Tooling

Source – SKH Ownership | Innovation & Excellence | Customer Delight | Respect, Fairness & Transparency
Source – SKH 2 Ownership | Innovation & Excellence | Customer Delight | Respect, Fairness & Transparency
NON CUTTING CUTTING PRESS
PRESS TOOL TOOL
CASTING TYPE PLATE TYPE

TOOL TOOL
LOWER HALF
BLANK HOLDER
OF DRAW TOOL
UPPER HALF
LOWER HALF
UPPER HALF
PAD
PUNCH RETAINER PLATE : PUNCH PLATE IS USED TO HOLD
THE PUNCH WITH ALIGNMENT
PUNCH RETAINER PACKING PLATE : PUNCH PLATE IS
USED TO PUNCH RETAINER BACK SIDE FOR HEIGHT MAINTAIN
PUNCH: PUNCH IS THE MALE EJECTOR PUNCH: THIS
PART OF DIE AND USED FOR TYPE PUNCH USED FOR SCRAP
HOLE OR PERCING EJECTION
DIE BUTTON:
FEMALE PART OF
THE DIE
ANGULAR DIE BUTTON PACKING: THIS IS USED FOR DIE
BUTTON BACK SIDE
STRAIGHT DIE BUTTON PACKING: THIS IS USED FOR DIE

BUTTON BACK SIDE
STRIPER PLATE:THE PLATE IS USED FOR
THE ALIGNMENT OF THE PUNCH ,EJECTION OF
STOCK STRIP AND POSITIONING OF PART
DOWEL: DOWEL IS THE USED FOR
ALIGNMENT OF THE TWO PLATE
SPRING PLUGS FOR DOWEL PINS :

THIS IS THE USED FOR THE DOWEL LOCK IN
UPPER HALF DIE
OIL-FREE GUIDE
POST SETS
HOW TO CHECK BUSH
HOW TO CHECK GUIDE PILLAR : GUIDE PILLAR DIA CHECKED BY VERNIER CALIPER AS PER BELOW PHOTO
GUIDE PILLAR & GUIDE BUSH: THE GUIDE PILLAR AND
GUIDE BUSH USED FOR THE ALIGNMENT OF DIE (CLERENCE
BETWEEN THE GUIDE PILLAR AND BUSH IS 0.010 MM)
BALL BEARING INTEGRATED TYPE GUIDE POSTS / GUIDE

PLAIN GUIDE
GUIDE POST PLAIN GUIDE HOLDERS / GUIDE
POST SETS
SETS POSTS BUSHINGS
STROKE END BLOCKS : THIS TYPE BLOCK GENERALLY USED
FOR DIE SHUT HEIGHT OR DIE STROKE DURING PRODUCTION TIME
DIE LIFTING PART : THIS TYPE PART USED FOR DIE LIFTING
URETHANE STOCK BLOCK SETS : THIS TYPE PART USED FOR
DIE STOREGE AND STOKEN
KEEPER PLATE: GENERALLY USED FOR PAD HOLDING AND PAD
SAFTY
RETAINER PIN : IN DIE GENERALLY USED FOR IN PAD HOLDING

HORIZONTAL SIDE SAFTY PURPOSE
STOPER PLATE: THIOS IS USED FOR RETAINER PIN LOCKING
SPOOL RETAINER: GENERALLY USED BLANK HOLDER & PAD
LOCKING
BLANK HOLDER STOPER: THIS IS USED FOR BLANK HOLDER

OR PAD STOPER (FOR STOCK MOVEMENT)
SHEET LIFTER : THIS TYPE GUAGE USED FOR SHEET LIFTING
ROUGH GUIDE: THIS TYPE GUAGE USED FOR PROFILE

GUIDEING AREA
NEST GUIDE: THIS TYPE GUAGE USED FOR PROPER PART
GUIDING FOR NEXT OPERATION
COILED MATERIAL GUIDES: THIS TYPE GUAGE USED IN

COILED BLANKING DIE FOR SHEET GUIDE
LOCATION PIN: THIS IS USED FOR PART POSITION AND AVOID
THE MISS MATCH IN NEXT OPERATION(WITH BOLTING)
LOCATING PILOT PIN: THIS IS USED FOR PART LOCATING FOR

NEXT STAGE(WITH THREADING)
SPRING PLUNGERS: THIS IS USED FOR PART EJECTION
OIL FREE SLIDE PLATE: THIS IS USED FOR UPPER AND LOWER
HALF DIE GUIDING
OIL FREE HEEL GUIDE: THIS IS USED FOR UPPER HALF AND
LOWER HALF DIE SLIDING WITH ALIGNMENT
CAM UNIT: THIS CAM UNIT USED IN ANGLE HOLE ,HORIZONTAL
HOLE ,SIDE CUTTING ,SIDE BENDING
CAM SLIDE PLATE: THIS IS USED IN CAM UNIT FOR CAM SLIDING
DURING PRODUCTION TIME
FEELER GUAGE: THIS IS USED FOR CHECKING BETWEEN TWO
SURFACE (MAX. USED IN WEARE PLATE CLEARCING CHECKING)
SPRING GUIDE RETAINER: THIS IS USED FOR SPRING GUIDE
DURING DIE MOVEMENT
COIL SPIRING:THIS IS USED FOR PAD EJECTION
TYPE OF COIL SPRING: DIFFERENT TYPE SPRING USED IN DIE
ACCORDING TO PRESSURE LOAD
GAS SPRING : THIS IS USED IN GENERALLY HIGH TENSILE PART
OF DEEP DRAW PARTS (N2 GAS)
GAS SPRING IN SIDE DETAIL:
BOTTOMING MARK: THIS IS USED FOR DIE DEAD CONDITION
CHECK
ENGRAVING BLOCK PUNCHES: THIS IS USED FOR PART

IDENTIFICATION MARK IN DIE WITH SINGLE BOLT
ID MARK SPECIFICATION:
DIFFERENT TYPE OF BOLT &SCREW:
SCREW PLUGS: THIS IS USED IN DIE FOR BOLT LOCKING IN
UPPER HALF DIE AND AVOID THE ANY ACCIDENT DUE TO BOLT
FALLING
DOWEL PIN EXTRACTOR: THIS IS USED IN DIE FOR DOWEL

OUT SIDE
DISTANCE PLATE: THIS IS USED IN DIE FOR DIE STROK
CONDITION CHECK BY OIL DROP
SHIMS FOR DISTANCE PLATE: THIS IS USED IN DIE FOR DIE

BLANCING ADJUSTMENT
SCRAP SHOOTERS TYPE: THIS IS USED IN DIE FOR EASY
SCRAP FALLING
REASON OF BURR: COUNTER MEASURE
PROVIDE PROPER CLERENCE BETWEEN DIE

BUTTON AND PUNCH OR REPLACE WITH NEW
DIE BUTTON AND PUNCH RESHARP OR

REPLACE WITH NEW
DIE BUTTON AND PUNCH FITTING TIGHT
REPLACE WITH NEW GUIDE PILLAR & BUSH
CORRECT THE ALIGNMENT BETWEEN PUNCH

AND DIE BUTTON
CORRECT THE PARALLSLISM BEFORE DIE

LOADING
ALL PACKING HEIGHT EQUALE AS PER

REQUIRED HEIGHT
CUTTING INSERT HARDNESS REQUIRED 58~60

HRC
BEFORE DIE LOADING CORRECT DIE PLATE

FLATNESS
PROVIDE DOWEL IN ALL CUTTING INSERT AND

PUNCH RETAINER
ISSUE OF TRIM /PIERCING DIE: COUNTER MEASURE
BLANK SIZE LESS OR GUAGE LOOSE
WEARE AND TEAR OF LOCATION PIN/STOPPER
MISS MATCH OF CUTTING EDGE
REPLACE WITH NEW GUIDE PILLAR & BUSH
PUNCH WORN OUT/POSITION NG OF PUNCH
WEARE AND TEAR OF LOCATING PINS

/STOPPERS /POSITION NG
PUNCH UNDER SIZE,BURR FOLDED INSIDE OF
HOLE,PUNCH WORN OUT,MISS FEED BY MACHIN
OPRATOR
PUNCH BROKEN DUE TO MISS FEED(DUBBLE
PART)
ON HOLE SURFACE AREA EJECTOR HOLDING
LESS (GAP BETWEEN EJECTOR AND
COMPONENT)
ISSUE OF DRAW/BENDING/RESTRIKE COUNTER MEASURE
DIE:
IMPROPER DRAW CLERANCE, HIGH GASS SPRING
PRESSURE /CUSHION PRESSURE,RAW MATERIAL NOT AS
PER SPEC,DIE MATCHING SURFACE WORN
OUT,PARALLELISM NG BETWEEN UPPER & LOWER HALF
LESS GASS SPRING PRESSURE,MAIN PRESSURE

DROP,IMPROPER MATCHING IN BLANK HOLDER,TOOL
MATCHING SURFACE WORN OUT,BLANK SIZE SHORT
DIE MATCHING SURFACE WORN OUT,IMPROPER

LUBRICANT,WRONG DRAW OIL USED
IMPROPER CLERENCE BETWEEN UPPER AND LOWER

DIE,FOREGINE MATERIAL IN DIE,IMPROPER
LUBRICATION(USED ONLY STD.DRAW OIL)
RELIEVING NOT PROPER IN DIE (AIR VENTILATION HOLE
IN UPPER HALF DIE), RAW MATERIAL PROBLEM ,FOREIGN
MATERIAL IN DIE
FOREIGN MATERIAL IN DIE ,SHEET THICKNESS NOT

PROPER,TOOL WORN OUT
MISS FEED BY OPERATOR ,DIE GUAGE BLANK

LOCATING PIN NOT PROPER,IMPROPER DIE SURFACE
LESS STROKR
NON CUTTING DIE
NON CUTTING DIE
NON CUTTING DIE
CUTTING DIE
CUTTING DIE
CUTTING DIE
.
 Both Side Trim.

 But next sheet trim one side
avoids.
 One side trim.
Advantage: Die cost
saving.
 This hole next sheet is op-
30.
 Advantage: Hole relation
and good accuracy.
.
Both hole shift in

op- 30 .
Advantage: For
relation hole.
.
 Final process sheet 45812-

68P00.
 All process according to panel
quality.
 All hole piercing according to
sub assy. and hole relation.
 Advantage: All hole CD
maintain and hole accuracy
quality is good.
Press Engineering
 Use of Die lay out– Process Plan for Child parts is provided by SKH group to Vendors to reduce the time for
development.
 Die Layout Check sheet – For efficient process design check and die design guidelines.
 Die Design Review mechanism – Three level of Design review to reduce die quality maturation time.
 Die design check sheets – Use Standard die design check elements.
 Countermeasure provided to manufacturer for design implement.
 How to control the thrust in high tensile dies by providing Anti Thrusters in dies.
 How to take the standard and pattern of insert bolting – Is decided as per thrust load on dies.
 How to compensate the spring back(5~6 degree) – Reference from Simulation and compensate in dies
accordingly.
 Implementation of Shift allowance sheet for better matching of parts during welding.
66
WHAT IS WELDING ?
TO JOINT THE TWO DIFFERENT/SAME
MATERIAL AT PERTICULAR TEMP. WITH OR
W/O PRESSURE & WITH OR W/O FILLER
METAL IS CALLED WELDING
HOW TO DO WELDING ?
ELECTRIC ENERGY CONVERTED IN
TO HEAT FUSION BY BASE METAL
AND FILLER A HOMOGENIOUS
FILLER MAINTAIN AND CONVERTED
INTO BEAD.
TYPES OF WELDINGS
THERE ARE MAINLY TWO TYPES
WELDING ARE USED :
* FUSION WELDING
* NON-FUSION WELDING
FUSION WELDING
DIFFERENT TYPES OF FUSION WELDING
ARE IN USE :
1. SHIELDING METAL ARC WELDING. (SMAW)
(INCLUDE, MANUAL ARC, STICK, COATED ELECTOD
WELDING)
2. SUBMERGED ARC WELDING (SAW)
3. FLUX CORED ARC WELDING (FCAW)
4. GAS TUNGESTEN ARC WELDING. (GTAW)
5. PLASMA ARC WELDING. (PAW)
6. GAS METAL ARC WELDING. (GMAW)
7. ELECTROSLAG WELDING. (ESW)
8. ELECTRON BEAM WELDING. (EBW)
9. RESISTANT WELDING. (RW)
10. ATOMIC HYDROGEN WELDING. (AHW)
PROCESS VARIATION
1 - WELDING CURRENT
2 - ARC VOLTAGE
3 - TRAVEL SPEED
4 - MIG WIRE EXTENTION
5 - MIG WIRE INCLINATION
6 - MIG WIRE SIZE
7 - WELD JOINT POSITION
GLOBULAR TRANSFER
1- SOME LESS VOLTAGE & FEED SPEED CALLED
GLOBULAR TRANSFER
2 - DROP SIZE OF DIAMETER GREATER THAN THAT OF WIRE

DIA.
CURRENT : 200 ~ 300 AMP.

VOLTAGE : 24 ~ 28 V
SHEET THICKNESS : 2 ~ 3.0 mm.
POSITION : MIDIUM GAGE
FLAT
DEPOSITION RATE : 1 . 8 ~ 3 . 2 KG. / HOUR
ARC LENGTH : 10 ~ 15 MM.
DISADVANTAGE : MORE SPATTER ,
WASTAGE OF
MIG WIRE
SPRAY - TRANSFER
1- HIGH VOLTAGE & HIGH FEED SPEED CALLED SPRAY
TRANSFER
2– DROPLET SIZE OF MIG WIRE IS EQUEL TO OR LESS
THAT OF WIRE DIAMETER
CURRENT : 220 ~ 500 AMP.

VOLTAGE : 28 ~ 40 V
SHEET THICKNESS : 3.0mm MIN.
POSITION : THICK PLATE FLAT
DEPOSITION RATE : 2.7 ~ 5.4 KG. / HOUR
ARC LENGTH : 10 ~ 15 MM.
ADVANTAGE : SPATTER FREE , SMOOTH
WELDING , SAVINGS IN
MIG WIRE
WELDING DEFECT
 POROCITY
 BLOW HOLES
 PENINTRATION LESS
 WELDING BEAD NOT SIMILAR
 MELTING IMPROPER
 CRACKING
 UNDER CUT
 SPATTER
WELDING DEFECT
POROSITY:
1- GAS FLOW TOO MUCH OR LESS.
2- NOZZEL BLOCK ( JAMMED WITH SPATTER ) &
SHIELDING IMPROPER.
3- LEAKAGE OF GAS LINE.
4- WELDING METHOD WRONG DURING WELDING
5- MORE DISTANCE BETWEEN JOB & NOZZEL.
6- DUST, PAINT, RUST,GREESE, WATER DEPOSITED ON SURFACE.
7- MIG WIRE USE RUSTY OR WET CONDITION.
8- COPPER COATING IMPROPER IN MIG WIRE
.
WELDING DEFECT
LESS PENITRATION :
1- LESS CURRENT.
2- LESS GAP OR NOT GAP IN WELD JOB.
3- MORE GAP BETWEEN METAL TO METAL.
4- CONTACTOR BURNT DURING WELDING
( CURRENT, VOLTAGE, FLUCTUATE )
5- WRONG POSITION OF TORCH.
6-WELD JOINT GETTING NOT SIMILAR.
7- NON AVALIBILITY OF MIG WIRE FROM FEEDER TO JOB
8- LEFT HAND ( PULL ) WELDING DONE ON JOB.
WELDING DEFECT
WELD BEAD NOT SIMILAR :
MIG WIRE .STICK OUT(EXTENSION FROM THE NOZZLE)
1- TENTION IN
2- ROLLER PRESSURE IMPROPER.
3- LESS TRAVEL SPEED .
4- WIRE DOES NOT STRAIGHT OUT FROM TIP .

5- HIGH VOLTAGE & LESS CURRENT .
WELDING DEFECT
MELTING IMPROPER :
1- LESS VOLTAGE .
2- SOME TIMES CURRENT AND VOLTAGE MORE
3- JOB SURFACE NOT SIMILAR
4- TORCH DRIVE IN WRONG DIRECTION .
WELDING DEFECT
CRACKING :
1- JOB TO BE PRE HEATED .
2- RIGHT QUANTITY OF SULPHER & MAGENESE

NOT MAINTAIN IN MIG WIRE .
3- TOO MUCH LESS THICKNESS OF ROOT BEAD.
WELDING DEFECT
UNDER - CUT :
1-MORE WELD SPEED
2-MORE CURRENT
3-WIRE FEED LESS & VOLTAGE MORE
4-OVER HEAT OF JOB
5-TORCH ANGLE NOT PROPER
6-GAS FLOW IMPROPER
WELDING DEFECT
SPATTERS :
1-MAXIMUM VOLTAGE
2-PURITY OF SHIELDING GASES
3-IMPROPER SHIELDING
4-VARIATION IN ARC STICK
5-MIG WIRE BEND,RUSTY,DUSTY MELTING
TEMPRATURE MORE,MAGNISE IMPROPER
6-TORCH ANGLE NOT PROPER
7-GAS FLOW IMPROPER
MIG WELDING:
TOLERANCE ON THICKNESS WISE:
Passion for People

Tooling

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Tooling

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Source – SKH Ownership | Innovation & Excellence | Customer Delight | Respect, Fairness & Transparency

CASTING TYPE PLATE TYPE

STRAIGHT DIE BUTTON PACKING: THIS IS USED FOR DIE

SPRING PLUGS FOR DOWEL PINS :

BALL BEARING INTEGRATED TYPE GUIDE POSTS / GUIDE

RETAINER PIN : IN DIE GENERALLY USED FOR IN PAD HOLDING

STOPER PLATE: THIOS IS USED FOR RETAINER PIN LOCKING

BLANK HOLDER STOPER: THIS IS USED FOR BLANK HOLDER

ROUGH GUIDE: THIS TYPE GUAGE USED FOR PROFILE

COILED MATERIAL GUIDES: THIS TYPE GUAGE USED IN

LOCATING PILOT PIN: THIS IS USED FOR PART LOCATING FOR

COIL SPIRING:THIS IS USED FOR PAD EJECTION

ENGRAVING BLOCK PUNCHES: THIS IS USED FOR PART

DOWEL PIN EXTRACTOR: THIS IS USED IN DIE FOR DOWEL

SHIMS FOR DISTANCE PLATE: THIS IS USED IN DIE FOR DIE

PROVIDE PROPER CLERENCE BETWEEN DIE

DIE BUTTON AND PUNCH RESHARP OR

DIE BUTTON AND PUNCH FITTING TIGHT

REPLACE WITH NEW GUIDE PILLAR & BUSH

CORRECT THE ALIGNMENT BETWEEN PUNCH

CORRECT THE PARALLSLISM BEFORE DIE

ALL PACKING HEIGHT EQUALE AS PER

CUTTING INSERT HARDNESS REQUIRED 58~60

BEFORE DIE LOADING CORRECT DIE PLATE

PROVIDE DOWEL IN ALL CUTTING INSERT AND

BLANK SIZE LESS OR GUAGE LOOSE

WEARE AND TEAR OF LOCATION PIN/STOPPER

MISS MATCH OF CUTTING EDGE

REPLACE WITH NEW GUIDE PILLAR & BUSH

PUNCH WORN OUT/POSITION NG OF PUNCH

WEARE AND TEAR OF LOCATING PINS

LESS GASS SPRING PRESSURE,MAIN PRESSURE

DIE MATCHING SURFACE WORN OUT,IMPROPER

IMPROPER CLERENCE BETWEEN UPPER AND LOWER

FOREIGN MATERIAL IN DIE ,SHEET THICKNESS NOT

MISS FEED BY OPERATOR ,DIE GUAGE BLANK

 Both Side Trim.

Both hole shift in

 Final process sheet 45812-

2 - DROP SIZE OF DIAMETER GREATER THAN THAT OF WIRE

CURRENT : 200 ~ 300 AMP.

CURRENT : 220 ~ 500 AMP.

2- ROLLER PRESSURE IMPROPER.

3- LESS TRAVEL SPEED .

4- WIRE DOES NOT STRAIGHT OUT FROM TIP .

2- SOME TIMES CURRENT AND VOLTAGE MORE

3- JOB SURFACE NOT SIMILAR

4- TORCH DRIVE IN WRONG DIRECTION .

2- RIGHT QUANTITY OF SULPHER & MAGENESE

3- TOO MUCH LESS THICKNESS OF ROOT BEAD.

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