Die Maintenance

Handbook

David A. Smith

Society of Manufacturing Engineers

Dearborn, Michigan
Die Maintenance Handbook

Copyright © 2001 Society of Manufacturing Engineers

987654321

All rights reserved, including those of translation. This book, or parts

thereof, may not be reproduced by any means, including photocopying,
recording or microfilming, or by any information storage and retrieval
system, without permission in writing of the copyright owners.

No liability is assumed by the publisher with respect to use of informa-

tion contained herein. While every precaution has been taken in the
preparation of this book, the publisher assumes no responsibility for
errors or omissions. Publication of any data in this book does not consti-
tute a recommendation or endorsement of any patent, proprietary right,
or product that may be involved.

Library of Congress Catalog Card Number: 2001094396

International Standard Book Number: 0-87263-525-2

Additional copies may be obtained by contacting:

Society of Manufacturing Engineers
Customer Service
One SME Drive, P.O. Box 930
Dearborn, Michigan 48121
1-800-733-4763
www.sme.org

SME staff who participated in producing this book:

Cheryl Zupan, Staff Editor
Rosemary Csizmadia, Production Supervisor
Kathye Quirk, Graphic Designer/Cover Design
Frances Kania, Administrative Coordinator
Jon Newberg, Production Editor
Printed in the United States of America

iv
 Dedication

I would like to dedicate this book to the many people that made
it possible, especially my wife Marlyn Smith who helped with the
formatting and proofreading of the original training manuals that
were used to produce this work. I would also like to thank mem-
bers of the production and editorial departments at SME who went
the extra mile to give this work polish and continuity. Those indi-
viduals include Cheryl Zupan, Bob King, Rosemary Csizmadia,
Kathye Quirk, Jon Newberg, and Frances Kania.

v
 Table of Contents

Preface ..................................................................................... xiii

Contributors ............................................................................ xvii
1 An Overview of Basic Die Operations ................................... 1
Cutting, Punching, and Perforating ........................................ 1
Bending and Forming ............................................................. 2
Bending and Straightening .................................................... 3
Stretching ............................................................................... 4
Drawing ................................................................................... 6
Squeezing or Coining Operations .......................................... 6
Analytical Tools ....................................................................... 8

2 Troubleshooting Punching and Cutting Operations ........... 11

Understanding the Sequence of Operations ....................... 11
Effect of Die Clearance ......................................................... 15
Cutting Forces ...................................................................... 21

3 Designing Large EDM Die Sections for Repairability ......... 27

Application of EDM Technology ........................................... 27
Throwaway versus Repairable Die Sections ........................ 28
Die Section Location and Retention ..................................... 29
Punch and Die-steel Design ................................................. 30
Conclusion ............................................................................ 32

4 Die-shaving Operations ........................................................ 33

Purpose ................................................................................ 33
Punch-to-die Clearance ........................................................ 34
Size of Shave Punch versus Part Hole Size ......................... 34
Multiple Shaving Operations ................................................ 34
Application of the Hollow-ground Concept .......................... 36

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Die Maintenance Handbook

5 Solving Punch Head Breakage Problems ........................... 39

Punch Head Breakage ......................................................... 39
Safety of Personnel ............................................................... 45
Function of the Punch Backing Plate ................................... 46
Ironworker- and Bulldozer-style Punches ............................ 47

6 The Cost of Punch and Die Maintenance ............................ 49

Record Causal Factors ......................................................... 49
The Real Cost of Die Damage .............................................. 51
The Value of Good Workmanship ........................................ 51

7 Good Maintenance Practice ................................................. 53

Good Grinding Practice ........................................................ 53
Stress-relieving Cutting Tools ............................................... 63
Shimming Die Components ................................................. 65
Ball-lock Punches and Die Buttons ...................................... 69

8 Compound Dies .................................................................... 73

Compound Blank and Piercing Dies .................................... 73

9 Pressure Pad and Stripper Selection .................................. 79

Positive or Tunnel Strippers .................................................. 79
Pressure Systems for Pads and Strippers ........................... 81
Elastomer Strippers .............................................................. 86
Stripping Forces ................................................................... 87

10 Anti-slug Pulling Methods .................................................. 89

Resolving Slug-pulling Problems ....................................... 89
Overview of Methods .......................................................... 97

11 Cutting Force and Snap-through Reduction ................... 101

Types of Punch Shear ...................................................... 101
Punching Thick Carbon Steel .......................................... 102
Importance of Timing ....................................................... 104
Press Reverse-load Capacity ........................................... 105
Die Timing Improvement .................................................. 106
Providing Angular Shear on the Die ................................. 108
Summary .......................................................................... 110

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 Table of Contents

12 Bending of Metals ............................................................. 111

Bend Allowances .............................................................. 113
Press-brake Operations .................................................... 115
Wipe-bending Die Operations .......................................... 117
Rotary-action Die-bending Operations ............................ 119
Control of Bend Angle by Adjusting Pad Pressure .......... 122

13 Forming Flanges and Hems ............................................. 129

Flanging Operations ......................................................... 129
Flange Types .................................................................... 129
Minimum Bend Radii ........................................................ 132
Stock Thickness Variation ................................................ 133
Hemming Operations ....................................................... 136
Pressures .......................................................................... 137

14 Drawing and Stretching of Metals ................................... 141

Deep Drawing of a Cylindrical Cup .................................. 141
Stretch Forming ................................................................ 148
Bending and Straightening .............................................. 149
Drawing and Bending ....................................................... 150

15 Stamping Analysis Techniques ........................................ 157

Computerized Analysis Techniques ................................. 158
Circle Grid Analysis .......................................................... 159

16 Die Maintenance Documentation and Tracking .............. 167

Die Maintenance Team ..................................................... 167
A Systematic Die Maintenance System ........................... 168
The Request for Maintenance Form ................................. 175
Case Study ....................................................................... 176
Continuous Improvement ................................................. 180

17 Effective Die Maintenance Program Strategy ................. 183

Understanding the Die Maintenance Facility ................... 183
Addressing Production-scheduling Problems ................. 184
Planning Die Maintenance ............................................... 185
Tracking the Cost of Maintenance and Downtime ........... 186

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Die Maintenance Handbook

Continuous Improvement ................................................. 186

Spare Parts Inventory ....................................................... 190
Calculating Costs ............................................................. 193
Pareto Charting ................................................................. 200
Dealing with an Outside Vendor ....................................... 203
Used Dies ......................................................................... 204
Good Engineering Practice .............................................. 205

18 Metallic Springs as Die-pressure Devices ...................... 211

Types of Metal Springs ..................................................... 211
Materials Used to Make Metal Springs ............................ 215
Selecting Springs ............................................................. 216
Considerations When Repairing Dies .............................. 220
Analysis of Spring Failures ............................................... 222
Winding Springs In-house ................................................ 225
Conclusion ........................................................................ 225

19 Gas and Hydraulic Die-pressure Systems ...................... 227

Pneumatic Cylinders ........................................................ 227
Nitrogen Die-pressure Systems ....................................... 231
Nitrogen Manifold Systems .............................................. 235
Self-contained Nitrogen Cylinders ................................... 237
Hydraulic Die-pressure Systems ...................................... 243

20 Press Selection and Maintenance ................................... 247

Press Terminology ............................................................ 247
Types of Presses .............................................................. 250
Overload Protection .......................................................... 259
Mechanical Press Drives .................................................. 260
Speed Reduction and Torque Capacity ........................... 268
Mechanical versus Hydraulic Presses ............................. 268
Upgrading Existing Presses ............................................. 275
Die Cushions .................................................................... 275
Centering the Load in the Press ....................................... 278

21 Troubleshooting Large Panel Stamping Dies .................. 283

Die Bolting ........................................................................ 283
Nitrogen Pressure Systems .............................................. 286

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 Table of Contents

A Systematic Approach to Die Tryout .............................. 286

Draw Beads ...................................................................... 291
Double-action Press Operations ...................................... 295
Dirt Problems .................................................................... 295
Forming Ribs and Embossments ..................................... 297
Knockout Bars .................................................................. 299

22 Waveform Signature Analysis .......................................... 301

Stress-strain Curves ......................................................... 301
Case Study: Webster Industries ....................................... 302
Diagnosing Hydraulic Overload Problems ...................... 307
Press-tonnage Curves ...................................................... 311
Detecting Waveform Changes ......................................... 315
Die- and Press-protection Systems .................................. 317
Conclusion ........................................................................ 320

23 Repairing Damaged Die Steels and Castings ................. 323

Making the Repair Decision ............................................. 323
Mechanical Repair Techniques ........................................ 325
Electrical Welding Repairs ................................................ 333

24 Die Materials and Treatments .......................................... 339

Characteristics of Tool and Die Steels .............................. 340
Choosing Tool Steels ........................................................ 340
Heat Treatment of Die Steels ............................................ 353
Tool Steel Production Methods ........................................ 358
Die Surface Coatings and Treatments ............................. 360
Wrought Low-carbon Steels and Cast Irons .................... 363
Nonferrous and Nonmetallic Die Materials ...................... 365

Appendix A: Generic Die Standards ...................................... 371

Design-and-build Process .................................................. 371
Production and Safety ........................................................ 372
Quotes ................................................................................ 373
Completion ......................................................................... 373
Cancellations and Damages .............................................. 374
Designing Strong Die Sections .......................................... 375
Screws, Dowels, and Keys ................................................. 377

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Die Maintenance Handbook

Die Shoes, Subplates, and Parallels .................................. 379

Die Springs ......................................................................... 380
Strip Starting Stops ............................................................ 382
Commercial Perishable Details .......................................... 383
Pads and Strippers ............................................................. 384
General Tool Steel Details .................................................. 385
Guide Pin, Bushing, Heel Block, Keeper, and Wear Plates 386
Scrap Discharge ................................................................. 387
Stock Sensors .................................................................... 388
General Good Practice ....................................................... 388
OSHA and Additional Die Identification ............................. 389

Appendix B: Case Study—

Phoenix Specialty Manufacturing Company ......................... 391
Order Entry ......................................................................... 391
Machine Shop Capabilities ................................................ 392
Plant Culture ....................................................................... 394
Spare Parts Storage ........................................................... 394
Ergonomics ........................................................................ 395
Aluminum Die Sets ............................................................. 396
Bench Die Build Up ............................................................ 398
Quick Die Change Capabilities .......................................... 399
An Eye to the Future ........................................................... 400
Conclusion .......................................................................... 400

Index ........................................................................................ 403

xii
 Preface

Developing a popular book on the topic of die repair has been a

challenging task. The goal of every shop should be to minimize die
maintenance expenditures through good die design. To do this, each
of the metal forming, pressworking processes need to be under-
stood from a simple, yet analytical, point of view. Thus, this refer-
ence work on die maintenance deals with metal-forming processes
in an elementary way, before looking at the bigger picture of cost
containment using damage avoidance and robust die designs.

CHOOSING THE CONTENT OF THIS BOOK

A goal of this reference work is to produce a handbook that will
make solving stamping-process problems understandable by new-
comers to the trade. At the same time, it is intended to serve the
experienced journeyman with reference information for solving
difficult problems. An essential theme is that die maintenance is a
cost that needs to be minimized. Too often, die maintenance is
treated as unavoidable and unacceptable, with its very real costs
lumped in with other overhead. Success in any critical mechani-
cal repair or defect correction necessitates that required tasks oc-
cur correctly and in the proper sequence. This takes both skill
and the ability to document results for future reference.
Those who have spent most of a lifetime in the tool and die
trade hope for the day when educators will quit teaching that
hourly employees in industry have chosen a second-rate alterna-
tive to completing a college degree. In reality, many journeymen
also hold two-year, technical degrees. Some go on to complete ad-
vanced degrees in engineering and business management. Yes,

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Die Maintenance Handbook

these skilled workers will continue to hold engineering and top

management positions in the future.
Most community colleges and trade schools do a good job of
teaching the basic principles of computer numerical control (CNC)
machining, industrial welding, hydraulics, pneumatics, and elec-
tronic technology. However, schools lack hands-on training in the
basic theories of die making and metal-forming processes. Hands-
on experience needs to occur in a die building and/or repair facil-
ity under the guidance of skilled workers.
Apprentices or trainees are not a source of low-cost labor. Die
builders and the manufacturers who depend on pressworking tool-
ing in their processes have a duty and an obvious, personal stake
to provide the best training to all in the trade, without regard to
experience level. Anything less deprives both the craftsperson and
employer of the critical skills that are essential to remain innova-
tive and competitive in a world market.

BOOK ORGANIZATION
An essential die-repair skill is the ability to modify existing tool-
ing to correct design mistakes and problems that can affect part
quality and proper tool operation. A good understanding of metal-
forming processes in pressworking tooling is necessary to main-
tain and correct die problems.
This book begins with an overview of basic die operations and
continues with the anatomy of how these processes work. Trouble-
shooting, or using insight into the process, is an essential factor
in problem solving. Formability theory and practice begin with
having basic knowledge of bending and stretching metals through
complex, forming states. Essential, analytical methods that are
needed to solve problems are also covered. Here, the information
is in a simple format, yet it is comprehensive enough to be techni-
cally correct from a tool-engineering perspective.
The appropriate use of electronic instrumentation for process
protection and optimization is essential in modern pressworking.
This ties in with pressworking safety—both of the process and
especially of the pressroom personnel.

xiv
 Preface

Troubleshooting of large dies, including casting repair, is based

on the experience of co-workers and the author with large, sheet-
metal-forming dies. The reader will find that much of the infor-
mation here is either hard to find, or that it has never been put in
print. Topics include solving dirt problems in automotive, outer-
skin-panel, forming operations, as well as repair methods for
broken cast-iron die shoes. This unique text is meant to aid those
faced with these repair and troubleshooting problems. Tool
engineering, including problem solving, is not a black art. It is a
discipline based mainly on mechanical engineering and material
science.
The material science behind die materials, heat treatment, and
tool coatings is objective and based on expert review. Objective
information is a problem area because of large amounts of con-
flicting information and negative comparisons prevalent today in
trade advertising.
This book offers detailed procedures for establishing a die main-
tenance program. Problem tracking and cost control to start or
improve a system are explained. Examples of die standards are
generic and recast subject to applicable law and good engineering
practice.
It is hoped that the individuals, organizations, and firms who
have contributed to this work will recognize the benefits gained
from cooperation and mutual assistance that extend far beyond
any financial recompense. By donating time, talent, and design
examples, contributors have provided a wealth of practical design
and troubleshooting information. Their help has made this work
possible.

xv
 Contributors

The author wishes to acknowledge the following individuals for

their contributions to this book:

Taylan Altan, Ph.D. Lisa Bisson

Professor and Director Editor
ERC/NSM Eagle Publications
Ohio State University Novi, Mich.
Columbus, Ohio Rollin Bondar
Gary Amin President
Supervisor MPD Welding, Inc.
Die Design and Standards Orion, Mich.
Ford Motor Company Arthur Brown
Dearborn, Mich. Publisher
Eagle Publications
Jim Austin Novi, Mich.
Director of Continuous
Improvement Douglas Burke
Michigan Seat Company Forms Consultant
Jackson, Mich. Superior Business Solutions
Kalamazoo, Mich.
James Barrett, Jr., Ph.D. Bill Christiansen
President Senior Process Engineer
Link Systems Jostens, Inc.
Nashville, Tenn. Princeton, Ill.
John Bates Daniel N. Falcone
President and CEO Vice President
Heidtman Steel Products, Inc. Toledo Transducers, Inc.
Toledo, Ohio Holland, Ohio

xvii
Die Maintenance Handbook

Kevin M. Fessler Bill Hays

Electrical Maintenance District Maintenance
Consultant Supervisor
Centerville, Ind. Governor’s Office of
Technology
Chuck Fitch
Director of Fluorescent Frankfort, Ky.
Operations John Heffelfinger
Cooper Industries Manufacturing Manager
Americus, Ga. Norlen, Inc.
Jeff Fredline Schofield, Wisc.
President James Hicks
Fredline & Associates Professor of Chemistry
Okemos, Mich. Cumberland College
Henry H. Gehlmann Williamsburg, Ky.
Blanking Area Manager
Robert Hurst
(retired)
President
Ford Motor Company
Phoenix Specialty
Woodhaven, Mich.
Manufacturing Company, Inc.
Leo Goepfrich Bamberg, S.C.
Tool and Die Manager
(retired) Casimir S. Janiszewski
Ford Motor Company President and CEO
Chicago Heights, Ill. Superior Die Set Corporation
Oak Creek, Wisc.
Bob Green
Engineering & Facilities Stuart P. Keeler, Ph.D.
Manager President
Cooper Industries Keeltech Technologies
Americus, Ga. Grosse Ile, Mich.
Roger P. Harrison Karl A. Keyes
Director of Training President
Rockford Systems, Inc. Feinblanking Ltd.
Rockford, Ill. Fairfield, Ohio

xviii
 Contributors

Gregory A. Kreps Harry J. Micka

Tooling Engineer Manufacturing Engineer
Capital Die, Tool and LA-Z-BOY Chair Company
Machine Company Dayton, Tenn.
Columbus, Ohio
Richard Micka
James L. Lehner Vice President
Applications Manager of Administration
HMS Products Company LA-Z-BOY Chair Company
Troy, Mich. Monroe, Mich.
Ernie Levine Arnold Miedema
President and CEO President
Admiral Tool Green Meadows Engineering
and Manufacturing Hudsonville, Mich.
Chicago, Ill.
Ernest E. Morgan
Cecil Lewis Consulting
Corporate Vice President Structural Engineer
Midway Products Group, Inc. Henderson, Ky.
Monroe, Mich.
Eugene J. Narbut
Albert A. Manduzzi Die Room Unit Leader
Supervisor (retired) Auto Alliance International
Die Design and Standards
Flat Rock, Mich.
Ford Motor Company
Dearborn, Mich. Al Nichols
Area Leader
John McCurdy
Stamping Engineering
President (retired)
Auto Alliance International
W. C. McCurdy Company
Oxford, Mich. Flat Rock, Mich.

Bradley K. Mettert Mark Nichols

Field Engineering Manager Corporate Safety Director
Toledo Transducers, Inc. LA-Z-BOY Chair Co.
Holland, Ohio Maplewood, Minn.
Carl Meyer Michael F. Ollie, Jr.
President President
Progressive Tool Company Henry & Wright Corporation
Waterloo, Iowa Fairforest, S.C.

xix
Die Maintenance Handbook

Pat Ontrop Brad Sauer

Applications Engineer Industrial Engineer
Minster Machine Company LA-Z-BOY Chair Co.
Minster, Ohio Monroe, Mich.
Dick Peoples Daniel A. Schoch
Metallurgist Mechanical Engineer, P.E.
Heidtman Steel Products, Inc. Minster Machine Company
Toledo, Ohio Minster, Ohio
Jim Pienta Mike Searson
Production Manager Machine Shop Supervisor
Jostens, Inc. Phoenix Specialty
Princeton, Ill. Manufacturing Company, Inc.
Gerald A. Pool Bamberg, S.C.
Consultant
Aniese Seed
Royal Oak, Mich.
President (retired)
Ronald E. Prater Toledo Transducers, Inc.
President, Koppy Corporation Holland, Ohio
Orion, Mich.
Kenneth L. Smedberg
Frank Randall President
Engineering Manager Smedberg Machine
(retired) Corporation
Zippo Manufacturing Company Chicago, Ill.
Bradford, Pa.
Anthony Rante Andrew D. Smith
Director of Engineering Mechanical Engineer, T. R. W
Fitzpatrick Company Livonia, Mich.
Elmhurst, Ill. Gary D. Smotherman
Jim Ricketts International Representative
Production Manager (retired)
LA-Z-BOY Chair Co. U. A. W.
Dayton, Tenn. Detroit, Mich.
Mike Riley Fredric Spurck
Mechanical Engineer, P.E. President
Consultant & Writer Webster Industries, Inc.
Pinson, Ala. Tiffin, Ohio

xx
 Contributors

Robert Stadler Ed Tremblay

Tool Engineer Vice President, Engineering
Ranger Tool & Die and Manufacturing
Grand Rapids, Mich. P/A Industries
Allan Steinbock Bloomfield, Conn.
Vice President Robert Vance
Superbolt, Inc. Consulting Marine Engineer
Carnegie, Pa. Glasgow, Ky.
Robert Storer Bob Wahls
President Chief Engineer
Toledo Transducers, Inc. Michigan Seat Company
Holland, Ohio Jackson, Mich.
Leslie Suthers Keith Weaver
Manager Press Engineer
Manufacturing Services Capital Die, Tool
Norlen, Inc. and Machine Company
Schofield, Wisc. Columbus, Ohio
Thomas A. Suthers Joe Wise
President Maintenance Supervisor
Norlen, Inc. H. J. Heinz Company
Schofield, Wisc. Freemont, Ohio
Nick Tarkany Wayne Wittaker
Director Vice President of Operations
Research & Technical Unisorb Machinery
Education Installation Systems
Dayton Progress Corp. Jackson, Mich.
Dayton, Ohio
Greg Yirga
Ed Tarney
Metal Department Manager
Director
LA-Z-BOY Chair Co.
CPM Development
Dayton, Tenn.
Crucible Materials Corporation
Camillus, N.Y.
Jack Thompson
President
Penda Corporation
Portage, Wisc.

xxi
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