Tool and Die Design

PTB 31304
Raja Aziz Raja Maarof
Institute of Product Design and Manufacturing
UniKL IPROM

References
Suchy
Suchy,, I., Handbook of die design;
design; McGraw Hill 2nd Ed.,

2006.
Boljanovic,, V., Sheet Metal Forming Processes and Die
Boljanovic
Design,, Alkem
Design
Alkem,, 2004.
Alvarez, W., Roll Form Tool Design: Fundamentals,
Fundamentals,
Alkem,, 2006.
Alkem
Szumera,, J., The Metal Stamping Process,
Szumera
Process, Alkem
Alkem,, 2003.
Spitler,, David (tech. reviewer),
Spitler
reviewer), Fundamentals of tool
design,, Society of Mechanical Engineers, 2003.
design
Paquin,, J. R., Die design fundamentals,
Paquin
fundamentals, Industrial Press,
1986

Credit hours
Four (4) credit hours (2K, 2P)
Lecture (room nr 2038)
Two credit hours
Two hours per week
Every Tuesday, 0830 1030 hrs

Practical (room nr 0016)

Two credit hours
Four hours per week
Wednesday, 0830 1230 hrs

Main topics
Sheet metal die design principles
Press machine specifications
Die plates and insert materials
Detail single die design
Detail design for progressive dies, incorporating
piercing, blanking, bending, forming, embossing,
etc.
Deep Drawing Dies
Casting Dies
Basic operation and design knowledge of
specialized dies
Large and Super Large Stamping Dies

Sheetmetal Die Making flow

Sheet metal product
& Product design
Ordered volume
Volume per batch

Forming machine
Forming machine
selection
Sheet metal die
design

Assessment
Coursework, 60%
At least two assignments: total 40%
At least one on sketching (at 10%)
At least one on Die design using CAD system
(SolidWorks / Catia / Inventor) (at 30%)

At least one test (mid semester): 20%

Approx 30% on theory
Approx 70% on practical using CAD system

Final exam, 40%

Approx 30% on theory
Approx 70% on practical using CAD system

Product design
Flat Blank design

Sheetmetal Die
Design

Strip layout design

Die design

Machining
Assembly
Trial and debugging
(trouble shooting)

Die commissioning

Sheet metal product design

Dimensioning tolerances
Positioning tolerances
Burr direction
Tensile strength (
( or Rm) (supplier)
Material content (supplier)
Thickness
Surface pressure...
Burr:

Flat blank / blank sheet design

Def: Unfolded representation of sheetmetal
product design.
It incorporated the forming processes, eg
eg..
Bending, deep drawing, embossing, lancing, etc.

Cutting clearance
Normally 2 to 5% of strip thickness per side
Die clearance: total clearance (both sides)
Less than 1% per side: to use fine blanking
technology
26 July 2011

Bending factor / processes

Drawing factor / processes

Blank design with bending

Bending factor (v) parameters
Bending radius (r)
Sheetmetal thickness (t or s)

L = a + b + c + - n.v

L = flat blank length

a, b, c = flange length (outer side)
n = number of bendings
v = bending factor

Bending operation: minimum

allowable internal radius (r)

Bending operation: determining

Bending Factor (v) value

Bending angle: other shapes

= 0 to 90

= >90 to 165

Verhaeltnis r:s =
Ratio of
radius:thickness

L=a+bv
v = Equivalent Value
k = Correction Factor
S = Material Thickness

Springback by bending
r1 = kR . (r2 + 0.5.s) 0.5.s

r1 = bending radius on tooling

r2 = bending radius on product
kR = springback factor
s = sheet thickness

1 = 2 / kR
1 = bending angle on tooling
2 = bending angle on product / workpiece

Springback by bending

Deep drawing (Tiefziehen

(Tiefziehen))
Deep drawing process and components:

Flat blank sheetmetal

Drawing punch
Drawing insert
Drawing thrust plate

Flat blank calculation

Refer to die catalogue #2
To be discussed in later

Piercing punch stroke

Punch stroke = x + t + y
x=
t=
y=
x
t
y

Punch & Die dimensions

Dpunch

Piercing / punching
Dpunch = hole dimension on product

Blanking
Ddie = blank dimension on product

Ddie

Cutting & Die clearances

Cutting clearance (Shneidspalt
(Shneidspalt),
), U
Per side
U = Ddie - Dpunch
2

Die clearance, 2U

Both sides

Punch (Schneidstempel
(Schneidstempel))
Die (Schneidplatten
(Schneidplatten))
Hole (Lochen
(Lochen))
Blanking (Ausscheiden
(Ausscheiden))

Draft (Free) angle (Freiwinkel)

Cutting angle on Die

Cutting Clearance

(Schneidspalt
Schneidspalt))
Material (Werkstoff
(Werkstoff))
Sheet thickness
(Blechdicke
Blechdicke))
Mit Freiwinkel (with
Flat cutting surface
cutting angle)
Ohne Freiwinkel
(Flate cutting
surface)

Cutting Clearance (U)

Based on:
1. Strip thickness
2. Cutting angle on Die
3. Strip Tensile Strength

14 Feb 12

Strip layout design

Production volume (yearly, monthly)
Type

Single
Compound
Transfer
Progressive (normally Production Vol > 10k /
month)

Burr direction

Strip layout design (2)

Strip flow
Scrap flow
Product flow
Force calculation

Cutting
Stripping
Spring
Bending
Drawing
Force centre point

Cutting force (F
(Fcut)
Tensile strength (
( or Rm) [N/mm2]
Shear Stress (t
(t) = 0.7 to 0.9
Fcut = t [N/mm2] x Acut [mm2]
Fcut = t [N/mm2] x Lcut [mm] x tcut [mm]
Where:
Acut = Cutting cross sectional area
Lcut = Cutting length
tcut = Material thickness

Stripping force
Function:
To strip punches from strip layout

The smaller the cutting clearance, the higher the

stripping force required
Also it depends on strip material and thickness
Fstrip = 0.2 to 0.5 (Stripping Factor, SFac) of cutting
force
SOP for piercing or blanking process
Thrust plate touches and holds strip layout
Then piercing or blanking punch cuts through the strip
layout

Thus, at opening position, punch must be

securely positioned inside the thrust plate

Spring
Types
Elastomer / urethane (normally for stripper
spring)
Coil (round & rectangular cross sectional
type)
Leaf
21 feb 2012

Strip layout design (3)

Pitch puncher / Notching
punch
Function: To ensure strip layout
moves forward at a fixed
distance
No autoauto-feeder machine
U profile; material overcut to
avoid obstruction of strip flow
Based on material thickness

Pitch / strip stopper

Function: to ensure strip layout
stops at the desired position
Fixed on guide fence or die
plate (more precise)
Web width

Web design
Minimum web width is required:
To have a stable strip layout
During forward motion
Avoid sagging
To have sufficient thrust force to hold the strip
Insufficient thrust, the strip will be pulled by the
punch, hence damaging the strip

Bridge / Web width (W

(Wweb)

Based on material thickness

Minimum width

To reduce scrap. Optimise material utilization, MatlUtil

(flat blank area / pitch area)

Optimum width

To have sufficient thrust force to hold the strip.

Insufficient thrust, the strip will be pulled by the
punch, hence damaging the strip
To avoid incomplete blank / punch operation
To avoid deformation on web, hence strip pitch
distance will be distorted
To minimise strip overhang

Streifenbreite
= Strip width

a = Web
width at
external
profile
b = Web
width
between
profiles

Web design

Strip layout design (4)

Bullet Casing, Mini Stapler
One
One--side carrier (bridge / web)
Consider also:
Burr direction
Strip flow (on die or with springspring-activated guide lifter)
Strip over hang condition

Strip layout design (5)

Hinge, Door Bracket
Centre carrier
Take note on three (3) idle stations

Strip layout design (6)

Cap
Two
Two--side carrier

Mon 31 Jan 2011

Strip layout design (7)

Opening and closed conditions
Punches and dies
Displacement (closed to open positions)

Punch and blank processes

From top preferred
Scrap downwards

Strip level position during forward direction

On die plate preferred. No over hang. No guide lifter.
Bend down on product parallel to flow (slot on die
plate)
At a distance above die plate (with strip lifters)
For product with bends.
For drawing process

Strip layout design (8)

Force calculation
Cutting (pierce, blank, etc.), bending, drawing
Spring
Stripping
Drawing
Return (bending, levelling)
Strip carrier

Stripper spring design

Gap

Stripper spring calculation

FTotalCut=?
FStrip =?
Punch travel distance (x + t + y)
Spring load, Fmax and Maximum deflection
fmax per spring?
Nr of spring?
Fstrip
strip/spring
/spring

Piercing punch stroke

Punch stroke = x + t + y
x = Distance inside trust plate
t = Strip thickness
y = Punch penetration distance from strip bottom

x
t
y

Citation & References

In text: Based on 90 bending formula, L =

a + b + c + -nv (Heinzler et al., 1997),
the flat length is thus xx mm. (p. 260).
In text: Heinzler et al. (1997) proposes the
90 bending formula, L = a + b + c + -nv
(p. 260).
In references: Heiznler
Heiznler,, M., Kilgus
Kilgus,, R.,
Nher,, F., Paetzold
Nher
Paetzold,, H., Rher
Rher,, W.,
Schilling, K. (1997). Tabellenbuch Metall
Metall..
Leinfelden--Echterdingen
Leinfelden
Echterdingen,, Germany:
Europa--Lehrmittel
Europa
Lehrmittel..

Die design
Standard plates
Top, pressure, punch holder, stripper, thrust
Bottom, die, guide fence

German
design

Die design

Japanese
design

Die design (Japanese typical

design)
Paper stapler, spring puncher
Note: stoppers on top & bottom dies are crucial
to avoid over travel of bending and drawing
punches

Die design (German typical design)

Paper Puncher: Base

Die design
Datum (normally die top position)
Closed position

Piercing / blanking punches

Bending punches
Drawing punches
Spring maximum load condition

0
Die
plate

Die design
Opening position
Spring prepre-load condition. Better life span
Spring selection
Elastomer / urethane spring
Higher force (approx. 20 times higher than coil spring:
150kN)
Lower compressible length (approx. 20%)

Coil spring
Higher compressible length (up to 50%)
Max. load approx. 7kN

Gas spring
Linear load increase (300N to 180kN)
Drawing and deep drawing process

Disc spring

Die design Spring selection

Lpre
pre--Comp, PrePre-load length: 2mm or 5% 10%
of spring length. Higher length for higher
compression
Lstroke, Punch stroke = X + T + Y
LDeflTotal compressed length (Deflection)
Consider punches (pierce, bend, draw, etc.)
movement

Load to strip the strip layout

Spring load at prepre-load length + piercing
punch travel up to thrust plate bottom level =
F strip

Die design Spring selection

Assume material: St 7070-2, 3mm thick, total

cutting length at 300mm

Tensile strength, or Rm for St 7070-2 = 690
- 830 N/mm2.
assume average, ave = (690 + 830)/ 2 =
760 N/mm2
Shear stress, t = 0.7 to 0.9 . Assume
average, tave = 0.8 x 760 N/mm2 = 600
N/mm2
F shear or cut = ? N
F strip = ? N

Die design Spring selection

F shear or cut = t x Area cut = t x Lcut x thick = 600
N/mm2 x 300mm x 3mm = 540,000N = 54,000kgf
=54T
F strip = 20% - 50% of F cut . Assume Fstrip = 35% of
54T = 19T
E.g. PrePre-load distance = 2mm (Lpt
(Lpt),
), pierce punch
distance to thrust bottom level distance is 3 (x) and
working stroke is 9mm (t + y)
Total spring compressed length = Lpt+x+t+y

Die design Coil spring selection

(Stripper Spring)
Compressed length, f = LPre
Pre--Comp + LStroke
LPre
Pre--Comp = PrePre-compressed length
fmax (Spring Tech Spec) > f

Compressed length, fmax = 2+3+3+6 =

14mm
Consider to use 20 springs
Thus, F strip/spring 19T/20= 0.95T =
9,500N
Select coil spring SB x dia50x70L
9,807N at 14mm compressed

Die design Elastomer spring

selection
Or 4 springs
Thus, F strip/spring 19T/4= 4.75T =
47,500N
Find spring fmax at 14mm, nearest Fmax
at 30,100N for elastomer spring
246.5.090.040
Nr of springs is 190,000N / 30,100N = 6
springs

Die design Strip lifter spring

Strip weight = x Volume
Number of springs
Weight per spring to hold strip
Spring selection
Compressed Length f = Lpc + Lstroke
Lpc = PrePre-compressed length
Lc = Ldefl = Lpc + Lstroke

fmax (Spring Tech spec) > f

Die design
Punches safety level
Opening and closed positions
Piercing / blanking punches
Bending punches
Drawing punches
Punch stroke
Die total stroke

Die type determination

Die life

Small life volume (<50k): Single die

High life volume: Progressive die
E/E: product life of 200k to 300k in two years
Automotive: product life of 500k to 2mil in five to
seven years

Case study
Die life of 500k in six years
Monthly volume required: 500k / 6yrs / 12mths =
approx. 6,945 monthly

Production data
Eight hours per shift
22 days per month

Production planning calculation

Production allocation (Volume per batch)

Press machine 80 SPM (eg

(eg AMADA TPTP-45
EX)
Press machine cycle time = 1/80 min x 60
sec/min = 0.75 sec
Daily time: 1day x 8hrs per day x 60 min/hr =
480 min / day
Volume / day = 480 min/day x 80 strokes/min
= 38,400 strokes / day.
For 6,945 volume per month requirement
Time allocation to produce the part: 6,945/38,400
x 8 hours / day = approx. 1.5 hours

Mon 7 Feb 2011

Production planning calculation:

Alternative
Machine cycle time: 0.75 sec
For 6,945 volume, time to produce = 6,945
x 0.75 sec = 5,209 sec
Or 5,209 sec / 3600 sec/hr = approx 1.5
hours

Production planning calculation

Production allocation (Volume per batch)

Press machine cycle time: 60 to 100 spm. Take average,

80 spm
Take average to cater down time & maintenance
Cycle time or time per stroke or time per piece
Cycle time = 1/80 spm or 0.0125 min/stroke or 0.75sec
(60sec/80spm)
Daily volume: 8hrs per day x 3,600sec per hr / 0.75sec
per stroke = 38,400 strokes per day (press machine
capacity).
For 6,945 volume per month requirement
Nr. of days allocation per month: 6,945 units/38,400 units per day
= approx. 0.2 day, namely 0.2day x 8hrs per day= 1.6hrs for one
shift to produce one month requirement (6,945 units)

Forming / Stamping machines

C-Frame
Hydraulic press

Stamping / forming machine

Machine tonnage
Bolster size
Slide size
Shut height
Stroke
Die height (closed position)

Tue 20 Sept 2011

Stamping machine selection

Tonnage
Cutting, bending, drawing, stripping forces

Opening height
Stroke
Tightening position
Bolster dimension
Slide dimension

Feeding method
Die height
Die weight

Bending force parameter

calculations
V-Bending
Rm = Tensile Strength
Fb = C x Rm x b x S02

Fb1 = 2 x Fb
S0
b

W
r
C = 1 + 4S0
W

W
C = Bending factor
Fb = Open bending
Fb1 = Closed bending

Bending force parameter

calculations
Fb

U-Bending
S0

Uniform bending

b1

b2

Fb = 0.4 x Rm x b x S0
L- Bending (one side)

Fb = 0.2 x Rm x b x S0

Non-uniform bending
Fb = 0.2 x Rm (b1+b2) x S0
Bending without opposing spring
Ff = 2.5 x Fb
Mon 12 Oct 09

Ff

Bending force parameter

calculations
U-Bending

Fos

Bending with opposing spring

Fos = 1.3 x Fb

Opposing spring

Deep drawing: flat blank

Tiefziehen = Deep drawing
Ziehtail = Drawn component
Zuschnittdurchmesser = Diameter of flat
blank
Ohne Rand = without additional flat ends
(lips)
Mit Rand = with additional flat end

Deep drawing: Flat blank

calculation

Deep drawing: Drawing clearance &

corner radii
Ziehspalt und
Radien am Ziehring
und Ziehstempel =
Drawing clearance &
drawing radius on
drawing ring &
drawing punch

Drawing Clearance

Sheet Thickness

Sheet Material Factor

(Wekstofffaktor)

rr

Corner Radius at Drawing

Ring

rp or rst

Corner Radius at Drawing

Punch

Cut Sheet Diameter

dr

Drawing Ring Diameter

Punch Diameter

Stahl = steel
Sonstige NE-Metalle = Special non-ferrous metal

Deep drawing: Drawing

clearance & corner radii

Deep drawing parameter: Number of

drawing stages and drawing factor
Ziehstufen &

Ziehverhaeltnis =
Number of drawing
stages and drawing
factor
Werkstoff = Material
Zwichengluehen =
heating during
drawing
Mit = with
Ohne = without

Zug = Travel
D

Cut Sheet Diameter

d1

First Stage Punch Diameter

d2

Second Stage Punch Diameter

b1

First Stage Drawing Factor

b2

Second Stage Drawing Factor

Sheet Thickness

Deep drawing parameter: Number of

drawing stages and drawing factor

Deep drawing parameter:

Number of drawing stages

Deep drawing: force calculations

Force calculation
Tiefziehkraft = Deep

FD or Fz

Deep Drawing Force

d1

Punch Diameter, first stage

Sheet Thickness

drawing force
Niederhalterkraft =
Thrust plate force

Rm

Tensile Strength (or )

Actual Drawing Factor

bmax

Highest Allowable Drawing

Factor

FT or FN

Thrust or Holding Force

Cut Sheet Diameter / Flat

blank diameter

dN

Diameter on holding plate

Thrust Plate Pressure

Drawing Clearance (per side)

Deep drawing: force calculations

Dimensioning & machining procedures

Standard: 0.1
Standard : 0.05 (pressure and punch
holder)
Thrust plate
Vertical: 0 to +0.05
Horizontal: 0.1

Guide fence
Horizontal top: -2 to - 3
Horizontal bottom: -0.1 to -0.2
Vertical: 0 to -0.05
In mm

Dimensioning
Die plate assembled in ground plate
Vertical: 0 to +0.1
Horizontal: -0.1 to 0

Die plate opening, on top of ground plate

Horizontal: +0.1 to +0.2
Vertical: 0.05

Die materials

Base plates: Mild steel. E.g. MS45, C45

Punches
Materials: HSS (Euro), DF2, SKD11, SKH
Hardness: HRC 60 - 64

Inserts
Materials: HSS, DF2, SKD11, SKH
Hardness: HRC 55 63 (normally lower than
punches for maintenance purpose. Insert to
break rather than punch)

Standard parts
Guide pillars & bushes (SUJ2,)
bolts

Common problems in sheetmetal products

Burr
Higher than specification
Wrong direction

Dented: Foreign materials

Different thickness / surface thinning
Elongated hole (bend after hole punch)
Wrinkle surface
Torn off
Springback
Surface crack
Rusty

Finished product problems in

sheetmetal

Wrinkle

Surface thinning

Common problems on sheetmetal die

Misalignment between top and bottom die

plate sets
Forming machine stops halfway through
Insufficient load
Obstruction between punches and dies

Tue 18 Oct
2011

Special sheetmetal dies

Cam design, angular cut / bend
Side cut
Sensors
Air
Air--assisted scrap / product removal

Special forming machines

Fineblanking
Highspeed forming machines
Multi
Multi--actions bending machines
Sensors in forming machines

Cost calculation: Main cost

components

Design
Raw materials and standard parts
Machining
Heat treatment
Handling
Delivery
Administration
Profit margin
Quotation

Design cost
RM / hr
Design duration
Design objective (based on problem
statement)
Design needs analysis
Research ideas
Design alternatives
Final design

Raw material & standard part

cost
Raw material, by:
Request for quotation from suppliers
Weight
Size or volume

Standard part catalogue

Price list from suppliers
Request for quotation from suppliers

Machining cost
Machine type

Milling
Turning
Grinding
Wirecut
Diesink
Welding

Machining accuracy
Machining time calculation
RM / hr rate, by machine depreciation

Machining cost

Normally based on depreciation

Cost to purchase a machine, e.g. RM300k (plus

interest)
For forming machine: E.g. 80 spm
spm.. Cycle time =
0.0125min/stroke or 0.75sec/stroke
Year to depreciate, e.g. 7 years
RM/yr:
RM/month:
RM/day:
RM/hr:
RM/min:
RM per 0.0125min or RM per stroke:

Heat treatment
RM / kg rate
RM for special requirement
Material
Heat treatment method
Electrical furnace
Induction
Process control

Handling cost
Machine setting
Assembly and dismantling
Quality control
Progress control
Storage
RM/hr

Delivery
Transportation mode

Lorry or car or motorcycle (depreciation)

Driver
Petrol
Maintenance (tyre
(tyre wear, engine oil, etc)
Toll

RM / km
Weight category , e.g.
Less than 150 kg at RM1/kg
Others at RM2/kg
Size or volume category

Administration cost

Apportionment: % to be budgeted on
capital expenditure, e.g. supporting
machines, furniture, forklift, etc
RM/hr
Eg
Eg..
Admin staff payroll: Total RM50,000 per
month
Power & utility: RM5,000 per month
Building depreciation or rentals: RM10,000
month
2 shifts, 8 hours / shift, 22 days / month.
Equals to 352 hours / month

Administration cost
Admin cost / month: RM65,000
Rate: RM65,000 / 352 hours
RM185 / hr
For e.g. 50 projects per year.
Apportionment equals 1/50. or RM3.70 / hr
/ project

Profit margin
% of total production cost
% value depends on:
Difficulty level
Timeline given by customer
Wisdom:
Can others do it?
Rule of thumb

Quotation to customer
Project name
Project reference number
Price
Warranty
Delivery date

Amortisation
Definitions (ref: Wikipedia)
of capital expenditures of certain assets under
accounting rules, particularly intangible
assets,, in a manner analogous to depreciation
assets
is the distribution of a single lump
lump--sum cash
flow into many smaller cash flow installments,
as determined by an amortization schedule

E.g. soft tools, R&D, prototype

Cost summary
Item

Basis

Rate (e.g.)

Design

Hrs

RM25/hr

Raw material

Kg

RM7/kg

Std. part

L/s

As manufacturer list

Machining

Hrs

RM5 to RM60/hr

Heat treatment

Kg

RM5/kg

Handling

Hrs

RM5/hr

Delivery

Km, weight, volume

RM5 to RM60/km

Admin

Hrs

RM4

Total

Profit margin

Quotation

50 to 200

RM

Cost summary

Tue 09 Mar 2010

Forming technologies
Forming
automation
High Speed
Forming Machine
Fineblanking

Yamada Omega: 3,000RPM

Fineblanking: 300 pcs/min

Forming machine with auto-feeder

Design samples

Special designs
Sensors in die

Ball catch

Strip utilization

Utilization rate of strip in producing the

workpiece flat blank
Determines a good design or otherwise
To determine the best configuration
Nr of row
Straight or slanting layout

Strip utilization
Calculation:

= Utilization efficiency (%)

R = Nr of row
A = flat blank surface area (inclusive holes)
V = Strip pitch
B = Strip width

R.A
=
V.B

Force centre point

U = perimeter of each punch
a = distance of punch centre point to a reference
point
x = distance between force centre point to
reference point

U1.a1 + U 2 .a2 + U 3 .a3 + ...

x=
U1 + U 2 + U 3 + ...