press tooling. ge24-070r /c tool for trimming, cutting out...

© RENAULT 2008 Origin: PEGI - Renault Page: 1 / 38

Press tooling. Tool for trimming, cutting out, punching. Basics on design

GE24-070R /C ________________________________________

Guide ________________________________________

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

version is referred to as the reference text and is binding on the parties. Object Define the recommendations for the design of trimming, cutting out, punching 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 05/2008

GE24-070R /C


History of versions

Version Update Object of main modifications Author A 02/2004 Creation (1) B. Nouhant Dept

65307 C 05/2008 • Addition of precision which concerning « Floating scrap

cutter». • Put in coherence of the information with the standard

EM24.01.100, for scrap cutters. • Addition of the type of die with "pin"; • Addition of information for the scrap evacuation. • Addition of information for the the stake in operation. • Replacement of the standards CNOMO E01…., for the

metal materials, by Renault standards • Replaced standard EN 10025 by EN 10025-2 All modifications are marked by a solid line in the margin.

B. Nouhant Dept 65307

Supersedes GE24-070R of 01/2005 version B Availability Inside Renault, on the Intranet: http://gdxpegi.ava.tcr.renault.fr

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

Documents cited Regulations : International : ISO 3755, ISO 4957. European : EN 10025-2, EN 10083-1. French : CNOMO : Renault : EB01.14.220, EB01.31.212, EB01.33.211, EB01.41.050,

EB01.45.030, EM24.01.100, EM24.02.030, EM24.02.033, EM24.15.100, EM24.53.100, EM24.53.300, GE24-017R, GE24-040R, GE24-120R.

Other internal doc : Other external doc : Coding ICS: 25.120.10; 03.120.20 Class E24 Key words emboutissage, outillage de presse, outil de presse, dessin, fondamentaux, conception,

détourage, ajourage, poinçonnage, pressing, press tooling, press tool, design, basics, trimming, cutting out, piercing

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

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

TCE 65307 MM. BIANCIOTTO / MARMANDE / TRADOTTI

LHA 04734 MM.BAUBE / PASQUIER / ROULIER TCR 64140 M. GOURDET

GE24-070R /C


Contents

Page

1 General ........................................................................................................................................ 4 1.1 Tooling constituents ......................................................................................................................................4 1.2 Instructions for frames and foundry parts .....................................................................................................8 2 Cutting elements (Trimming)................................................................................................... 11 2.1 aterial tables ................................................................................................................................................11 2.2 Cast blades .................................................................................................................................................11 2.3 Welded or cast blades for thickness > 1,5 mm ...........................................................................................13 2.4 Moulded scrap cutter for panel thickness ≤ 1,5 mm ..................................................................................14 2.5 Scrap cutter for thickness > 1,5 mm............................................................................................................14 2.6 Scrap cutter by breakdown .........................................................................................................................15 2.7 Implantation instruction for scrap cutter ......................................................................................................15 2.8 Floating scrap cutter....................................................................................................................................20 3 Cutting elements....................................................................................................................... 21 3.1 Material tables .............................................................................................................................................21 3.2 Slotting.........................................................................................................................................................21 3.3 Punching......................................................................................................................................................24 4 Part centring and clamping ..................................................................................................... 26 4.1 Centring the part..........................................................................................................................................26 4.2 Punch range ................................................................................................................................................27 4.3 Pressers ......................................................................................................................................................28 5 General guidelines for scrap evacuation ............................................................................... 30 6 Start up ...................................................................................................................................... 35 7 Normative references for metallic materials cited in this document................................... 37 8 List of documents cited ........................................................................................................... 38

Foreword This guide is not:

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

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

The reference documents related with the different materials cited in this guide are mentioned in the table included in chapter 7.

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

GE24-070R /C


1 General

1.1 Tooling constituents

For foundry thicknesses see paragraph 1.2.

1.1.1 Lower frame The frame includes or supports:

Column guiding and precentring stops. The storage spacers (elastic spacers, gas springs, fuse system). The adjustment spacers. The pneumatic fittings. The electric or electric-pneumatic fittings. The handling pins + handling with clamps. The safety jack ranges. The centrings and fasteners on production and backup press.

In addition, it ensures the functions specific to Trimming – Cutting out – Punching tools: Support and centre the punch. Support the gutters and scrap slopes. Allow evacuation of scrap. Material FGL 215HB *

Lower frame

Guiding gap

PIN AXIS

Offset punchP

ress

axis

GE24-070R /C


1.1.2 Punch The punch includes or supports: The lower cutting edges. The punching dies. The part centrers. The scrap cutters. The evacuation gutters. The detection probes. Material G50CrMo4 * T3+T7 local Offset grains (X153CrMoV12 * or 42CrMo4 *) Part centring with or without offset cover.

1.1.3 Lower frame / Single block punch. It groups the frame and punch functions

Material = FGL 215HB * + recharged edges (see EM24.15.100) Offset grains

This single block solution must be banned for: TGP tooling. Parts likely to be modified such as lateral door caissons, boot door caissons. THLE panel parts. Very narrow parts. For thickness, see table in paragraph 1.2.

Guiding gap

PIN AXIS

Pre

ssax

is

Lower frame single block without offset punch

GE24-070R /C


1.1.4 Presser The presser ensures the part clamping and stripping function. It is constructed with minimum vertical ribs to facilitate application of modifications. Material: FGL 215 * HB / FGS 600 3A * or, for complex shapes, to reduce fragility, for parts likely to be modified (e.g. door caisson), it is in cast steel 270-480W *. Presser guide

Guiding by cupro plate with inserts implanted on the presser. Plan on the frame the possibility to implanter a plate.

Plate guiding is preferential over column guiding, which must remain exceptional (Easier fitting/removing with plates), see paragraph 5. For aspect parts, cones or stands are implanted between presser and punch (or lower crane). Cones are mainly to be implanted for parts with "edge" lines. Note: if the presser is guided by columns, do not fit cones, only stands. Possibility to use "suspenders" (natural outlets) to implant cones or stands

Cones: seeEM24.52.100

Cones

Bea

rings

GE24-070R /C


1.1.5 Upper frame The upper frame includes or supports:

The bush guides and precentring. The storage spacer stands, jack ranges. The adjustment spacer stands. Handling pins + handling with clamps. Snap clamps + manual fitting Retainer pins of the presser or retaining/locking. Pressure elements (nitrogen equipment or spring). Punch holders and risers. Opening and trimming blades. Presser guides. Pneumatic fittings (or clearance) for new generation TGP/TTGP socket.

1.1.6 Reactions For "open" trimming lines exceeding 200 mm. For parts thickness ≥ 1.25 mm and HLE and THLE panels.

GE24-070R /C


1.2 Instructions for frames and foundry parts The sizes below are for indication only and must be adapted individually.

Type of press FOUNDRY ELEMENTS MATERIAL SIZES MP GP TGP Lower frame A 40 40 50 Upper frame

FGL 215HB * B 50 60 60 C 40 50 50 FGL215HB *or

FGS 600 3A * D 30 40 40 C 30 40 40

Presser 270-480W *

D 20 30 30 Cover 270-480W * E 30 30 30 Punch See paragraph 2 F 40 40 40

Note: For the design of the foundries, see Renault standard EM24.01.100 and Renault guide GE24-

040R.

Partial cross-sectionof entire tool

Partial cross-section : upper frame, presser, punch, cover

Cover

Punch

Presser

Poinçon

Upper frame

Presser

Lower frameExtend the blade bearings by 50 mm for key housingif required

Upper frame

Lower frame

4 or 6 contacts according to presser dimensions and shape

Pen

etra

tion

She

arin

g

Presser stroke + 10

GE24-070R /C


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

Adjustment spacer located opposite ribs. If working reaction: Implant steel plates on insert cupro. "storage" position

50 m

in b

efor

e co

lum

n in

serti

on

Field of working parts

Tool

axi

s

Tool tip view Free tool position (HOL)

Tool

and

pre

ss a

xis

Eng

agin

g in

the

plat

es =

40

mm

GE24-070R /C


1.2.1 Calculations See GE24-040R paragraph 2

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

1.2.3 Narrow parts, thick parts, HLE, THLE panels Narrow parts Fitting from top of presser Other presser design Blade holder design Other blade holder design

2 machining possibilities

Fitting from top of presser

Stro

ke

Ribs above blade parting lines

HA

ND

LIN

G

Blades

Compensation blocks

P

Blades

Blade holder270-480W

Holes Ø10H7 for reference

Tie-rod axis

Tie-rod axis

GE24-070R /C


2 Cutting elements (Trimming)

2.1 aterial tables Refer to standard EM24.01.100

2.2 Cast blades

Pour lames inférieures et coupe déchets

Vis

Trous M12 pour manutention et arrachage

Centrage par goupilles

Trous M12 pour manutention et arrachage

VisCentrage par goupilles

Rou

gh re

mov

al (m

axim

um w

eigh

tof

the

blad

e 20

Kg)

Zone treated(see EM24.15.100)

Machining overthickness

H =

60

min

Rib

Afte

r grin

ding

co

unte

rwei

ghts

Stripping possibleFor lower blades and scrap cutters

Centring by 2 pins GT 16 55

Fastening by CHc screws M16-50

2 M12 holes for pulling if required or handling for weight > 15Kg

Fastening device

Centring by pinScrews

M12 holes for handling and pulling

M12 holes for handling and pulling

Screws

Centring by pin

GE24-070R /C


Cast blades (cont’d) In the case of fragile zones or steep slope, include offset grains. The material of these grains varies according to the panel’s thickness To prevent rising of scraps or to evacuate them it is necessary to plan, in the blades, the implantation of separators. They must be implanted in flat scrap shapes.

Locking compoundor Loctite

Clearance possible according to push-rod stroke

Standard separator

See standard EM24.57.100

2 CHc screws M10-40

1 pin GT. 10-40

Offset grain

Blade profile

Sharpening face

GE24-070R /C


2.3 Welded or cast blades for thickness > 1,5 mm Solution with or without offset cover. Tabs and notches Its opening must be requested to facilitate scrap evacuation.

VIEW ALONG: F

Ver

tical

con

stan

t 20

mm

re

com

men

ded

VIEW ALONG: F

Ver

tical

con

stan

t 20

mm

re

com

men

ded

Stripping possible

GE24-070R /C


2.4 Moulded scrap cutter for panel thickness ≤ 1,5 mm

2.5 Scrap cutter for thickness > 1,5 mm

View along: FLower blade

Zone treated ≥ 54 HRC

About 30°

Pen

etra

tion

1-0.

5 m

in

She

arin

g About 10

1 M12 hole for pullingif required

Upper blade2 GT 16-55 pins 2 CHc screwsM16-35 Blade profile see page 7

Zone cleared to facilitate scrap evacuation

1 M12 hole for pulling

About 10

2 GT 10-40 pins2 CHc screws M10-40

GE24-070R /C


2.6 Scrap cutter by breakdown This solution is used for low width scraps, 5 to 8 mm max.

2.7 Implantation instruction for scrap cutter

IN NO EVENT CAN THE PART TO PRODUCE BE CENTRED ON THE SCRAP CUTTERS

This sticker is affixed on drawing No.1 of the INVENTORY. The scrap cutter profile must be below 5/10 in respect of the shape of the part covered on the centrer (Figure 1) The scrap cutters must not be implanted in part zones in counter blank (Figure 2)

Scrap cutters can be embedded in the punch to prevent spangle (skin parts).

5 to 8 max

View along « f »

Lower punch

Upper blade

Scrap

0.5 mm to specify in drawing0.5 mm to specify in drawing

GE24-070R /C


Positioning of scrap cutters.

REMOVE THE SCRAP CUTTERS FACE TO FACE AVOID BACK TO BACK SCRAP CUTTERS

. Scrap cutters must protrude from the theoretical blank by 10 mm min. Two consecutive scrap cutters must be open outwards by 5°. In no event should they form a closed angle, as the scrap remains keyed.

No centring on the part on the scrap cutters

Theoretical blank

GE24-070R /C


If "face to face" layout impossible

Include push-rods in the upper part and build the blank and cylindrical of the scrap cutters as follows:

Open the angle between the two scrap cutters at maximum.

If the scrap does not drop by gravity, fit the tool with tilting jacks. OTHER SOLUTION Scrap cutting in two steps. Use this process in all cases to maintain a sufficient loading and extraction tunnel, as well as a small slope with a drop exceeding 30°. Trimming of parts in 1 step with minimum scrap cutting, then, recutting large scrap. Framed scrap cutters are removed using the two step scrap cutter solution.

Stipping possible

High clearance at right angle

GE24-070R /C


Case of highly balanced parts. Ban protruding seating under scrap cutters.

The upper scrap cutters must not work on the trimming line angles.

10 mm to specify in drawing

Stripped

Che

ck b

y ca

lcul

atin

g th

e cr

oss-

sect

ion

10 mm to specify in drawing

Stripped

Che

ck b

y ca

lcul

atin

g th

e cr

oss-

sect

ion

AA CROSS-SECTION

Trimming scrap cutterScrap recuttingscrap cutter

Scrap end stopScrap 500 max. in diagonal(2nd cutting at next pressstroke)

Scrap cutter

1st scrapramp

1st ramp at 30° Cutting outline sketch

Straight cuttingtilted at 15° Punch

GE24-070R /C


Scraps must not form a U and include two angles of the trimmed part. The movement of the scraps must not meet other trimming lines. Scrap cutter(cont’d) These various scrap cutter layouts are applicable for scrap evacuation. However, consider relative

locations of scrap cutters in high locations Scrap cutters in counter-slope

Not OK OKNot OK OK

Notch Tab

If impossible

Avoid OK

GE24-070R /C


Sloping When the slope available is insufficient between two scrap cutters, exceptionally the latter can be increased by locating its top at 2/3 distance between scrap cutters.

2.8 Floating scrap cutter Necessarily used on toolings " aluminum parts ", it can be, nevertheless; used for the toolings of any other part

Attention : to obtain a push of the working forces in the axis of the RG, the floating t scrap cutter has to be in reach with the lower scrap cutter. Furthermore, when there is a force of lateral work, it is necessarily to implant reactions..

Initial slope

of

f1

f2

a a

f1 f2

section a

View f

DETAILS ON FLOATING SCRAP CUTTER

GE24-070R /C


3 Cutting elements

3.1 Material tables Refer to standard EM24.01.100

3.2 Slotting

3.2.1 The opening is not inside a 250mm-side square The lower frame has a single block punch acting as a die in the part to cut out (see § 3.1) The upper frame holds blades

3.2.2 The opening is not inside a ∅ 48 mm circle, but is contained in a square 250 mm side The lower frame has a single block punch or a blade holder acting as a die in the area to cut

out (see § 3.1) In the upper part, the cutting out punch is single block

Cyl

indr

ical

8 m

m

Blades

Single block punch

Pen

etra

tion

+ sh

earin

g

2 pins

Screws

Cyl

indr

ical

8 m

m

Single block punch

GE24-070R /C


3.2.3 Die

There are several types of dies: (according to Renault standard EM24.53.300). - die with pin - flanged dies - smooth die - flat die They are with or without orientation. Use preferably flanged dies for shape spans. They have a cylinder of 5 to 8 mm If the die is placed in a die holder, apply the implantation shown below. If punching must be performed at least at 15 mm from the trimmed edge, implant a grain used both as trimming blade and punching die.

3.2.4 Flanged punches Use preferably standardised punches defined in Renault standard EM24.53.100. Material X153CrMoV12 * T6 (56-58 HRC) If the punch is very fragile, use high speed steel HS6-5-2C * T6 (58-60 HRC). Reduce the cylindrical part to strict minimum. Dimensions and tolerances according to Renault standard EM24.53.100 Imperative height 80. Profile of punch made j6. The cutting gap is specified on the die. If punching is not contained in a circle ∅ 24: consider a single block punch for a basic shape or an offset pad on a riser for complex shapes. For punches ∅ ≤ 5.2, the working direction must be normal to the panel and for HLE, THLE panels, they will be lined. When lining the presser, the latter must be guided by columns.

Non through pins

Sleeved punch

Punch holder

Presser

Acc

ordi

ng to

pun

chØ

13

or 1

6

Dépouille cylindrique ou conique acceptées.

Accepted cylindrical or conical blank

GE24-070R /C


3.2.5 Housing for punch and die

Use preferably standardised punch holders defined in Renault standard EM24.53.100. For "non aspect" parts, punch holders can be used as die holder. Punch holder riser

Single block with upper frame: ensure stability of the stop with small ribs. Offset Specific punch holder.

Die

Standard punchholder

Plan large base for proper seating

Block

If possible STD punch holder

GE24-070R /C


3.3 Punching Dimension included in diameter 48.

3.3.1 Punching profile and tolerance An execution drawing should be sufficient for production without having to mention dimensions on an existing part or a reference. The execution drawing of a punch must show:

The punch profile Tolerances on punching profile

For non standardised dies and punches, refer to the "POKA-YOKE" drawings, available in Renault guide GE24-017R.

N° E 15 900 1019 die punch detail, N° E 15 900 1020 punch holder detail. Definition of the punch and die according to the type of punching.

PUNCHING

NON STANDARD STANDARD Panel th. / indifferent Panel th. ≤ 1 Panel th. > 1

Punch Die Punch Die Punch Die

POKA-YOKE POKA-YOKE Standard Standard Standard POKA-YOKE

In all non standard punching cases, punch dimensions are specified in the manufacturing sheet, in the folio on the appropriate operation.

Refer to table below for the number of items to include to nomenclature (spare included)

Number of identical

punches or dies

Number of spares

Total to include to nomenclature

1 2 3 2 2 4 3 2 5 4 2 6 5 2 7

n ≥ 6 n/2 3n/2

Clearances: The dimensions of the dies are deducted from the dimensions of the punch,

to which cutting clearances are added.

GE24-070R /C


3.3.2 Shock plate Delivered with punch holder

3.3.3 Penetration – Cutting gaps Punching: Penetrate by 1 to 2 mm beyond the die cylindrical. Trimming: Penetration 2 mm constant + shearing 3 mm. Cutting out: Penetrate by 1 to 2 mm beyond the die cylindrical and allow the scrap to loosen.

TRIMMING GAP: The constant gap measured between punch and die must be 4% panel thickness ± 0.01 mm.

PUNCHING GAP

MATERIAL THICKNESS e (in mm)

GAP BETWEEN PUNCH AND DIE: a

TOTAL GAP a x 2

0.5 0.03 0.06 0.6 to 1 0.05 0.1 1.25 0.08 0.16 1.5 0.1 0.2 2 0.15 0.3 2.5 0.2 0.4 3 0.25 0.5 3.5 0.3 0.6 4 0.4 0.8 5 0.5 1 6 0.6 1.2

Note: this table must be included in the tooling study drawings according to Renault standard EM24.02.030, paragraph 1.8.4.

a a

e

Pen

etra

tion

1 to

2 m

m

Separators

She

arin

g 3

mm

GE24-070R /C


4 Part centring and clamping

4.1 Centring the part The part is centred on its volume, on edges already trimmed or existing punches (Except for reference holes) which must not be used for driving the part. NOTE: any additions of precentring profile templates For parts centred exclusively on shape (Handle individually)

Centring on shape For parts with sufficient curves, centring is performed on the single block punch.

Fixed and mobile centrer If the part’s shape is insufficient to ensure proper centring, fit centrers on the punch outside the location of the scrap -cutters.

Centring upon cutting rework operation Use profile templates on lines trimmed definitely or pilots on punchings.

Flag centring If none of the solutions evoked above is appropriate, centring holes must be created by the OP for stamping.

Cross-section A

Centrers fitted « in flag »

Fixed centrer if blade between blade and centrer

Less

than

5 m

in

Mobile centrer(avoid)

Cross-section B

Centring

GE24-070R /C


4.2 Punch range The punch range for skin parts is ensured over a projected width of 100 mm. In the centre, support the part with a cross, plus strips to prevent collapse.

Support edge lines

Range for suction cupPunch range

Tool

axi

s

Tool axis

GE24-070R /C


4.3 Pressers Presser stroke

Add 10 mm to the stroke defined by scrap cutters to compensate for any spring load. Load on presser (tightening - stripping)

Plan a margin sufficient to cover the additional load resulting from subsequent modification. The choice of the type of pressure means is made according to the number of metal,

polyurethane or gas springs (RG) required. Check the balancing of clamping loads in respect of guiding and work loads.

Presser range for skin part The range width is 45 mm over the periphery and 95 mm beside the scrap cutters. Presser range for non visible part The range width is 30 mm over the periphery and 95 mm beside the scrap cutters.

In all cases, the cover range must protrude by 5 mm the presser range in order to prevent distortion.

For ALU parts, see Renault guide GE24-120R Note: The lower ribs are cleared by 10 mm.

For punchings, do not include an inspection door. For skin parts, the presser is balanced by cones or stands.

(See paragraph 1.1.4)

Fitting without elastic stripper and without inspection door

Punch range

Trimming line

Scrap cutter

Presser range

45 or 30

GE24-070R /C


PRESSER GUIDE - Guide / Plate Operating clearance Principle for very narrow parts

2 machining possibilities

Fitting from top of presser

Rib above bladeparting lines

HAN

DLI

NG

stro

cke

Examples : panel thickness 0.67 mmPlate guide min +0.1

max +0.37Column guiding min +0.1

max +0.57

Gap 0.5Punch/presser

Guiding clearance0.1 between frame/presser

Presser

Blade parting line

Gap ≤ 0.03 (between blades, flat)

Min: +0.1Max: panel th. -0.3

Column guiding

Min: +0.1Max: panel th. -0.1

GE24-070R /C


5 General guidelines for scrap evacuation Evacuation of trimming and punching scrap must be performed without manual intervention

and at each press stroke. This evacuation is performed at the front and back of the press. The minimum slope must be 30°. Avoid elbowing plane gutters. At the exit of the tool, the scrap is recentred in the pit by hoppers (EM24.02.033) The width of the scrap depends on the width of the evacuation flaps (EM24.02.033) Evacuation accessories have a perfectly smooth sliding surface, any welding spots are grinded

and smoothened to ensure no protrusion interferes with scrap evacuation. The lower scrap is evacuated on the natural slopes included in the study. Outline scraps are evacuated, in all possible cases, on natural slopes or ramps in drawn steel

∅ 10 mm. Include protection panels for the guides.

Scrap

Platform

Scrap

Machining if required

Separators

L = curved line length

GE24-070R /C


Evacuation of punching scraps

The scrap must arrive 1 by 1 at slope entrance. No scrap can be jammed in a slot or hole nor be blocked by protrusions. However, jamming can occur if several pieces of scrap get tangled in a bottleneck or if descent speed is insufficient. Therefore: Build an evacuation without strangling (grind the frame if required)

If several pieces of scrap must fall in the slope, avoid having them crossing at 90°.

Panel thickness 3 mm (scrap break)

Size D

XSize X + 2

YESNO

YESNO

90°θ ≥ 90°and differentdrawings

GE24-070R /C


Evacuation of scrap outside the lower frame Outside scrap For trimming scraps of sufficient dimensions and with an appropriate shape, use preferably deflectors in drawn steel ∅ 10. Implantation of ramps in drawn steel ∅ 10

These are laid out according to the configuration of the part during MAP for scrap evacuation.

When the scraps are too small or too complex-shaped or still when the evacuation path is not straight, use fairings or gutters in steel panel S185 * th. 3 mm with smooth surface and without welding. When using gutters, these must be easy to disassemble. They are protected by the tool sole which is extended to this effect close to the edge (even up to the edge) of the press platform, and chamfered. Gutter fasteners must not interfere with scrap evacuation. Use Fhc countersunk hex head screws. The sheets must be adjusted on the foundry.

Opening for scrapsPress platform

Tool and press axis

Tool

and

pre

ss a

xis

Handling zones must not be obstructed by scrap and recentred in respect of the opening outside platform

∅10

.5D

epth

1.6

Welding

∅ 6.5Fastening by chc screw M6X20

Adx panel gussetDepth : 3 to 4 mm

GE24-070R /C


Fhc screw recessed from sliding plane

Platform

Fhc screw recessed from sliding plane

Platform

Press frame

Not ok

OK

Protruding : 10 mm

The gutter joint must not protrude on the scrap path

M8 Countersunk head

If required gutter folding for storage (held by chain + hook)

No pipe or cable on scrap path

GE24-070R /C


To prevent "shelving" problems due to shrinkage of the frames during casting, for imprecise foundries or modifications, apply the following guidelines: In the case of rectangular scrap, include the passage under the foundry wall. BEWARE NOT TO WEAKEN THE TOOL By applying a constant angle, passage P is smaller than scrap X. Increase the passage by implementing two different slopes, slope 1 increases scrap inertia to compensate lack on slope 2. X < P < Q Ramp for evacuation of scraps in the tooling

If scrap evacuation is impossible, include other means of evacuation: conveyor belt, vibrating gutter, jack.

In very difficult cases (e.g. low height, flat scrap) use stainless chequered plate (X6CrNi18-10 T1, Company ALMET) provided the slope is 15°.

P

Q

P

Q

Platform

GE24-070R /C


6 Start up To start up punching:

Use clip-on punch holder sets according to standard EM24.53.100

To start up a cutting out/trimming operation: 2 Solutions:

• Double HOF (Validate this solution with production and backup sites) Beware the risks of interference between the different elements of the tool. This solution is

forbidden (due to impossible operation) for tools with strike function. • Start-up by means of pneumatic jack according to the principle of punch holders

mentioned above.

Punc

h w

ith

stan

dard

flat

Punch return strokeStroke

Jack

Flange punch

View along F (without shock plate)

Orientation pad

GE24-070R /C


Supply of pneumatic jacks

• Press type MP/GP/TGP Implement a pneumatic fitting between the lower and upper frame (helicoil) + the position handle, mention for each position the number of the product part.

4 Chc screws M 6 60

Note: to place at front of press,as low as possible

4 M6 holes

Legris pneumatic valve X234 391 801

Single blade tapered union G1/4X 155 061 104

Note: in the case of simultaneous RR L and lateral fitting, include circuit selectors for each pneumatic movement

Front of pressLower frame

Circuit selector

Connection of pneumatic and

electric-pneumatic plate

Connection of pneumatic and

electric-pneumatic plate

Circuit selector

Cross out inappropriate marks

Plastic tube P 14x2 SRX 215 141 901 For jack | A 63 or 80

Upper frame

Single tapped male unionX153 062 203

Connecting tip RBES male 3/8X 191 132 702

Double nip 3/8X 144 01 101

HC helicol-combi balancer HC 50-10STAUBLI X 217 146 301

Connecting block2X2 Chc screws M8X50

M 431 513 501

Lower frame

Plastic tube P14x2 SRX215 141 901(For connection to air inlet)

Plastic tube P 10x1.5 SRX 215 111 404 For jack | A 40 or 50

Plastic tube P10x1.5 SRX215 111 404 (To use the valve)

Single tapped male unionX153 062 203

2 holes |A9

GE24-070R /C


• New generation TGP press

Press fitted with pneumatic fitting blocks built into the ram (see drawing 454 82 in guide GE24-017R) No helicoil connection. (Beware the backup press) Management of positions is performed by the press program. Plan compatibility with the backup press.

7 Normative references for metallic materials cited in this document

Designation Reference document

270-480W * standard ISO 3755

42 CrMo4 * standard EN 10083-1

T4 pre-treated steel * standard EB01.14.220

FGL 215HB * standard EB01.41.050 FGL 240HB * standard EB01.41.050

FGS 600-3A * standard EB01.45.030

G 42Mn5 * standard EB01.31.212

G 50CrMo4 * standard EB01.33.211

HS6-5-2C* standard ISO 4957

S185 * standard EN 10025-2

X 153CrMoV12 * standard ISO 4957

FITTING WITH TOOL REMOVED

PRESS RAM

TOOLING

FITTING WITH TOOL CLOSED

4 Chc screws M12x80

4 washers DE 12

Foundry clearance

Semi rigid tube PN10 | 18x2Inserted and glued

PRESS RAM

GE24-070R /C


8 List of documents cited NOTE : For non dated documents, the latest version is applicable. ISO 3755 : Tempered steel. Section 1: Technical delivery conditions for special steel. ISO 4957 : Tool steel EN 10025-2 : Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-

alloy structural steels EN 10083-1 : Tempered steel. Section 1: Technical delivery conditions for special steel. EB01.14.220 : Bars in T4 pre-treated steel. Technical specifications. EB01.31.212 : Cast steel. G42Mn5. Technical specifications. EB01.33.211 : Moulded steel G50CrMo4. Technical specifications. EB01.41.050 : Lamellar graphite cast iron. FGL 175HB. FGL 215HB. FGL 240HB. Technical

specifications EB01.45.030 : Spheroid graphite cast iron FGS 400-18A and FGS 600-3A. Technical

specifications. EM24.01.100 : Presentation of the basic offer and free offer in press tooling design EM24.02.030 : Press tooling. Technical drawings. General presentation principles. EM24.02.033 : Press tooling. Evacuation of scrap and collection of "wire blanks". EM24.15.100 : Reloading press tooling. EM24.53.100 : Press tooling. Punch holder. Punches. Strippers. Shapes and dimensions. EM24.53.300 : Press tooling. Punching dies for round and shaped holes. GE24-017R : Press tooling. Miscellaneous master. GE24-040R : Press tooling. General design guidelines. GE24-120R : Design rules for press tooling for aluminium stamping.