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Types of Dies

The document discusses dies and their components and types. It defines a die as a specialized tool used in manufacturing to cut or shape material using a press. It then discusses the main components of a basic die set, including the die block, die holder, punch plate, stripper plate, backup plate, and punch. It also categorizes different types of dies based on the press operation (cutting vs forming dies) and method of operation (simple, compound, combination, progressive, transfer, multiple dies).

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0% found this document useful (0 votes)
677 views17 pages

Types of Dies

The document discusses dies and their components and types. It defines a die as a specialized tool used in manufacturing to cut or shape material using a press. It then discusses the main components of a basic die set, including the die block, die holder, punch plate, stripper plate, backup plate, and punch. It also categorizes different types of dies based on the press operation (cutting vs forming dies) and method of operation (simple, compound, combination, progressive, transfer, multiple dies).

Uploaded by

Jayditya Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Definition of Die:

A die is a specialized tool used in manufacturing industries to cut or


shape the material mostly using a Press.
Lesson 21

Introduction to dies

Objective:

At the end of this student will be able to understand the

i) definition of dies
ii) Types of dies
iii) Applications o f dies

A die is a specialized tool used in manufacturing industries to cut or shape


material mostly using a press. Like molds, dies are generally customized to the
item they are used to create. Products made with dies range from simple paper
clips to complex pieces used in advanced technology.

In this article, we are going to study regarding types of dies and punches. A die
could be a specialized tool utilized in manufacturing industries to chop or form
the material largely using a Press.

It is the fundamental heart of the many manufacturing operations starting from


drawing to bending. It may be outlined as a feminine a part of a whole toolset
used for manufacturing work in the press.

Similar to molds dies also are customized in step with the item they’re created
for. Dies are used for producing an easy product like paper clips to complicated
items used in different advanced technology.

The types of dies and punches are according to the type of press operation and
according to the method of operation.

(A) According to the type of press operation:

According to this criterion, the dies may be classified as cutting dies and
forming dies.

 Cutting Dies: 
Cutting dies used primarily to cut metals by their cutting or shearing action.
Common cutting dies to incorporate blanking dies, shaving dies, trimming dies.

Shaving dies: These dies are those dies that take away tiny amounts of material
from the edges of the part to enhance the part accuracy.

 Trimming Dies:
These are those dies that help take away any unwanted or excess irregular
amounts from the part, so employed in the last operations largely before the
final product obtained.

 Blanking Dies:

These die manufacture typically a flat piece of material by cutting any desired
form in an exceedingly specific single operation. This finished part addressed as
blank and therefore the name-blanking dies. These dies usually cut the outer
contour of the part, therefore used for performing on components requiring no
internal options.

 Forming Dies: 

Forming dies are those dies that change the looks of the blank without removing
any stock. Common forming dies are drawing dies, compression dies, coining
dies.
Source: I ndia Mart

Drawing dies may be used for drawing several materials as well as wire, tubes,
pipes, rods, and bars. These drawing dies have a hole through their center. From
one facet of this hole, wire or rod of steel, copper or alternative alloys enters
and additionally lubricated and reduced in size.

These dies divided into numerous sections as well as entrance angle, approach
angle, bearing and back relief. the entrance angle guides the wire into the die,
whereas the approach angle brings the wire to the central die-nib, initiating the
wire-reduction.

Coining dies are those dies that used to kind fully different options on either
facet of the blank, with these options present on the die. The coining die and
punch flow the metal by compression the blank among a confined space.
(B) Types Of Dies & Punches: According to the method of operation:

According to this criterion, the dies could also be classified as a single operation
or easy dies, compound dies, combination dies, progressive dies, transfer dies
and multiple dies.

 Simple Dies:

Simple dies also known as single operation dies as a single operation performed
for each stroke of the die press. These generally used for very simple operations
listed undercutting or forming dies.

 Compound Dies:

Compound dies are those dies whereby over one operation takes place on a
single station. These dies largely used for cutting operations and therefore
addressed as cutting tools.
These dies to permit synchronous cutting of internal also as external part
options during a single stroke in some cases. Compound dies are continuously a
lot of accurate and economical as compared to a single operation or simple dies.

Ex: Washer.

Advantage:
One component produced for stroke. Hence, the production rate is high.

Limitations:

 Both of the ways of reducing the punch force cannot use. Therefore,
the force needed for the compound die is higher.
 The design and production of punch and die combination is tough if
the no. of operations is larger than three.

 Combination Dies:

A combination dies used for operations involving over one operation on a work
station. the most important difference between compound dies and combination
dies is that in these dies a cutting operation combined with a bending or drawing
operation, and therefore the name “combination dies”.

Ex:

 Blanking combined with Deep drawing


 Punching combined with Deep drawing
 Blanking combined with bending etc.

 Progressive Dies:

Progressive dies additionally referred to as follow on dies have a series of


operations. In this, more than one cutting operation is performed in one stroke
however at completely different stages and punched out sheet is progressing
from one stage to a different stage for finishing the punching operations so
Blanking is the last operation.

o This also, one element created for stroke. thus the assembly
rate is that the same as that of a compound die.
o Also, either by providing the shear or by staggering the
punches methodology, the force needed can reduce.
o Also, as a result of the operation performed at completely
different stages, the design, and production of punch and die
combination is less complicated with whatever could also be
the no.of operations.
o But the only drawback is the leveling of forces on the punch
head is tough.

 Transfer dies:

Transfer dies have the same operating development as progressive dies. Here
additionally the stroke is fed increasingly from one station to a different.
However, here the already cut blanks are fed automatically to alternative
stations. Thus, transfer dies to supply completely different stations for
operations. Here, the work increasingly changed at every station till the final
operation ejected the finished part.
Limitation:
When compared to progressive die, the blank needs to set in each stage however
any style of strap-strip layout is feasible to implement.

 Multiple Dies:

Multiple dies additionally called gang dies ate those dies that manufacture 2 or a
lot of items at every stroke of the press. In these dies, some simple die ganged
along to provide 2 or a lot of components via every stroke of the press.

Ex: 
To produce 10 washers per stroke,10 compound dies or 10 progressive dies are
kept in parallel called as multiple dies.

This is a close clarification of various types of dies and punches utilized in sheet
metal operations.

Applications of Dies:

Like molds, dies are generally customized to the item they are used to create.
Products made with dies range from simple paper clips to complex pieces used
in advanced technology.
Lesson 22 Die block design for simple die

Objective:

At the end of this student will be able to understand the

i) Lay-out conventional position of the die


ii) Components of the die set
iii) Die block design for simple die
Die and punch assembly as easy of sheet metal forming

Die and Punch

A die and punch assembly is a metal working process. That is convert raw
material (sheet metal) into components. And also die is a tool to manufacturing
of parts and component from sheet metal.The Compound die, combination die
and progressive types of dies are produced in mass production quickly.

The die placed on a press. When the press moves upward direction and die is
opened. As the press is moved down and die is closed. The sheet metal move
through die which is open and fed into the die a precise amount with each press.
The die is a closed together, the die performed work on the metal and finish
parts are ejected from the die. The die sheet metal operation such a ways like as
punching, bending and coining.

Die key is made of tool steel to withstand high shock load, sharp cutting of edge
and resist the abrasive forces involved.
For punching and blanking operation which the simple cutting dies are used.

Main components of die as

 Die holder
 Die block
 Punch plate
 Stripper plate
 Back up plate
 Punch
 Guide pin
 Stroke

Die block:

The die block contain with die cavity. The shape of cavity is replica of require shape of
component. That is female part of die block.

Die holder:

The die block is mounted on die holder and supported with bloster plate. Both die holder
and block is mounted on press bed.

Punch plate:

Punch plate hold the punch and attached to top ram of press.

Punch:

It is male part of die assembly and also that fastened to ram press through punching
plate. Which punch matches with die shape. This punches the metal strip again the die
and necessary operation. Small clearance available between die and punch.
Stripper plate:

During the forming and cutting operation when the stripper plate is used to strip the
sheet metal.

Guide pin:

The guide pin is used to align the upper and lower half and also used for die changed
from one operation complete to start another operation.

Back up plate:

The intensity of pressure does not reach the punch holder which is placed on die. It is
also called as pressure plate. The pressure plates distribute the pressure over wider
area.

Stroke:

It is distance between ram moments from upper position to lower position.

i. Die Block Design:


Overall dimensions of the die block are determined by the minimum die wall thickness
required for strength and by the space needed for mounting screws and dowels and for
mounting the stripper plate. For its design, generally ‘rule of thumb’ method given below
gives quite satisfactory results.

1) For die block of tool steel, a thickness of 20 mm minimum is used for a blanking
perimeter of 75 mm or less, and 25 mm thickness is used for perimeters 75 to 250 mm
and 30 mm for larger perimeters.

(2) There should be a minimum of 30 mm margin around the opening in the die block.

(3) The die opening should be straight for a maximum of 12.5 mm and then it should
angle out at 0.25° to 1.5°

(4) In order to secure the die to the die plate or die shoe, the following rules
provide sound construction:
i) On die blocks upto 175 mm square, use two 10 mm alien screws and two 10 mm
dowel pins.

(ii) On sections up to 250 mm square use 3 alien screws and two dowel pins.

(iii) For heavier stock and still bigger blocks, use screws and pins of 12.5 mm dia.
Counter bore the die block to accommodate alien heads at least 3 mm deeper than
length of heads to compensate for die sharpening.

ii. Punch Design:


The punch length should always be

where d = diameter of punched hole,

fc = Unit compressive stress on punch


E = modulus of elasticity

t = thickness of sheet.

Methods of Punch Support:


There are a number of methods to mount punches to meet various production
requirements.

In the case of blanking punches, the punches are comparatively bigger in size and are,
therefore, generally provided with flanges which are mounted into the punch holder
directly with the help of dowel pins and alien screws without the use of backup plate.

The other methods for supporting the punch are:


(i) Headless punches are held in the hole of the ram or punch plate with the help of a set
screw which bears on flat portion machined on the bed.

(ii) Peen-head punches are made from drill rod of the size of punch and are left
shoulder-less until assembly, when the punch is pressed tightly into a counter-sunk
reamed hole in the punch plate and then riveted over.

(iii) Quilled punches are used for piercing very small holes in heavy stock. The punch
having a uniform point and shank diameter is enclosed in a quill which is of hardened
tool steel with an internal diameter concentric to its outside diameter.
(iv) In the case of large punches, they are provided with heads or shoulders which fit into
the recess in the punch plate and are dowelled into the position.

(v) Very thin rectangular punches are mounted with the help of low melting point alloys
also.

iii. Stock Stops:


In the simplest form, it may be a pin or small block against which an edge of the
previously blanked opening is pushed after each stroke of the press. With sufficient
clearance in the stock channel, the stock is momentarily lifted by its clinging to the
punch, and is thus released from the stop.

Generally the starting stop is mounted between the die shoe and die block to initial
position of the incoming stock. During downward stoke the stop is pressed down. After
every die operation is completed, the compression springs return the stop in its position.

In the case of automatic stops, they register the strip at the final die station automatically
and the operation has only to keep the strip pushed against the stop in its travel through
the die.

iv. Pilots:
When establishing the sequence of operations for progressive dies, piercing operations
are done first. Advantage is taken of these holes for piloting so that the blanks formed
are concentric to the pierced hole. The piloting is achieved with the help of pilots secured
under the blanking punches. These are generally made of suitable tool-steel, heat-
treated properly for maximum toughness and hardness. The various ways of fitting pilots
are by press fitting, threading or by socket set screws.

v. Stripper:
Its function is to strip the work piece from a cutting or non-cutting punch or die. It also
helps in holding down the strip. It is usually of the same width and length as the die
block. In the simple die employing fixed type stripper, it is fastened to the die block with
the same screws and dowels that fasten the die block and screw heads are counter-
bored in the stripper. The stripper thickness should be sufficient to withstand the force-
required to strip the stock from the punch.

Other than fixed type of strippers are spring operated or pressure pad strippers. In a
simple blanking die the pressure pad contacts the strip ahead of the punch and holds the
material flat just before the blank is cut.
The spring operated strippers have the advantages that the spring pad pressure prior to
piercing operation removes all the waved irregularities in thin sheets and also the work
performed is in full view of the operator and not covered by the stripper plate except at
the time of blanking.

vi. Knock-Out:
It is the means of ejecting on the upstroke the cut blank which might, otherwise, be
retained, in the die block by friction. A knock-out assembly consists of a plate, a push
rod and a retaining clear. This arrangement of ejecting the parts gives positive action, is
quite cheap and pressure requirements are low.

Generally the plate is a loose fit with the die opening contour and is capable of moving
as the blank is cut. A heavy push rod which slides in a hole in the shank of the die set is
attached to the plate by rivets. This rod projects above the shank, and a collar retains
and limits the stroke of the knockout assembly. Near the upper limit of the ram stroke, a
knockout bar in the press contacts the push rod and ejects the blank-out.

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