching metal enough to exceed its elastic limit and
stopping prior to fracture
• Spring back– Amount which material tries to return to its original
shape after forming
MACHINE CONSIDERATIONS FOR CORRECT SETUP
• Shut Height:– Measurement from ram bottom dead center to top
of new die• Amada 205 mm
• Finn Power 203 mm
• Murata Wiedemann (Variable by Model)
• Ram Operation– Mechanical– Hydraulic– Electro Mechanical– Ram stroke control
= Forming Tool
= Adjacent stations without tooling
20 Station Turret
STANDARD PUNCH PRESSTYPICAL TURRET LAYOUT
FORMING IN A TURRET PUNCH PRESS
• Because the forming die is higher than a standard die, the forming die must protrude above the material pass line on the conventional turret
• When the sheet is moved or the surrounding stations are used, then the forming tool may mark or scratch the sheet
CONVENTIONAL TURRET
CONVENTIONAL STATION VS.UPFORMING STATION
This lance and form could never be achieved in a conventional machine.
Machine with forming station makes it possible!
Forming die operated by forming cylinder
Die Line
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Standard vs. Upforming
• Standard– Shorter form height
capabilities due to forming die height
– Form can be up or down.
• Upforming– Higher form height
capabilities: Use the entire feedgap
– Conventional forming dies sit at or below die line
– Special forming dies(Amada P&F)
– Form can be up or down.
DISADVANTAGES WITH CONVENTIONAL FORMING IN TURRET PUNCH PRESSES
Conventional Turret Finn-Power Upforming SystemB D B D
Example: 3mm material, 8mm forming
Example: 3mm material, 12mm formingTo perform any forming operation on a conventional turret:
• Forming die must be higher than a regular die• If a formed part’s height is more than ~12mm
(including material thickness), it will crash into the upper turret when it goes over the forming die
• A higher die also scratches the lower side of the sheet and may cause problems during sheet movement
NOTE: These conditions limit the forming height in a conventional turret solution to a maximum 5.9mm
Finn-Power upforming system:
• Allows formed heights equal to the feed clearance between turret plates
• Eliminates scratches and other problems
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Finn-Power Upforming
•Optional in Series 10 and newer Finn-Power F, SG and LP model•Consists of an upper and lower hydraulic cylinder (250 kN, e-machines only 200 kN)•Forms as high as .590"(15mm) (higher with foot tool)•Lower ram travel .472"(12mm) max•Form tools manufactured for conventional stations will produce forms in the upforming station without any modifications, shims or spacers.
•To achieve maximum form heights, the die assemblies must be manufactured to these forming requirements. •These tools should not be used in conventional stations.
•Travel is limited by a mechanical stop at the bottom of the stroke. •Forming is typically done at mechanical bottom.
• Forms up to 13.0mm high.
• No contact with sheet by forming tool
• Form stroke controlled within 0.001mm
FINN-POWER UPWARD ACTING FORMING STATION
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Amada P&F
Only for EM machines with Z-turret
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Amada P&F
Amada P&F
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‘Retractable’ Forming Station
Wiedemann and Euromac Forming Station
•Forming bar slides to activate forming•The sheet is lifted since the lower activates first.•Max form height same as standard
•Euromac = 6mm travel•Wiedemann = …
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Calculating Maximum Form Height?
• Conventional Machines: (typical form 3mm above die line)
– Standard maximum form height is about 6.0mm
– Standard maximum form height is calculated:
TURRET GAP /2 - material thickness - (safety) 1mm = MAX FORM HEIGHT
• Upforming Machines: (typical form at or below die line)
– Upform maximum form height is about 14.0mm (dependent upon material thickness and gap between upper and lower turret, and machine type)
– Upform maximum forming height is calculated:
(TURRET GAP + UPFORM STROKE) /2 - material thickness – (safety) 1mm = MAX FORM HEIGHT
MINIMUM SPACING BETWEEN FORMS
Minimum = 3 x material thickness to sheet edge or form on sheet
Minimum = 6 x material thickness to like forms
3 x TMinimum
MaterialThickness (T)
6 x TMinimum
3 x T + RMinimum
Radius(R)
Radius= 1/2 x T
SPRING LOADED VS. NON-SPRING LOADED
Non-Spring Loaded
DieLine
Spring Loaded
DieLine
ULTRAFORM™ LENGTH ADJUSTMENT
Adjustments up or down in easy steps of 0.05mm
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ULTRAFORM FX AND XT
• Ultraform FX and XT– Objectives:
• Incorporate interchangeability of Ultraform without all the features
• Improve price positioning over Ultraform
• Reduce holder complexity to leverage new press technology
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Ultraform XT
• Low Cost• Adjustable Length• For bottom stroke
machines• B-E Station• Same inserts as Ultraform
today• OAL= 203 – Material (FP)
• OAL= 205 – Material (Others)
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Ultraform FX
• Low Cost• Fixed Length• B-E Stations• For Precision controlled
Ram Machines• Same inserts as
Ultraform today• OAL=208mm !! (longer
than normal)
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Forming Tool Recommendations
• Always form as far from the clamps as possible.
• Forming should be the last process on the sheet whenever possible.
• Additional Dwell Time may be necessary to allow tools to strip properly (Programming command)
• Forming tools should be run at a slower punching speed to allow material to flow/form.
• Stations next to the forming tool should not be used. It is recommended to have a die in the die holder in these stations. Roller or brush dies are recommended for both sides of a forming station.
• Lubricate the sheet and use machines lube system if available.
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Forming Tool Recommendations
• Periodically remove the tool from the turret and check the sharpness of any cutting edges.
• Form down operations should be avoided because formed material can drop into dies, get caught and pull the work piece out of the work holders, or distort the form. If a form down operation is the only solution for a particular part, make it the last operation on the sheet.
• Machine stroke lengths are different from machine to machine.
• A tool that works in one machine may not work in another.
• Set up using the tools minimum length and adjust in 0.15mm steps to achieve a sharp form where the tool is properly bottomed. Keep a setup record sheet for all special tools to minimize setup time for each subsequent use of that tool.
SOME FORMING TOOLS IN DETAIL
MATE SOLUTIONS TRAINING
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Most Common Special Assemblies
• Top 10 Special Assemblies explained in detail.
Rank Description
% of SA Items Sold
1 Clusters 43.9%
2 Extrusion: Round 8.9%
3 Undefined 8.5%
4 Lance and Form 5.4%
5 Knockout 4.2%
6 Countersink 3.6%
7 Emboss 3.3%
8 Louver 3.0%
9 Engrave Stencil Down 1.6%
10 ShearButton 1.3%
11 EasySnap 0.7%
84.3%
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• USE: To produce multiple holes with minimal hits.Ideal to guarantee center-to-center tolerances.
• TYPICAL APPLICATION: – Material thickness from 0.020(0.50) to
0.157(4.00). – Other constraints dependent upon station size,
punch size and shape, press tonnage capacity, distance between the border of the holes (web).
• For greater hole uniformity and flatter sheets, spread the punches to avoid punching adjacent holes in the same hit.
• Complete the desired pattern with the technique known as bridge hitting.
• Do not re-punch through previously punched holes to complete a pattern, single hit tool may be necessary.
Clusters2 to 100+ holes round or shaped
Limited to press tonnage and station parameters
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• TYPICAL APPLICATION: – Material thickness from 0.020(0.50) to
0.157(4.00). – Other constraints dependent upon station size,
punch size and shape, press tonnage capacity, distance between the border of the holes (web).
Clusters
2 to 100+ holes round or shaped – Limited to press tonnage and station
parameters
ULTRA AND ORIGINAL STYLE THICK TURRET CLUSTERS: GUIDED & NON-GUIDED WITH
INSERTS
Minimum/Maximum
• 0.5mm minimum, 4.0mm maximum thickness
• Other restraints dependent upon station size, punch size and shape and machine tonnage
Punch head must be within pattern
øS = cluster punch retainer
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CLUSTERS
Replaceable InsertsFully Guided
Replaceable InsertsNon-Guided
(shape cluster)
Note: Round cluster uses backing disc, shape cluster
uses punch screws.
Solid Standardor Solid Fully Guided
Cluster punch
burned from solid blank
BENEFITS OF FULLY GUIDED• Guiding at punch point• Increases hole accuracy• Improves stripping • Point Size closer to material thickness
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Insert Style
Clusters: Solid or Insert
Features Solid Insert
Fully Guided Available Yes Yes
Initial Cost Lower Higher
Replacement Costs Higher Lower
Punch Point Spacing Closer Farther
Pattern Size Larger Smaller
Punch Point Size Recommended Larger Smaller
Sharpening Easier Harder
Solid Style
Cluster Pitch Rounds
• The minimum cluster pitch is determined by the die in most cases
• Minimum is 3.0mm STEEL between holes in the die. Example; 5.0mm hole in 1.0 mild steel with die clearance of 0.2mm will have a center to center spacing of 8.2mm
• Cluster pitch with many holes is determined on a case by case basis based upon spacing and material thickness.
• In most cases double spacing recommended as this produces a stronger die and less sheet distortion.
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Cluster Pitch Shapes
• 12.0mm is the minimum pitch between punch points on a shape cluster. This limit is imposed by the upper assembly screws used to hold the inserts in place.
• For some special applications the pitch spacing can be reduced to 10.0mm but will require a full Mate engineering review based upon complete cluster pattern and material being processed.
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Clusters: Tips for Success
Tips for Success: (addressed in upcoming slides)
1. Slug Pulling
2. Sheet Flatness
3. Tonnage or Noise
4. Tool Life
5. Tool Maintenance
6. Press Maintenance
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Clusters: Slug Pulling
1. Sharpen tools
2. Correct die clearance
3. Proper die penetration
4. Accurate station alignment-• Furthest punch point distance from
center is multiplied.
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Clusters: Sheet
Flatness
1. Bridge Hitting improves part flatness.
2. Sharpen Tools
3. Proper die clearance
4. Move in one direction each sequence
5. Increase Station Size or Stripping force
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• Start punching pattern away from clamps and work toward clamps
Clamps
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Shorten half of the cluster punches by 50 – 60% of the sheet thickness in order to reduce noise, vibrations and required punch tonnage.
Example:
16 punch cluster of 10mm square punches
Perforating in 1mm mild steel
Insert Punch length 37mm
Shorten 8 Punches to length 36,5mm ( Balanced Shortening)
Clusters: Tonnage or Noise
For safety, plan on all inserts hitting at the same time for tonnage. Do not exceed 75% press tonnage.
Lowers the force on a die and could extend die life
Increases slug pulling,
decreases insert grind life.
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CALCULATING CLUSTER TONNAGE
PUNCHING FORCE FORMULA = linear length of cut x material thickness x shear strength = punching force in kilonewtons (kN). PUNCHING FORCE SHOULD NOT EXCEED 75% PRESS
CAPACITY.EXAMPLE: Grid of .250(6.35) diameter holes. Area of punch covers 48 holes; punch every
4th hole (12 holes). Mild steel .060 (1.52) thick. (Linear length of cut = 3.14 x diameter x number of punches).
Spring pressure of the spring-loaded cluster assembly runs under a ton (9 kN) and can be ignored in calculations for machine capacity.
SHEAR STRENGTH IN US tons/in2 (kN/mm2):
Aluminum 5052 H32 = 15.0(0.2068) Brass = 17.5(0.2413)
Mild Steel = 25.0(0.3447) Stainless 304 = 50.0(0.6894)
Clusters: Tonnage
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Clusters: Tool Life
• More tolerances with insert style. Try Fully Guided• Machine alignment critical• Turret bore wear• Guide wear• Sharpen Tools• Consider punch stagger if tonnage is high or die failure.• No Double Hitting DO NOT DOUBLE HIT HOLES. Because
of tolerances built into the punch press, using the cluster punch to finish missed holes in patterns will cause punches to
shave sides of previously punched holes. The great lateral thrust from this
shaving shortens punch life. Use a single -hole punch to complete the
pattern.
4848
Using cluster tools reduces the number of hits…and
machine and tool wear
Cluster tooling will produce patterns with just 172 hits vs.
current 2,064 hits
Clusters: Tool Life
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Clusters: Tool Maintenance
• Sharpen before the tool requires it
• Lubricate guide assembly
• Remove galling from points in direction of punching. Find root cause and eliminate!
Sheet lube, maxima, alignment, clearance, guide, bore wear, double hitting,
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Clusters: Press Maintenance
• Station Alignment
• Good condition bore. Select the best one you have.
• Turret bore key in good condition
• Work Holder Condition
• Die holder and shim condition.
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Alignment
0.1 degree is too much
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Clusters: Review
• Several Types of Tools: – Fully Guided 1 PC & Inserts, Standard 1 PC & Inserts
• Tips for Success:– Slug Pulling: Sharpen Tools, Proper Die Penetration, Alignment– Sheet Flatness: Bridge Hit, Move in 1 direction, Spring Force– Tonnage or Noise Limits: Stagger punch points– Tool Life: Use FG, Sharpen Tools, Align Station, No double
hitting.– Tool Maintenance: Sharpen Often, Lubricate, Eliminate Galling– Press Maintenance: Bores, Alignment, Workholders, Bore Keys
Piercing and Forming Clusters
Piercing and Forming Clusters
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Extrusion
• USE: Threading for screws and increased bearing area for tubes, etc.
• TYPICAL SCREW APPLICATION: – Material thickness from 0.031(0.80) to
0.106(2.70). – Overall Height 2x to 2.5x material
thickness. – Diameter 0.374 (9.50) (M-10)
50mm diameter
•Maximum diameter can be increased by using an alternative
design.
Extrusion - Tapping
• Buy additional inverted dies to accommodate different material thicknesses.
• Maximum diameter can be increased by using an alternative design.
• Pre-pierce determines height.
Extrusion - Tapping
• Lubrication:- Ultra-Form can provide lubrication.- Lube the sheet (bottom if forming up).
• Problems:- Galling : use optional Maxima coating- Stripping : use PowerMax design- Smaller size die inserts can break : order spares
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Extrusion
Most Common (95%)
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Extrusions: Different Styles
One of 4 lower assemblies is used based upon the applicationMore Common
Less Common
• Standard design• Max
diameter 9.5mm
• Disc springs = Strong
• Replaceable insert
• ID is 9.5-15mm
• Disc springs = Strong
• Replaceable inserts
•ID up to 25mm•For low form
extrusions due to shoulder
•Coil springs = weaker
•Solid lower, no replaceable insert
•ID up to 16mm•Coil springs =
weaker•Replaceable insert•Most applications
that can fit the maximum diameter
have stripper requirements that
requires a C station.
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Extrusion
General Limitations:– Overall Height 1.5x to 2.5x material thickness. Beyond
2.5 the material will likely fracture– Effective Range=Extrusion Height – thickness – radius
• Largest Range under 1.5 x thickness– Consider “PUNCH and SHAVE” vs Extrude!
Extrusion Height1.5 – 2.5 x thickness
Radius.015” (0.4mm)
Eff
ect
ive
Ran
ge
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Extrude, OR …Punch and Shave
Finished hole size is the starting point.
Punch #1 = finished hole size – clearance (20%)Die #1 = finished hole size + 0.1 mm
Punch #2 = finished hole size (full mat’l contact : Maxima !)Die #2 = die #1
.
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Extrusion: Extrude or Punch
• When is a tapping extrusion not the best choice for achieving the highest number of tapped threads and punching and shaving is a better option?
– Small diameter extrusions in thicker material would require an extremely small pre-pierce diameter to achieve a significant form height.
– Using a pre-pierce that is appropriate for the material thickness may not leave enough material to achieve a significant form height.
– For this reason, the largest number of useable threads may be available from punching and shaving the hole. This is more likely when the material thickness exceeds .078” (2,00mm) and the extrusion ID is less than .315” (8,00mm).
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Extrusion: Tips for Success
Tips for Success
1. Use Pre-Pierce Calculator
2. Sharpen tools for pre-pierce hole (to avoid inside burr)
3. Form Height no more than 2.5 X Thickness
4. Tonnage= Slightly more than punching same size hole
5. Material thickness not practical to exceed 2.7mm 6. Buy additional inverted dies (Upper Insert) to accommodate
different material thicknesses.7. Pre-pierce controls form height.
8. Lubrication:- Ultra-Form can provide lubrication.- Lube the sheet (bottom if forming up).
9. Galling : Consider Maxima coating
10. Smaller size die inserts can break : order spares
11. Stripping Problems: Consider PowerMax design, larger station size, or down forming
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Lance & Form
• USE: For air flow, decoration, card guides, location markers, shear tabs, wire harnesses or clip attachments.
• TYPICAL APPLICATION: – Material thickness from 0.020(0.50) thick to
0.118(3.00). – Maximum recommended top-to-top height is
0.250(6.50). – Other limitations include material type, thickness,
station size and press tonnage capacity.
• The inclusion of a 5° draft angle is recommended to assure reliable operation.
Ultraform B
Upper Insert
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Lance and Form
The ‘form’ part of the operation takes place as
the work piece is squeezed between the lower unit and
an inverted die in the upper unit.
The ‘lance’ is normally performed by the lower
unit using an inverted punch.
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Lance and Form Design Considerations
• Draft Angle: An important consideration for trouble free production.
• Made for a single material thickness, sometimes lighter material can be used.
TOP VIEW: Without Draft angle...
DRAFT ANGLE5º Minimum
TOP VIEW: With draft angle, showing effect as front edge of tab
moves back in die...
SIDE VIEW: Front edge of tab moves
back in die as it is formed.
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Lance and Form: Design Considerations
SHEET METAL PARAMETERS
MaximumHeight
.250(6.4mm)
R = .060(1.5mm)Minimum
85º Maximum
MaximumThickness
.120(3.0mm)
OPEN END
85º Maximum
45º Maximum
OPEN END
CLOSED SHAPE
Lower tool travel is what
typically limits the form
height.
Spring Back
Thicker materials may break before
completing form and cause too
much abuse on lower insert.
Angle is typical, may
be increased if form height
decreased.
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Lance & FormSnaplock™
• Self-locking spring loaded tab- fits into hole
• Eliminates spot welding, riveting or fastening with threaded hardware
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Lance & FormSnaplock™
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Lance & FormSnaplock™
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Triple Lance & FormHexLock™
Positive retention
Common size bolts
Robust easy to use tooling
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Lance and Form: Tips for Success
Tips for Success:• Use forming lubricant on the sheet• Replace the cutting components when they become dull• Confirm the tool was designed for the material type and
thickness being formed• Increasing the form radii• Decrease the form height• Sometimes requires pre-piercing around form, then
using an emboss. • Use a more ductile material for forms with sharp angles
or curves• Form up whenever possible• Avoid plastic coatings if possible
Avoid forms sticking, creating a burr, or becoming
damaged in processing
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Knockout
• USE: Allows optional pathway for electrical cable.
• TYPICAL APPLICATION:– Material thickness from 0.024(0.60) to 0.118(3.00). – Maximum size dependent upon material type, thickness
and press tonnage capacity.
• The tool can be used with other material thickness within a range of + or - 0.016(0.40) from design thickness.
• Maintain minimum of 0.236(6.00) difference between diameters used for knockout.
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Knockout: Sample
50 Ton Application
100
mm
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Knockout
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Knockout: Process
1. The knockout process uses a single tool to create a slug and the tabs.
2. The tabs are stretched and weakened when the slug is displaced.
3. Small tabs in thicker material may not be able to stretch enough to keep the slug attached to the sheet
4. Precise, consistent stroke control in the press is very important for producing high quality, consistent knockouts.
5. It is common for knockouts to be pressed back into the sheet (planished) to create a closed feature. Although this flattening process will not press a knockout completely flat back into the sheet it does prevent dust intrusion into the enclosure.
6. Planishing knockouts introduces stresses into the sheet that may result in a slight bowing of the knockout and/or the surrounding sheet.
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ELECTRICAL KNOCKOUTS
SPLITTING PUNCHING FORCE WITH TWO HITS
DOUBLES…If punching force is over capacity, make first hit
single K.O. down, second hit single K.O. up with relief.
1.1 x materialthickness
1st Hit
2nd HitTRIPLES…Make first hit
single K.O. up, second hit double K.O. up with
relief.
1st Hit
2nd Hit
Thickness Variation: • Knockout tool assembly accommodates a + .016(0.4mm) range in material
thickness• Beyond + .016(0.4mm), penetration is affected and knockout performance
deteriorates
Planishing:• Planishing punch pushes knockout back to 75% material thickness, leaving 25%
still raised• Planishing the knockout further makes it difficult to remove and distorts the
sheet• Knockouts can be produced without planishing
1st Hit
2nd Hit
QUADS…Make first hit double K.O. up, second hit double K.O. up with
relief.
If diameter is closer than 6mm, this process helps too
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Knockout: Beat Out or Fall Out
• Consistency is the key factor. – Machine repeatability– Good tool condition (sharpened)– Tool Length and Programmed depth
• The depth of planishing impacts force to remove.• The number, size and location of tabs are
important.• Material type impacts force required• The force is subjective. To you it was easy, for me
it was hard….
79
Knockout: Tips for Success
• Be aware of tonnage limits• Beat out or fall out• Use lubricant on the sheet• Confirm the tool was designed for the material
thickness range being formed• Sharpen or replace the cutting components when
they become dull. Note: Sharpening can change form height and tab strength.
• Review tab sizes, locations, and quantities• Confirm the form height is correct (1 to 1.1 times
the material thickness)• Form up whenever possible
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Countersink
• USE: Allows screw head to reside flush or below the surface of the material.
• TYPICAL APPLICATION: Material thickness from 0.048(1.22) to 0.250(6.35), dependent upon press tonnage capacity.
• 2 styles:• Universal style: Prototype work• Shoulder style (dedicated), generally ordered
for one material thickness and screw size
81
Countersink
Countersink Up
Countersink Down
Solid body die available for
up.
82
Countersink: Dedicated
Shoulder (dedicated) Style•Designed for one material thickness and screw size•May be used with thicker material but not thinner•Coins the surrounding area producing a clean, flat countersink with minimum burring•Maximum 85% of material thickness•Very repeatable and accurate forms
Blank Die
Upper Insert
83
Countersink: Universal
Note: Use UltraTec instead of Ultra Form holder for pilot-nose Countersink down (universal).
UltraTec Fully Guided B station is recommended as slight stripper movement may cause breakage.
Universal style•Used for various material thicknesses•Maximum 60% of material thickness•Where precision and repeatability is not as important
84
Countersink: Material
Deformation
– The plastic deformation of the material is generally opposite to the direction of the applied force, moving material back into the sheet and down into a pre-pierced hole, typically causing the final hole size to be smaller than the pre-pierce hole size.
– This form can be done either to the top or the bottom of the sheet.
The area in yellow must be displaced to areas in red.
Only the angle can be controlled reliably.
Notice the finished hole is smaller than pre-pierce
85
Cuntersink: Dedicated vs Universal
Universal Style
Dedicated Style
Dedicated countersinks are preferred:
•Less material moving to the top of the sheet
•More material into hole (control via pre-pierce)
•One Die fits all
86
Countersink
Material Considerations and Maximum Depths
A=Major diameterB=Minor diameterC=Form angleD=Form depthE=Approximate pre-pierceT=Material thickness
Typical: Metric= 90, Inch=82, Rivets=120
87
Countersinks: Tips for Success
Tips for Success:• Confirm the material thickness is correct for the tool design• Check that the form is being sufficiently coined (witness mark
around shoulder diameter)• Adjusting pre-pierce size changes depth
– (smaller = deeper, larger = shallower)
• Final hole size is less than pre-pierce (use calculator supplied)• Use dedicated vs. universal when possible• If using Universal
– understand limitations of repeatability and capable tolerances– Use a new die with no shims always. Ground dies will not produce the
same result unless you modify length of upper or adjust program.
88
Emboss - Formed
• USE: – Provides a recess or a protrusion– Mounting locations and stand offs on electrical
cabinets– As a sump to collect condensation inside of
refrigeration units
• TYPICAL APPLICATION: Material thickness from 0.027(0.70) to 0.250(6.35), dependent upon press tonnage capacity.
• Best results are attained when the side wall angle is 45° or less.
• Optimum form height is 3 times the material thickness or less.
89
Emboss - Formed
90
Emboss - Formed
91
Emboss - FormedExample of emboss down
UltraTEC punch holder
with special punch
Special form-down die
92
Emboss – Tips For Success
Tips for Success• Lubricant will help reduce punching force and produce
a better emboss.• Decreasing the form angle• Decreasing the form height• Increasing the form radii• Pre-piercing a hole in the center of the emboss• Use material that is more ductile
93
LOUVERS
Use: • To provide air flow or ventilation.
Recommended:• 2.7mm material maximum• Maximum top height is 6.5mm• Length is unlimited if continuous• If non-continuous:
• Usually 12.7mm shorter than the station size used
General:• One tool cuts the sheet and produces
the form.• The tool is limited to one material
thickness.• Generally require tonnage equivalent to
punching a hole equal to the cut length of the louver.
Open End Louver Closed End Louver
94
Louvers
95
Louvers
• Closed End– Stronger design
– Smooth ends
– No exposed corners
– For exterior panels or outdoors
• Open End– Maximum air flow– Closer spacing– For interior panels or indoors– Shorter front edge and longer back
design allows sides to strip easilyDraft Angle -- 10º standard, 5º minimum. During
forming, the shorter front edge rises and the longer back edge bends to allow the sides to
strip easily.
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Continuous:
• Prototypes.
• Short production runs.
• Extra long louvers.
Continuous louvers are made by forming a closed end louver and then gradually
advancing the tool along one axis to expand the opening.
LOUVERS
• Continuous louver tools are designed to produce smooth-edged, level-topped louvers
• Start in the center and form to one side and then the other in .030(0.8mm) increments
• If needed, complete the process by re-hitting the center for ultimate flatness
97
Louver Spacing
99
Louvers – Tips For Success
Tips For Success.
• Use forming lubricant on the sheet • Move material in opposite direction of openings• Continuous Louvers: Start in the middle (Hit A) and work toward
one end, go back to the middle (repeat Hit A) and continue to opposite end. Then repeat Hit A for the third and final time.
• Replace the cutting components when they become dull • Confirm the tool was designed for the material type and thickness
being formed • Decrease the form height • Use a more ductile material • Form up whenever possible
If problems are experienced with a closed end louver sticking, creating a burr, or becoming damaged in processing, improved
results can be achieved by:
100
V-Line Emboss
USE: To produce a logo / design / messages on a part.
TYPICAL APPLICATION:– A thin sharp line is produced outlining
the shape required and produces an etched appearance.
– Minimum 0.8mm thick, maximum can be up to machine capacity. Maximum size is dependent on station size and size of symbols or characters.
– Low punching force; complex shapes are possible; usually trouble free.
– Depth 0.3mm; does not disappear with painting.
An exact drawing, CAD file or sample of logo is required in order to produce this type of assembly.
101
V-Line Emboss
102
V-Line Emboss
103
V-Line Emboss – Tips For Success
Tips For Success• Relatively trouble free application• Proximity of adjacent lines (not too close)• Closed end features fill with material (tool stops
moving down)• Use enough punching force to get designed
depth without leaving “witness” marks• Required: good artwork with clean lines
– At least two times larger image than required
104
Shear Button
• USE: To position sheet metal parts for welding or as stops as for shear stops.
• TYPICAL APPLICATION: – Minimum material 0.9mm– Maximum material 5.0mm– A diameter of 5.0mm is
standard, but up to a diameter of 9.5mm is possible.
• Maximum height is 65% of the material thickness
105
Shear Button
106
Shear Button
One tool produces the form in each mating part.
Using shear buttons to square large sheets...
Conventional use of shear buttons...Shear buttons in lower plate fit
into matching holes in upper plate...
Shear buttons used as weld projections for precision placement of plates to be welded
together...
107
Shear Button
Use slotted for small diameter and
thin materials
Multiple Material Thickness Tool:
•Use slotted insert for up to 2.3mm material and non-slotted for material up to 5.0mm thick
•Slotted insert leaves a tab (like a knock out)
108
Shear Button
• Traditional wire style micro-joint.
– Sharp point needs to be removed, creating a secondary operation
– Material left may cause inaccurately formed parts
• Square Shear Button style micro-joint– Adjustable in length when strength
is required– It can be snapped off easily, leaving
a clean edge– Square shape allows it to be used
at both 0° and 90° without the need of an auto-index station
109
Shear Button – Tips For Success
Tips For Success• Low tonnage operation that’s relatively trouble
free• When using in Stainless Steel, the diameter
should be twice the material thickness• In thin material, a slotted tip insert may be used to
help buttons stay in place• Tools can and should be sharpened
110
EasySnap™
• V-line stencil from both sides creates snap-line
• USE: Like a micro-joint – but better!
• Can be snapped-off with no burr
• Reducing waste of skeleton
• TYPICAL APPLICATION:
– Material thickness from 1.0mm thick to 1.5mm MS and SS, and 2.0mm ALU
– Tool dedicated for 1 thickness only
– Max. recommended length 300mm
111
EasySnap™
– Using tool for proper (designed) material thickness allows easy breakage of parts in two
– Using tool on material too thin for design could shear through material
– Using tool on material too thick for design won’t allow easy breakage of parts
112
EasySnap™
Use for easy part removal and skeleton breakdown
Use when a formed flange needs extra material for gauging and forming. Snap off extra after form is made
114
EasySnap™ - Tips For Success
Tips For Success
• Designed for one thickness– Punch depth should be about 33% into
material, both top and bottom
• Run at a slower machine speed
• Use as last operation if possible
115
• Complex bending made easy
• V-line stencil creates line of weakness
• Allows subsequent bending by hand
• Suitable for MS or SS < 1.50mm and Al < 2.00mm
• Maximum recommended length 300mm
• Available for all tooling styles
Before punching.
After punching with EasyBendT.
Hand bend along bend line created with EasyBend™
Component after hand bending.
Mate EasyBendMate EasyBend™™
LIT 00002
LIT 00002
JOHN ALPHA NUMERIC MARKING
• Use standard, replaceable, economical inserts.
• Message or letter changed easily
CARD GUIDE
Use:
• As a retainer for printed circuit boards
Minimum/Maximum
• 1.0mm thick minimum 2.0mm thick maximum
CARD GUIDE
• Length of the card guide is dependent upon station size and machine tonnage
• Maximum height recommended is 3.2mm
Pre-pierce ends can be rectangular or rectangular with radiused corners
CARD GUIDE
• Two tools are required– Pre-pierce – One that forms the card guide
• Each tool is made for a specific material thickness
• Galling can be a problem– lubrication through the tool and
on the sheet is beneficial
• Mild steel give the best form– Aluminum is fair– Stainless can be a problem
due to spring back of the material
• A post dwell should be used to allow stripping
COLD FORGED EMBOSS
Use: • To produce a logo or design on a part.
Minimum/Maximum:• Minimum 0.3mm thick, Maximum 3.0mm thick,
depending on the tooling style, station size and the machines tonnage
• Can be used on varying material thickness (within a range)
• Best if made in 1.0-2.0mm thick material
General:
• Exact drawing or sample of logo required to produce
• Tonnage can be high dependent on design and material
• Usually simple trouble free operation
• Width of characters should be minimum of one material thickness, more is better
• Space between characters or lines should also be one material thickness minimum
• Tools are not designed to be sharpened
• Can be dusted to sharpen the emboss after the tool is older
UPPER INSERTUPPER INSERT
MATERIALMATERIAL
LOWER INSERTLOWER INSERT.016(4.0mm)
to.020(0.5mm)
For clear definition and readability, raise characters at least .016(0.4mm) to .020(0.5mm) above the surface.
This cut-away of the MATE logo shows how a complex form is rendered by the cold forged embossing process.
MAXIMUMSTATION PERIMETERS
B Ø .787(20.0mm)C Ø 1.575(40.0mm)D Ø 2.362(60.0mm)E Ø3.346(85.0mm)
COLD FORGED EMBOSS
HINGE TOOLS
Tool 1 makes 2 hits: Pre bending and rising the pre-bended tap with axis movement in between
Tool 2 makes one hit and finishes the hinge
Tool 1 Tool 2
HINGE TOOLS
Tool 1
Tool 2
Use: • Logos, messages or symbols• Produces an etched appearance
Minimum/Maximum:• Minimum 0.8mm thick, maximum
can be up to machine capacity• Maximum size is dependent on
station size and size of symbols or characters
General:• Thin, sharp line produced,
outlining the shape required and• Low to high tonnage, usually
trouble free
V-LINE CUSTOM INSCRIPTION
V-Line Stamping -- renders the image with a thin, sharp line stamped into the surface. It requires relatively small force. Large complicated images are possible.
V-Line Stamping:• Thin, sharp line
reproduces the outline of the shape for an etched appearance. Low punching force.
• Within press capability, figures may be any size up to station maximum
• When ordering, an accurate indication of each figure’s size, shape and depth below surface (0.30mm maximum) are required
• Typefaces may be specified or artwork may be furnished, depending on the requirements of the subject matter.
RAM CONTROL TOOLS
Press must be capable of holding the ram down while the sheet is moved in the X and or Y direction.
MATE ROLLERBALL™
• Rollerball™ provides the benefit of making forms not possible with single hit forming tools
• Takes advantage of punch press extended programming capabilities
• Machine must be capable of operating in the x and y axis with the ram down
Rollerball™ Capabilities:• Make stiffening ribs in light gauge sheet
metal• Cross-break operations on the punch
press• No secondary press brake operations • Form ribs, flanges and raised areas
across the entire work surface• Offsets and embosses not limited to
station range
•Max. thickness 2.7mm
•Rib width ~22 mm (fix)
•Max. height 3.7mm incl. thickness
Ribs
Offsets
MATE ROLLERBALL™
Rollerball Examples
Rollerball® Beading in 1mm mild steel
Detail inside corner Roller Ball Beading
Mate RollerBall DeburrMate RollerBall DeburrTakes away the burrs on every hole – even small diameters and in corners, also slitting lines on both sides
Machine must be capable of holding down he ram while moving the sheet
Can be used in combination with EasySnap to get a burr- free product
Up to 4.0mmthickness
SHEETMARKER™
Three springs, two points (120 & 150) allow control of depth and width of the line scribed
Flexible, programmable marking
Score Plastic Protection for removal before laser cutting
or fabrication ( bending lines etc.)
Cuts trough the protective plastic film without leaving any marks on the metal surface .
Mate EasyMarkMate EasyMarkSprings: 3 Types to be
used for diamond orBrass Inserts
Spacer: Use for dead weight on
top of InkMarker
Punch: for installing and removing
inserts
Ink Marker pen Insert Holder 3 Inserts (2 diamond, 1 brass)
Allen Wrench: for installing and removing inserts
Die: Used forSheetMarker
and InkMarker
Spacer: Use with
SheetMarker
A-station Holder
Mate EasyMarkMate EasyMarkApplications with Inkmarker Pen
MATE SOLUTIONS TRAINING
PROBLEM-SOLVING CHECKLIST
PROBLEM-SOLVING CHECKLIST
• Is the material correct for the tool that was ordered?
• Is the tool length set correctly?• Is the forming being done close to the clamps?• Does the tool require sharpening?• Is galling present on the tool?• Was the correct pre-pierce used?• Is there a delay in the program to allow stripping?• Is the turret aligned properly?• Is there any damage to the tool?• Was lubrication used on the tool and sheet?
MATE SOLUTIONS TRAINING
SUMMARY
SUMMARY
• Using forming in your operations will help you…
– Increase efficiency
– Expand your capabilities
– Eliminate of secondary operations
– Increase machine time
– Reduce tool wear
THANK YOU!
MATE SOLUTIONS TRAINING