Copyright 2008 Society of Manufacturing Engineers. FUNDAMENTALS OF TOOL DESIGN Progressive Die Design

Transcription

1 FUNDAMENTALS OF TOOL DESIGN Progressive Die Design SCENE 1. PD06A, tape FTD29, 09:14:22:00-09:14:48:00 pan, progressive die operation PROGRESSIVE DIES PERFORM A SERIES OF FUNDAMENTAL CUTTING AND FORMING OPERATIONS TYPICALLY ON CONTINUOUS SHEET METAL STRIP, OR COIL, STOCK. THESE OPERATIONS ARE PERFORMED SIMULTANEOUSLY AT TWO OR MORE STATIONS DURING EACH PRESS STROKE AS THE STRIP PROGRESSES THROUGH THE DIE TO PRODUCE A PART. SCENE 2. PD07A, tape FTD35, 15:36:20:00-15:36:45:00 zoom in, pilot hole during progressive stamping STRIPS ARE FED THROUGH THE PROGRESSIVE DIE USING AUTOMATIC FEEDS AND THEN ARE POSITIONED AT EACH STATION BY PILOT HOLES OR SLOTS. SCENE 3. PD08A, tape FTD35, 15:20:25:00-15:21:00:00 scrap cut from progressive strip UNWANTED PORTIONS OF THE STRIP ARE CUT OUT AS IT ADVANCES THROUGH THE DIE STATIONS. ONE OR MORE TABS, RIBBONS OR BRIDGES CONNECT THE PARTIALLY COMPLETED PART TO THE STRIP AS IT S CARRIED THROUGH THE DIE STATIONS. SCENE 4. PD09A, tape FTD28, 08:52:03:00-08:52:23:00 wide, progressive die COMBINING STRIP TRANSFER, CUTTING AND FORMING IN A SINGLE PROGRESSIVE DIE,

2 GREATLY REDUCES THE TIME AND COST OF PERFORMING THESE OPERATIONS SEPARATELY. SCENE 5. PD10A, tape FTD28, 08:31:24:00-08:32:02:00 zoom out, part ejected from die PD10B, tape 271, 01:23:02:00-01:23:26:00 manual stamping operation PROGRESSIVE DIES ARE ESPECIALLY COST- EFFECTIVE IF PRODUCTION RATES ARE HIGH, IN WHICH CASE DIE COST CAN BE APPRECIABLY LESS THAN THE TOTAL COST OF INDIVIDUAL OPERATIONS AND RELATED MATERIALS HANDLING. SCENE 6. PD11A, tape FTD29, 09:16:37:00-09:17:02:00 pan, progressive die operation PD11B, tape FTD30, 10:04:27:00-10:04:47:00 pan, progressive die operation THE DECISION TO PRODUCE A PART USING PROGRESSIVE TOOLING IS USUALLY DETERMINED BY PRODUCTION VOLUME AND PART COMPLEXITY. ALTHOUGH THEY ARE NOT THE ONLY FACTORS, PRODUCTION VOLUMES AND PART COMPLEXITY ARE INSTRUMENTAL IN THE DESIGN AND CONSTRUCTION OF THE PROGRESSIVE TOOLING. SCENE 7. PD12A, tape FTD31, 08:18:06:00-08:18:20:00 pan, cad design of progressive die PD12B, tape FTD30, 10:06:10:00-10:06:36:00 zoom in, progressive die operation PD12C, CGS: Part Orientation Part Transport Stock Positioning Number of Progressions COMMONLY, DESIGN TRADE-OFFS ARE REQUIRED IN STRIP DEVELOPMENT TO ADDRESS FACTORS CONTRIBUTING TO PART QUALITY, TOOL MAINTENANCE, TOOL LIFE, AND ULTIMATELY TOOL COST. SOME OF THE PRIMARY FACTORS INCLUDE: PART ORIENTATION, PART TRANSPORT,

3 STOCK POSITIONING, AND THE NUMBER OF PROGRESSIONS. --- TOUCH BLACK --- SCENE 8. PD13A, CGS: Part Orientation PD13B, tape FTD31, 08:24:28:00-08:24:49:00 pan, cad design of progressive die PD13C, tape FTD35, 15:24:40:00-15:25:15:00 pan, part running through progressive die STRIP DEVELOPMENT BEGINS BY DETERMINING THE ORIENTATION OF THE PART AS IT WILL BE RUN THROUGH A PROGRESSIVE DIE. PART ORIENTATION IS GOVERNED BY THE PART FEATURES, CRITICAL TOLERANCES, AND THE LOCATION OF DATUM POINTS AND SURFACES. SCENE 9. continue previous shot PD14A, ANI: strip with grain, part stamped in it, part rotated SINCE PROGRESSIVE DIES ARE STRIP FED, OPTIMIZING MATERIAL USAGE MAY REQUIRE ROTATING THE PART IN THE STRIP. THIS CAN CHANGE THE GRAIN DIRECTION OF THE STEEL UNFAVORABLY, AFFECTING PART STRENGTH WITHIN PART FORMS. SCENE 10. PD15A, tape FTD35, 15:19:41:00-15:20:06:00 zoom out, progressive die operation IN MANY CASES ROTATING THE PART TO ENSURE MORE CONSISTENT FORMS DOES NOT PROVIDE THE MOST EFFICIENT MATERIAL USE, BUT IT MAY BE NECESSARY TO ADDRESS PART TOLERANCE CONCERNS. SCENE 11. PD16A, tape FTD28, 08:21:57:00-08:22:24:00 zoom out, use of cams during progressive die operation THE USE OF CAM FORMING OR PIERCING OPERATIONS ALSO INFLUENCE PART ORIENTATION. CAM FORMING TOOLS CAN TAKE

4 UP A SIGNIFICANT AMOUNT OF ROOM, SO PARTS ARE TYPICALLY ORIENTED TO ALLOW CAM FUNCTIONS PERPENDICULAR TO THE COIL. THIS PROVIDES THE EASIEST AND MOST ACCESSIBLE CONDITION FOR THE CAMS. SCENE 12. PD17A, tape FTD36, 16:09:21:00-16:09:46:00 zoom out, progressive die with cams OFTEN, A COMPROMISE BETWEEN ROTATING A PART TO OPTIMIZE MATERIAL USE AND POSITIONING THE CAMS SAFELY OUTSIDE THE COIL IS THE RESULT. SCENE 13. PD18A, tape FTD35, 15:45:15:00-15:45:35:00 zoom out, part lifted during progression THE AMOUNT OF LIFT NEEDED TO CARRY THE STRIP THROUGH THE DIE ALSO AFFECTS PART ORIENTATION. LIFT CAN SOMETIMES BE REDUCED SIGNIFICANTLY OR ELIMINATED BY PROPERLY ORIENTING A PART. SCENE 14. PD19A, tape FTD28, 08:55:59:00-08:56:18:00 zoom in, part being formed upward IF ALL THE FORMS IN A PART ARE IN THE SAME DIRECTION, LIFT CAN BE ELIMINATED BY FORMING UPWARD. THOUGH THIS USUALLY ADDS COST TO THE PROGRESSIVE DIE. SCENE 15. PD20A, tape FTD35, 15:42:16:00-15:42:35:00 pan, part being formed in both directions WHEN A PART HAS FORMS IN BOTH DIRECTIONS, COMPROMISES MUST BE MADE REGARDING EXCESSIVE LIFT, MATERIAL USE, AND TOOL COMPLEXITY AND COST. SCENE 16. continue previous shot

5 PD21A, tape FTD28, 08:27:15:00-08:27:34:00 progressive die operation, heavy narrow material PD21B, tape 799, 18:15:10-18:15:28 zoom in, slitting of thick coil PROGRESSIVE FEED MUST ALSO BE CONSIDERED WHEN DETERMINING PART ORIENTATION. FEED SHOULD BE AS SHORT AS POSSIBLE, ESPECIALLY FOR HEAVIER MATERIALS AND NARROW COILS. THIS IS DUE TO THE CAMBER THAT CAN BE CAUSED BY THE COIL SLITTING PROCESS, WHICH CAN MAKE STOCK FEED DIFFICULT. SCENE 17. PD22A, tape FTD30, 10:04:59:00-10:05:21:00 pan, short progressive feed A SHORTER PROGRESSIVE FEED RUNS FASTER AND HAS LESS CHANCE OF CAUSING MISFEEDS. WHEN A SUBSTANTIAL DIFFERENCE BETWEEN PART LENGTH AND WIDTH EXISTS, IT IS USUALLY MORE COST-EFFECTIVE TO BUILD THE TOOLING WITH THE SHORTER LEAD. --- TOUCH BLACK --- SCENE 18. PD23A, CGS: Part Transport PD23B, tape FTD28, 08:12:30:00-08:13:05:00 zoom out, progressive die operation BECAUSE PROGRESSIVE STAMPINGS ARE LINKED IN THE STRIP, A CARRYING DEVICE BETWEEN PARTS IS NECESSARY. HOW PARTS ARE ATTACHED TO THE STRIP AFFECTS HOW WELL THE DIE FEEDS, THE ABILITY TO LIFT THE STRIP FOR FEEDING, AND THE PRODUCTION OF CONSISTENT-QUALITY PARTS. SCENE 19. PD24A, tape FTD28, 08:34:36:00-08:34:55:00 pan, progressive die operation, parts held with material between them PD24B, tape FTD35, 15:10:24:00-15:10:35:00 zoom out, parts carried on one side of THERE ARE THREE BASIC METHODS FOR CARRYING A PART, THOUGH VARIATIONS OF

6 part PD24C, tape FTD27, 07:13:05:00-07:13:18:00 progressive die operation, parts carried on both sides of part EACH ARE COMMONLY USED: PARTS THAT ARE CARRIED BY THE MATERIAL BETWEEN THEM..., PARTS CARRIED BY ONE SIDE OF THE STRIP..., AND PARTS CARRIED BY BOTH SIDES OF THE STRIP. SCENE 20. PD25A, tape FTD28, 08:57:20:00-08:57:45:00 zoom out, progressive die operation PARTS THAT ARE CARRIED BY THE MATERIAL BETWEEN THEM IS THE MOST STRAIGHTFORWARD CARRIER METHOD. EXCESS MATERIAL EQUAL TO ONE OR TWO MATERIAL THICKNESSES PER SIDE ARE REQUIRED FOR TRIMMING. THIS METHOD TYPICALLY PRODUCES MINIMAL SCRAP, OR NO SCRAP IF THE TWO ADJACENT PARTS HAVE SYMMETRICAL EDGES. SCENE 21. PD26A, tape FTD35, 15:08:55:00-15:09:22:00 progressive die operation, parts carried on one side of part PARTS CARRIED BY ONE SIDE OF THE STRIP ARE SUITABLE FOR PARTS REQUIRING FORMING ON AS MANY AS THREE SIDES. THIS STYLE CARRIER ALSO IMPROVES ACCESSIBILITY IF CAM-PIERCING OR CAM-FORMING IS REQUIRED. SCENE 22. PD27A, tape FTD29, 09:11:38:00-09:12:14:00 pan, progressive die operation, parts carried on both sides of part PARTS CARRIED BY BOTH SIDES OF THE STRIP, OFTEN CALLED LADDER-STYLE CARRIERS, ALLOW A STRIP TO FEED EASILY, AND ARE OFTEN USED IN HIGH FEED-RATE

7 APPLICATIONS. LADDER-STYLE CARRIERS WORK WELL WITH COMPLEX PARTS AND WITH THOSE REQUIRING A LARGE AMOUNT OF LIFT. SCENE 23. PD28A, tape FTD29, 09:13:10:00-09:13:25:00 progressive die operation, parts carried on both sides of part LADDER-STYLE CARRIERS USE MORE MATERIAL PER PART. OFTEN, HOWEVER, A PART CANNOT BE STAMPED PROGRESSIVELY USING ANY OTHER CARRIER METHOD. SCENE 24. PD29A, tape FTD35, 15:15:30:00-15:15:51:00 tilt, part with drawn form PD29B, CGS: Stretch Webs Ribbon Strips Bridges PD29C, tape FTD27, 07:03:46:00-07:04:07:00 zoom out, bridge distorted by formed part PROGRESSIVE BLANKS FOR DRAWING OR FORMING OPERATIONS SHOULD BE DEVELOPED TO PROVIDE FREE METAL MOVEMENT WITHOUT AFFECTING PART POSITIONING IN EACH SUBSEQUENT DIE STATION. THIS IS ACHIEVED THROUGH SEVERAL MEANS, SUCH AS STRETCH WEBS, RIBBON STRIPS AND BRIDGES. THESE CARRIERS PROVIDE SUSPENSION AND ALLOW FOR LITTLE OR NO DISTORTION OF STRIP EDGES DURING DRAWING AND FORMING. SCENE 25. PD30A, tape FTD35, 15:16:10:00-15:16:29:00 zoom out, strip guided with carrier rail CARRIER RAILS OR PINS ARE COMMONLY USED TO SUPPORT AND GUIDE THE STRIP AS IT IS MOVED FROM DIE STATION TO DIE STATION. --- TOUCH BLACK --- SCENE 26. PD31A, CGS: Stock Positioning PD31B, tape FTD29, 09:31:12:00-09:31:36:00 zoom out, progressive die operation, parts held with material between them PD31C, tape FTD26, 06:31:05:00-06:31:30:00 OF PRIME IMPORTANCE IN STRIP DEVELOPMENT IS THE STOCK POSITIONING IN EACH

8 pan, pilots in die PROGRESSIVE DIE STATION. THE STOCK MUST BE POSITIONED ACCURATELY IN EACH STATION SO THAT THE OPERATION CAN BE DONE IN THE PROPER LOCATION ON THE STRIP. A COMMONLY USED METHOD OF STOCK POSITIONING INCORPORATES PILOTS IN THE PROGRESSIVE DIE. SCENE 27. continue previous shot PD32A, CGS: Direct Indirect THERE ARE TWO METHODS OF PILOTING IN DIES: DIRECT, AND INDIRECT. SCENE 28. PD33A, CGS: Direct Piloting PD33B, tape FTD35, 15:06:16:00-15:06:30:00 tilt, holes in part used as pilot DIRECT PILOTING INVOLVES PILOTING IN HOLES OR SLOTS PUNCHED IN THE PART AT A PREVIOUS STATION. SCENE 29. PD34A, CGS: Indirect Piloting PD34B, tape FTD35, 15:39:00:00-15:39:28:00 zoom out, indirect pilots INDIRECT PILOTING INVOLVES PIERCING HOLES IN THE CARRIER STRIP AND LOCATING THEM WITH PILOTS IN LATER OPERATIONS. SCENE 30. continue previous shot PD35A, tape FTD29, 09:12:30:00-09:12:56:00 zoom out, indirect piloting holes LOCATING INDIRECT PILOTS IN THE SCRAP REGION HAS TWO ADVANTAGES: THEY ARE NOT READILY AFFECTED BY PART CHANGES AND THEIR SIZE AND LOCATION ARE NOT AS LIMITED AS DIRECT PILOTS. SCENE 31. PD36A, tape FTD35, 15:37:36:00-15:38:00:00

9 zoom out, indirect piloting holes ON THE OTHER HAND, THERE ARE TWO DISADVANTAGES: MATERIAL WIDTH AND LEAD MAY INCREASE TO ACCOMMODATE PILOT HOLES, AND CARRIER STRIPS MAY DISTORT ON SOME FORMING OPERATIONS, ELONGATING PILOT HOLES OUT OF TOLERANCE. SCENE 32. PD37A, ANI: part with close tolerance holes PD37B, ANI: part with holes too close to part edges IF PART HOLES ARE CLOSE TOLERANCE, DIRECT PILOTS CAN AFFECT HOLE SIZE IN THEIR EFFORT TO MOVE THE STRIP TO PROPER LOCATION. IF DIRECT PILOT HOLES ARE TOO CLOSE TO PART EDGES, WEAK OUTER PORTIONS ARE APT TO DISTORT ON PILOT CONTACT. SCENE 33. PD38A, zoom in, part with holes close to the part edges AS TO HOW CLOSE A HOLE MAY BE TO PART EDGES, TWICE STOCK THICKNESS IS GENERALLY PREFERRED, ALTHOUGH HALF THAT AMOUNT IS ACCEPTABLE WITH PROPER STOCK CONTROL. SCENE 34. PD39A, ANI: part with holes in weak area indirect piloting of part IF HOLES ARE IN A WEAK PART OF THE INSIDE PART AREA, THE PART MAY BUCKLE BEFORE DIRECT PILOTS CAN POSITION THE STOCK. THEREFORE, INDIRECT PILOTING IN THE CARRIER STRIP IS ADVISABLE. SCENE 35. PD40A, tape FTD35, 15:08:22:00-15:08:33:00 zoom in, progressive parts with direct piloting holes MOREOVER, FOR ACCURATE PART LOCATION,

10 PD40B, ANI: part with holes too close together PILOTS SHOULD BE AS FAR APART AS POSSIBLE. IF PART HOLES ARE TOO CLOSE TOGETHER, INDIRECT PILOTING IN THE CARRIER STRIP SHOULD BE USED. SCENE 36. PD41A, tape FTD28, 08:25:01:00-08:25:39:00 pan, progressive die operation PD41B, CGS: Dwell Pitch Press Stroke Operational Speed SEVERAL OTHER PARAMETERS AFFECT STOCK POSITIONING, INCLUDING: DWELL, PITCH, PRESS STROKE, AND OPERATIONAL SPEED. SCENE 37. PD42A, CGS: Dwell PD42B, tape FTD29, 09:27:15:00-09:27:48:00 zoom in, progressive die operation DWELL IS THE UPWARD PORTION OF THE PRESS STROKE NECESSARY TO COMPLETELY CLEAR DIE AND PUNCH ELEMENTS FROM THE PART SO THAT THE PART MAY BE ADVANCED. DWELL HAS TO BE A MINIMUM OF TWICE THE HEIGHT OF THE PART. THE DWELL PERIOD CANNOT BE USED TO MOVE THE STRIP INTO THE NEXT DIE STATION. SCENE 38. PD43A, CGS: Pitch PD43B, ANI: top view, progressive die showing pitch PD43C, ANI: top view, progressive die showing successive pitches PITCH, WHICH IS ALSO CALLED THE PROGRESSION OR ADVANCE IS THE DISTANCE BETWEEN THE CENTERLINES OF TWO ADJACENT DIE STATIONS. PITCH DIMENSION MUST BE CONSTANT BETWEEN ALL SUCCESSIVE STATIONS THROUGHOUT THE DIE.

11 SCENE 39. PD44A, tape FTD28, 08:16:06:00-08:16:29:00 short pitch progressive die operation PD44B, tape FTD28, 08:26:08:00-08:26:33:00 zoom out, progressive die operation with thick stock ADDITIONALLY, PITCH MUST BE THE SHORTEST PRACTICAL DISTANCE BETWEEN DIE STATIONS WITHOUT SACRIFICING DIE STRENGTH. THE SHORTER THE PITCH, THE LESS SCRAP MATERIAL THAT S CREATED. PITCH MUST BE INCREASED IN PROPORTION TO ANY INCREASES IN MATERIAL THICKNESS. SCENE 40. PD45A, CGS: Press Stroke PD45B, tape FTD29, 09:31:46:00-09:32:08:00 wide, press stroke of stamping press during progressive die operation THE PROGRESSIVE DIE PRESS STROKE MUST BE LONGER THAN WHAT IS ACTUALLY REQUIRED TO FORM A PART. THE EXCESS PORTION OF THE STROKE IS NECESSARY TO PROVIDE TIME FOR STRIP POSITIONING IN SUBSEQUENT DIE STATIONS. SCENE 41. PD46A, CGS: Operational Speed PD46B, tape 290, 02:03:52:00-02:04:05:00 wide, progressive die operation OPERATIONAL SPEED OF THE PRESS CANNOT BE FASTER THAN THE DRAWING SPEED OF THE METAL BEING FORMED. --- TOUCH BLACK --- SCENE 42. PD47A, CGS: Number of Progressions PD47B, tape FTD26, 06:49:51:00-06:50:05:00 zoom out, progressive die tooling ONCE A BASIC DESIGN IS DETERMINED, THE EXACT NUMBER OF DIE STATIONS CAN BE EVALUATED. SCENE 43. PD48A, tape FTD28, 08:37:38:00-08:38:03:00 zoom in, progressive die operation PD48B, tape FTD25, 06:01:51:00-06:02:06:00 zoom out, progressive die tooling stamping ALTHOUGH INDIVIDUAL OPERATIONS IN A

12 prototype PROGRESSIVE DIE CAN BE SIMPLE, WHEN COMBINED IN SEVERAL STATIONS, STRIP DESIGN CAN BE QUITE COMPLEX. THE SEQUENCE OF OPERATIONS MUST BE CAREFULLY DEVELOPED. AS THE COMPLEXITY OF THE PROGRESSIVE TOOL DESIGN INCREASES, SEVERAL FACTORS SHOULD BE CONSIDERED. SCENE 44. PD49A, tape FTD35, 15:31:40:00-15:32:00:00 zoom out, pilot holes punched at first station PILOT HOLES OR SLOTS SHOULD BE PUNCHED IN THE FIRST STATION. OTHER HOLES ALSO CAN BE PUNCHED HERE PROVIDED THEY WILL NOT BE ADVERSELY AFFECTED BY SUBSEQUENT NONCUTTING OPERATIONS. SCENE 45. PD50A, tape FTD28, 08:10:04:00-08:10:26:00 pan, insinkerator grinder being pierced PIERCED REGIONS SHOULD BE DISTRIBUTED OVER SEVERAL STATIONS IF THEY ARE CLOSE TOGETHER OR NEAR THE EDGE OF THE DIE OPENING. SCENE 46. PD51A, tape FTD35, 15:21:53:00-15:22:23:00 zoom out, material blanked from coil over progression CONSIDER THE SHAPE OF BLANKED REGIONS IN THE STRIP FOR DIVISION INTO SIMPLE SHAPES. THIS IS SO PUNCHES OF SIMPLE CONTOUR CAN PARTIALLY BLANK A REGION AT ONE STATION AND THE REMAINING REGIONS AT LATER STATIONS. THIS MAY PERMIT THE USE OF COMMERCIALLY AVAILABLE STANDARD PUNCHES AND SAVE TOOLING COSTS.

13 SCENE 47. PD52A, tape FTD26, 06:47:31:00-06:47:44:00 zoom out, punch with shedder pin PROGRESSIVE DIE PUNCHES SHOULD HAVE SHEDDER PINS OR OIL-SEALED BREAKER PINS TO AID IN SLUG DISPOSAL. SCENE 48. PD53A, tape FTD36, 16:07:22:00-16:07:43:00 zoom out, idle station USE EMPTY, OR IDLE, STATIONS TO SPACE OUT DIE ELEMENTS AND OPERATIONS. THIS AVOIDS CROWDING PUNCHES AND DIE BLOCKS, ENABLING UNIFORM WORKLOAD DISTRIBUTION THROUGHOUT DIE LENGTH AND STRENGTHENING OF DIE ELEMENTS. SCENE 49. PD54A, tape FTD36, 16:05:20:00-16:05:42:00 pan, progressive die operation IDLE STATIONS SIMPLIFY DIE CONSTRUCTION, ADD ACCESS FOR DIE MAINTENANCE, AND PROVIDE SPACE FOR ANY ADDITIONAL OPERATIONS BROUGHT ON BY PART DESIGN ALTERATIONS. SCENE 50. PD55A, tape FTD29, 09:18:39:00-09:18:59:00 zoom out, forming in progressive die PD55B, tape FTD28, 08:42:31:00-08:42:48:00 forming downward in progressive die PD55C, tape FTD28, 09:00:18:00-09:00:36:00 zoom out, forming upward in progressive die PLAN FORMING OPERATIONS IN AN UPWARD OR DOWNWARD DIRECTION AND CHOOSE THE ONE THAT ENSURES THE BEST DIE DESIGN AND STRIP MOVEMENT. TYPICALLY, PROGRESSIVE DIES THAT FORM DOWNWARD ARE MORE COST EFFECTIVE TO PRODUCE, BUT CAN BE PROBLEMATIC. DIES THAT FORM UPWARD ARE MORE VERSATILE, YET GENERALLY MORE COSTLY TO BUILD.

14 SCENE 51. PD56A, tape FTD36, 16:03:29:00-16:03:41:00 zoom out, guideposts PD56B, tape FTD35, 15:23:57:00-15:24:15:00 alternate shot, zoom out, guideposts PRECISION, ANTI-FRICTION GUIDEPOSTS AND BUSHINGS SHOULD BE USED TO MAINTAIN ACCURACY BETWEEN UPPER AND LOWER DIE HALVES. SCENE 52. PD57A, tape FTD28, 08:56:52:00-08:57:03:00 zoom out, progressive die operation BALANCE THE POSITION OF CUTTING AND FORMING OPERATIONS FOR UNIFORM LOADING ON THE PRESS SLIDE. SCENE 53. PD58A, tape FTD36, 16:02:29:00-16:02:56:00 pan, progressive die operation A HIGH CUTTING LOAD AT ONE DIE END AND A COINING LOAD ON THE OTHER CAN DEFLECT THE PRESS RAM ON DIE CLOSING EVEN THOUGH THE LOADS ARE EQUAL. THIS IS BECAUSE THE OPERATIONS DO NOT OCCUR SIMULTANEOUSLY. SCENE 54. PD59A, tape FTD28, 08:33:13:00-08:33:35:00 pan, progressive die operation IF THE WORKLOAD HAS BEEN PROPERLY DISTRIBUTED THROUGHOUT DIE LENGTH, NO DEFLECTION SHOULD OCCUR. IF REQUIRED PRESS FORCE IS CONCENTRATED IN ONE STATION OR DIE REGION, OPERATIONS SHOULD BE SHIFTED FOR BALANCE. SCENE 55. PD60A, tape 272, 02:14:22:00-02:14:44:00 zoom in, two parts per stroke operation PD60B, tape 272, 02:16:55:00-02:17:19:00 two parts per stroke operation CHECK STRIP LAYOUT TO MINIMIZE SCRAP; USE A MULTIPLE LAYOUT, SUCH AS A TWO- PER-STROKE, FOUR-PER-STROKE, OR RIGHT- AND LEFT-HANDED PART DESIGN IF FEASIBLE.

15 SCENE 56. PD61A, tape 791, 09:05:52:00-09:06:15:00 scrap being ejected DESIGN THE STRIP FOR PART AND SCRAP EJECTION WITHOUT INTERFERENCE. SCENE 57. PD62A, tape FTD35, 15:50:16:00-15:50:30:00 zoom out, part ejected from die DROPPING THE PART THROUGH THE DIE IS THE MOST DESIRABLE METHOD OF PART EJECTION BUT IS NOT ALWAYS POSSIBLE. SCENE 58. PD63A, tape 785, 02:21:40:00-02:21:55:00 parts falling from die end PD63B, tape FTD28, 08:17:29:00-08:18:02:00 parts ejected from die end WHEN A DIE IS DESIGNED SO THAT PARTS ARE CUT AND ALLOWED TO FALL OFF THE DIE END, SEVERAL FACTORS MUST BE CONSIDERED. FOR INSTANCE, PART WEIGHT MUST BE SUFFICIENTLY OFF-BALANCE TO ASSIST PART EJECTION. A SHEDDER PIN OR AIR ASSIST CAN BE ADDED TO ENSURE PART REMOVAL. SCENE 59. PD64A, tape FTD35, 15:47:24:00-15:47:42:00 part with flanges formed down PD64B, tape FTD27, 07:19:29:00-07:19:44:00 zoom in, part with flanges formed up being ejected IF PART TABS OR FLANGES ARE FORMED DOWN, CLEARANCES MUST BE ADDED. IF THAT S NOT POSSIBLE, IT MAY BE NECESSARY TO REDESIGN THE DIE TO ENSURE THAT THE PART EJECTS. IF FLANGES ARE FORMED UP, STRIP ADVANCEMENT MAY BE ENOUGH TO EJECT THE PART FROM THE DIE. SCENE 60. PD65A, tape FTD27, 07:19:03:00-07:19:15:00 zoom in, scrap cutting at end of progressive die operation CUTTING THE SCRAP INTO SMALL PIECES SIMPLIFIES MATERIAL HANDLING AND PROMOTES GREATER SCRAP-SALE RETURN.

16 --- TOUCH BLACK ---