01 Ih - Stamping Fundamentals
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11/08/2010
Oscar Olvera
1
11/08/2010
} } } } } }
}
Automotive Transport Military Railway Aircraft Household appliances Navy
2
11/08/2010
}
}
}
Is a manufacturing process that cuts and forms sheet metal into a desired shape or profile, without chip removal. The stamping press provides the power to transform the material The stamping dies give the desired shape or profile.
5
Part
Die
Process
6
3
11/08/2010
}
}
Is a cold-forming operation, which means that no heat is introduced into the die or the sheet material intentionally. The stamping die's cutting and forming sections typically are made from special types of hardenable steel called tool steel or wear-resistant materials.
7
} } } } }
High productivity Fast tool depreciation Part repeatability Part low cost Easy to automate
4
11/08/2010
}
}
Sheet metal is the engineering material most used for the manufacturing of products in all industry fields. It is the ideal material, due to the following characteristics: ? ? ? ?
}
}
Easy manufacturing Forming capacity Low cost High productivity
Sheet metal parts produced by stamping can replace parts produced by sinterig, welding and casting. With the following benefits. ? ? ? ?
Lower weight (ligther) Higher mechanical strength Lower cost Higher productivity (more parts/hr). notable
5
11/08/2010
}
Large dimensions parts can be produced from sheet metal by stamping allowing great plastic deformation, without material removal.
6
11/08/2010
Punching Shearing
Bending
Blanking
Drawing
Profiling
}
Cutting
? Punching ? Shearing ? Blanking ? Others (Notching, Trimming, Slitting)
}
Forming
? Bending ? Drawing ? Others (Flanging, Spinning, Profiling)
14
7
11/08/2010
}
The sheet metal, positioned between two dies, is severed as the die cutting edges move past each other.
15
8
11/08/2010
9
11/08/2010
}
}
Forming operations deform sheet material by exposing it to tension, compression, or both. Most part defects, such as splits and wrinkles, occur in forming operations.
}
26
10
11/08/2010
}
Forming operation in which the metal is plastically deformed along a straight axis.
Punch
Sheet
Die
28
}
Metal forming process in which the part shape is formed by controlling sheet metal flow into a cavity and over a punch.
30
11
11/08/2010
32
12
11/08/2010
}
} }
Is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a desired shape or profile as the sheet metal is pressed, or stamped, between two mating components. A die gets the force it needs from a press. Dies range in size from those used for making microelectronics components, to those used for making entire autobody sides.
Production Vol., speed
Material
(Type, consumption)
¿Die type?
Equipment, $$$, etc.
Part Size, Shape and Tol.
36
13
11/08/2010
Single-station
Dies Transfers
}
}
} }
}
}
Progressive
Each station that forms or cuts the sheet metal represents a single operation die. Tools that typically are hand or robotically loaded. Low-production parts Production of parts that are too big and bulky to handle with automation. Large line dies are placed in individual presses Small line dies can be placed within a single press.
14
11/08/2010
}
Advantages:
Cutting dies
40
}
Disadvantages:
Drawing die
? Lower production speeds ? Require expensive robots or human labor. ? Several presses to manufacture a single part.
42
15
11/08/2010
}
}
}
}
Line dies that are timed together and spaced an even distance apart in a single press. The distance between each die is referred to as the pitch. Piece parts are transferred by special traveling rails mounted within the press boundaries. Transfer systems can perform numerous motions. The two basic types are 2-D (two-axis) and 3-D (three-axis).
44
45
16
11/08/2010
1
2
3
4
5
6
7
8
9
10
11
1. 2.
Parts
Embutir. Reducir embut. 3. Reducir embut. 4. Perfilar. 5. Calibrar. 6. Perforar. 7. Recortar 8. Punzonar. 9. Agujerear. 10. Bordonar. 11. Cortar.
46
} } } } }
Is one of the most common, fastest methods available for producing piece parts. Parts are tied together by a portion of the original strip or coil, called a strip carrier. Can produce as many as 1,500 parts per minute. All necessary stations are mounted on a single common die set. Stations are timed and sequenced so that the piece part can be fed ahead a constant given distance called the progression or pitch.
17
11/08/2010
No blank-holder Part insufficient flatness
50
No blank-holder Part insufficient flatness
51
18
11/08/2010
Blank-holder Better part flatness All types of operations
52
All types of operations
53
19
11/08/2010
}
}
}
}
}
Die plates are steel or aluminum plates that correspond to the size of the die. They serve as the foundation for mounting the working die components. Must be machined so that they are parallel and flat within a critical tolerance. The machining methods are milling and grinding. The upper and lower die shoes assembled together with guide pins create the die set
20
11/08/2010
} } }
}
Align the upper and lower die shoes precisely. Precision-ground components, often manufactured within 0.0001in (0.002 mm) There are two basic types of guide pins and bushings: ? Friction pins ? Ball bearing-style pins.
21
11/08/2010
22
11/08/2010
Stripping force
Stripping pad Sheet Die
Cutting
Drawing
Bending
23
11/08/2010
}
Springs supply the force needed to hold, strip, or form metal.
UPPER PLATE (BASE SUPERIOR): Materials: Casting GG25 Steels: F111 – F112
PUNCHES: Materials: Steels: F521-F522 1.2379 – 1.3343+T y R + PVD Widia (Metal duro) TEMPERED – ANNEALED, 60 -64 Rc GUIDE PINS (ELEMENTOS GUÍA) Materials: Steels: F151F152 Cementado T. y R. Bronze + Graphite
DIES (MATRICES): Materials: Steels : F521 – F522 HT 1.2379 - 1.3343+T y R. + PVD Widia (Metal duro) TEMPERED – ANNEALED 60 -64 Rc
TOOL HOLDER (PORTA PUNZONES): Materialss: Steels: F111 - F112 F114 TOOL GUIDE (GUÍA PUNZONES): Materiales: Ac. F111 - F112 – F114 BLANK HOLDER PAD (PISADOR): Materiales: Ac.: F112 – F114 HT F522 HT (CEMENTADO)
TOOL HOLDER (PORTA MATRICES): Materiales: Ac. F111 - F112 – F114
LOWER PLATE (BASE INFERIOR): Materials: Casting GG25 Steels: F111 – F112
79
24
Oscar Olvera
1
11/08/2010
} } } } } }
}
Automotive Transport Military Railway Aircraft Household appliances Navy
2
11/08/2010
}
}
}
Is a manufacturing process that cuts and forms sheet metal into a desired shape or profile, without chip removal. The stamping press provides the power to transform the material The stamping dies give the desired shape or profile.
5
Part
Die
Process
6
3
11/08/2010
}
}
Is a cold-forming operation, which means that no heat is introduced into the die or the sheet material intentionally. The stamping die's cutting and forming sections typically are made from special types of hardenable steel called tool steel or wear-resistant materials.
7
} } } } }
High productivity Fast tool depreciation Part repeatability Part low cost Easy to automate
4
11/08/2010
}
}
Sheet metal is the engineering material most used for the manufacturing of products in all industry fields. It is the ideal material, due to the following characteristics: ? ? ? ?
}
}
Easy manufacturing Forming capacity Low cost High productivity
Sheet metal parts produced by stamping can replace parts produced by sinterig, welding and casting. With the following benefits. ? ? ? ?
Lower weight (ligther) Higher mechanical strength Lower cost Higher productivity (more parts/hr). notable
5
11/08/2010
}
Large dimensions parts can be produced from sheet metal by stamping allowing great plastic deformation, without material removal.
6
11/08/2010
Punching Shearing
Bending
Blanking
Drawing
Profiling
}
Cutting
? Punching ? Shearing ? Blanking ? Others (Notching, Trimming, Slitting)
}
Forming
? Bending ? Drawing ? Others (Flanging, Spinning, Profiling)
14
7
11/08/2010
}
The sheet metal, positioned between two dies, is severed as the die cutting edges move past each other.
15
8
11/08/2010
9
11/08/2010
}
}
Forming operations deform sheet material by exposing it to tension, compression, or both. Most part defects, such as splits and wrinkles, occur in forming operations.
}
26
10
11/08/2010
}
Forming operation in which the metal is plastically deformed along a straight axis.
Punch
Sheet
Die
28
}
Metal forming process in which the part shape is formed by controlling sheet metal flow into a cavity and over a punch.
30
11
11/08/2010
32
12
11/08/2010
}
} }
Is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a desired shape or profile as the sheet metal is pressed, or stamped, between two mating components. A die gets the force it needs from a press. Dies range in size from those used for making microelectronics components, to those used for making entire autobody sides.
Production Vol., speed
Material
(Type, consumption)
¿Die type?
Equipment, $$$, etc.
Part Size, Shape and Tol.
36
13
11/08/2010
Single-station
Dies Transfers
}
}
} }
}
}
Progressive
Each station that forms or cuts the sheet metal represents a single operation die. Tools that typically are hand or robotically loaded. Low-production parts Production of parts that are too big and bulky to handle with automation. Large line dies are placed in individual presses Small line dies can be placed within a single press.
14
11/08/2010
}
Advantages:
Cutting dies
40
}
Disadvantages:
Drawing die
? Lower production speeds ? Require expensive robots or human labor. ? Several presses to manufacture a single part.
42
15
11/08/2010
}
}
}
}
Line dies that are timed together and spaced an even distance apart in a single press. The distance between each die is referred to as the pitch. Piece parts are transferred by special traveling rails mounted within the press boundaries. Transfer systems can perform numerous motions. The two basic types are 2-D (two-axis) and 3-D (three-axis).
44
45
16
11/08/2010
1
2
3
4
5
6
7
8
9
10
11
1. 2.
Parts
Embutir. Reducir embut. 3. Reducir embut. 4. Perfilar. 5. Calibrar. 6. Perforar. 7. Recortar 8. Punzonar. 9. Agujerear. 10. Bordonar. 11. Cortar.
46
} } } } }
Is one of the most common, fastest methods available for producing piece parts. Parts are tied together by a portion of the original strip or coil, called a strip carrier. Can produce as many as 1,500 parts per minute. All necessary stations are mounted on a single common die set. Stations are timed and sequenced so that the piece part can be fed ahead a constant given distance called the progression or pitch.
17
11/08/2010
No blank-holder Part insufficient flatness
50
No blank-holder Part insufficient flatness
51
18
11/08/2010
Blank-holder Better part flatness All types of operations
52
All types of operations
53
19
11/08/2010
}
}
}
}
}
Die plates are steel or aluminum plates that correspond to the size of the die. They serve as the foundation for mounting the working die components. Must be machined so that they are parallel and flat within a critical tolerance. The machining methods are milling and grinding. The upper and lower die shoes assembled together with guide pins create the die set
20
11/08/2010
} } }
}
Align the upper and lower die shoes precisely. Precision-ground components, often manufactured within 0.0001in (0.002 mm) There are two basic types of guide pins and bushings: ? Friction pins ? Ball bearing-style pins.
21
11/08/2010
22
11/08/2010
Stripping force
Stripping pad Sheet Die
Cutting
Drawing
Bending
23
11/08/2010
}
Springs supply the force needed to hold, strip, or form metal.
UPPER PLATE (BASE SUPERIOR): Materials: Casting GG25 Steels: F111 – F112
PUNCHES: Materials: Steels: F521-F522 1.2379 – 1.3343+T y R + PVD Widia (Metal duro) TEMPERED – ANNEALED, 60 -64 Rc GUIDE PINS (ELEMENTOS GUÍA) Materials: Steels: F151F152 Cementado T. y R. Bronze + Graphite
DIES (MATRICES): Materials: Steels : F521 – F522 HT 1.2379 - 1.3343+T y R. + PVD Widia (Metal duro) TEMPERED – ANNEALED 60 -64 Rc
TOOL HOLDER (PORTA PUNZONES): Materialss: Steels: F111 - F112 F114 TOOL GUIDE (GUÍA PUNZONES): Materiales: Ac. F111 - F112 – F114 BLANK HOLDER PAD (PISADOR): Materiales: Ac.: F112 – F114 HT F522 HT (CEMENTADO)
TOOL HOLDER (PORTA MATRICES): Materiales: Ac. F111 - F112 – F114
LOWER PLATE (BASE INFERIOR): Materials: Casting GG25 Steels: F111 – F112
79
24
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