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What is a Die?

Elad Ashkenazi
Die Design
Content:

Environment
What is Die ?
Die technology
Environment

Sheet metal parts characteristic:

Mechanical strength

No sharp edges

Mostly - Uniform Wall thickness

Thickness up to ~6 mm (0.7 to 3.4)


Environment
Terminology

Die = press tool

Punch = male

Die = Matrix = Female

Blank = sheet format


Environment
Press
The Dies Driven force

Common propulsion

Mechanical - simple force curve , cheap


Hydraulic - controlled force & motion curve.
Pneumatic - controlled force curve , expansive , use for small parts
Environment
Press
Features
Clamping Force
Stroke
Size
Open \ Close wall
Cycle rate
Strip in focus
Blank

Pilot
Carrier Intermediary
Shapes

Punch

Progression
Metal forming Machine

Press parameters :

Force – clamp force available.


Length – sheet metal size available.
RATE – number of cycles per minutes.
Stroke size – opening motion size
Metal forming Machine

Press - general structure


Static side
Sliding unit
Motor
Environment
Die Product
Ability to Unfold

No sharp corners
Sharp corners >> Inner radius < sheet metal thickness
Environment
Die Product
Environment
Single axis part
At least one face keep its position along the operation

Multi axis part


Operations required part rotation
What is a Die ?
Die - transform a flat strip of metal into a part.

Coil Product
Die
What is Die ?
Detailed information is available on the provider net
Go to:
Provider net >> Die Design
Theoretical course document
Theoretical course presentations (2)
Demo Movies
Demo part
Die Technology
Die production – A combination of basic operations:

Material removing
Blanking (cutting)
Punching (cutting)

Plastic Forming
Bending
Forming
Stamping
Die Technology

Cutting Die
Die Technology
Cutting Die
Die Technology

Cutting Die tools


Punch geometry – reduce punch force

Flat bevel Double bevel Concave


inner shapes Big areas
External areas
Die Technology
Die Technology
Die Technology
Cutting Die example
Compound Die – Multi operations in one stroke
Die Technology

Stamping Die
Die Technology

Stamping Die
Die Technology

Forming Double effect Die


Blank edges are fix
Die Technology
Forming Single action Die
Die Technology
main Dies are:

Progressive Dies

Line Dies

Transfer Dies

Compound Die
Die Technology
Progressive Die
Combines a number of forming and trimming functions
performed continuously metal strip.
Die technology
Progressive Die
Great Production rate ~100 per min and Up
Steel is fed into the die, typically from a coil.
Each die cycles perform multi operations along the strip
Material is progress automatically along the die.
Completed parts is cut and ejected each cycle
Die technology
Progressive Die
9 Great volume production
9 They often can run unattended.
9 Require only one press.

expensive
Require precision alignment and setup procedures.
Require a coil feeder system.
Require an open-ended press.
Damage to a single station requires removing the entire die set.
Much heavier than single-station line dies.
Die technology
Progressive Die
Die technology
Line Dies
Die 1 Die 2 Die 3
Die technology
Line Dies
Each Operation required press

9 Big parts
9 Run together in a common press
9 Cheap Die , Cheap Maintaining
9 Allow Multi axis rotation - complex geometries.
9 Smaller tools ,lighter die
Low production volume

Several presses required to manufacture a single part.


Require expensive robots or human resource.
Die technology
Transfer Dies
Why ? The volume is high enough
Big and complex parts
How its work
A piece is trimmed from the strip as the first Operation
Metal piece is transferred independently along the Die
Die technology
Transfer Dies
Mechanical feeders
Clamps transfer
Balance with/without pilots
Die technology
Transfer Dies
Die technology
Transfer Dies
Die technology
Transfer Dies
Die technology
Transfer Dies
9 Large parts
9 Stamped parts can be turned over or
rotated. (Multi axes parts)
9 Material savings - No strip

Expensive.
Require sophisticated equipment
Thank You