Basic Good Diesetting Practices C121.

doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

BASIC GOOD DIESETTING PRACTICES

Success in any activity requires that a number of tasks be done correctly. In metal stamping, everything from poor quality parts to catastrophic die and press damage have often had the root cause traced to poor diesetting practices. Examples of good practices and warnings against bad practices are to be found throughout this training. It is very important that the good practices that are appropriate for your shop are the ones that you adopt as your standard diesetting procedures.

Diesetters Are Manufacturing Professionals

Diesetters are the elite among pressroom employees. They are chosen for the position based upon their knowledge, experience, and the desire to accept the challenge of being a key person upon whom the safety and productivity of the shop depends. Professionalism in any field requires continuous improvement of knowledge and work habits. There is no substitute for good diesetting work habits. Shortcuts that are intended to make the job easier soon become bad habits, which can cause catastrophic damage to dies and presses. Serious or fatal injury can result. The right method is usually the easiest procedure, and the safest way. In many pressrooms, the diesetter is expected to help train the operator to efficiently produce quality stampings and to use safe operating practices. In other cases, the diesetter is a multi-skilled technician. Here, he or she may do everything from run semiunattended press operations to performing equipment maintenance and die repair tasks.

Following Good Practices

Basic diesetting skills apply to all diesetting situations. It doesn't matter if the assignment is to set a die weighing less than fifty pounds in an OBI press, or dies weighing many tons each in a multi-slide transfer press. Checking for enough shut height with a tape measure is usually essential. Making sure that there is enough press shut height before setting the die is one of the most basic tasks that diesetters must do. Simply stated, the closed height of the die must not be greater than the shut height (at bottom dead center) of the press. Never guess; instead carefully double check with a tape measure.

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

The Moon Shot

Figure 1. The moon shot. Alex McNeilly

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

The Importance of Establishing Enough Shut Height

Many a diesetter has tried a moonshot without government permission simply because of leaving the tape measure in the toolbox or locker. Many stamping plants have flat roofs and are located in rainy climates. There are usually enough problems with roof leaks without trying to launch press parts into outer space through the roof. Figure 1 is an exaggerated view of what might happen if the diesetter cycles the press with insufficient shut height. The procedure to make shut height is: 1. Measure and note the die shut (closed) height. 2. Inch the press on bottom dead center. 3. Measure the opening to make sure that there is enough room. 4. Adjust the press opening to the die shut height plus a safety factor of typically 1/4-inch (6.35 MM). The tape measure is as important to a good diesetter as his or her wrench.

Figure 2. A slug between the lower die shoe and the bolster: (A) before the run; (B) during production; (C) the damage remains after the next dieset. Smith & Associates.

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

Keep the Bolster Clean

Slugs are a frequent source of problems to the diesetter. While the best plan is to have sufficient chutes of good design and construction to convey all scrap and slugs to the scrap bin or conveyor, frequently a few slugs remain.

Damage Caused by Slugs

Figure 2 illustrates a slug between the bolster and the lower die shoe. During the run, the slug will become imbedded in both the die shoe and bolster. Even if the slug is removed with the corner of a scale or scriber, the damage remains to cause an out of parallel condition.

Figure 3. A slug under the die shoe forces the slide to tip out-of-parallel with the bolster. Smith & Associates For general presswork, the accepted maximum tolerance for slide to bolster parallelism is 0.001" (0.025 mm) per foot (305 mm). Precision dies for cutting silicon steel used in electrical motor production require an even more precise out-of-parallel tolerance. A single 0.030" (0.76 mm) slug under one end of a three-foot (914-mm) long die shoe will cause an out-of-parallel condition that will exceed the generally accepted tolerance by a factor of ten. Figure 3 is an exaggerated view of a slug under a die shoe.

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

Slugs can become a Safety Hazard

When the slug becomes embedded in the die shoe and bolster, the die clamps may loosen. Slugs underfoot are a slipping hazard. All slugs must be cleaned up before proceeding with setting a new die.

Slugs Can Damage Dies

The out-of-parallel condition caused by slugs under a die can result in press and die damage. Figure 4 illustrates a type of damage that can occur. The damage is not confined to cutting edges. The entire press and die can be damaged by misalignment.

Figure 4. Example of damage to a cutting die caused by an out-of-parallel caused by a slug or other foreign object under the die shoe. Smith & Associates

Slugs can affect the process

Since a single slug can cause a drastic change in the die clearances that determine the actual product produced. SPC data is an excellent source of information on the effect that poor diesetting practices such as setting a die in the wrong bolster location or on a foreign object can have on the process. If the process running is out of the control limits, an improper setup may be the root cause. A foreign object under the die can literately be buried into the die shoe. Several causes can be responsible which include: 1. A slug or foreign object under or on the die. 2. Press misalignment. 3. Die out of parallel or not centered in the press.

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

Figure 5. Close-up view of cutting edge damage shown in Figure 4. Smith & Associates

Figure 6 illustrates the damage that can occur. In (A) the set-up block is making normal contact with the upper die shoe. (B) Illustrates the block mushroomed out and literately imbedded into the upper die shoe. The lower shoe is damaged as well. The displaced metal in the shoes will spoil the precision fit of the guide pin and bushing holes.

Figure 6. Die damage caused by an out of parallel condition such as a slug under the die. Smith & Associates

Repairing a Slug Mark 6

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

Setting dies on slugs and the resultant slug marks greatly accelerate bolster plate wear. Metal is displaced and worn away. Care in avoiding slug marks will greatly reduce the need to resurface bolster plates. In the event that a slug becomes embedded in the bolster plate, it should be picked out with a pointed tool. Next, the upset metal is peened down with a hammer. The spot is then finished flat with a file or oilstone. This procedure minimizes the amount of metal removed and the size of the remaining low spot.

Avoiding Slug Problems

The best cure for any problem is prevention. Proper slug chutes are a necessity for top quality pressworking. In some shops, the diesetters are expected to fabricate the required scrap chutes. Often large stamping plants have a millwright or tinsmith that makes the needed chutes. This may also be a responsibility of the diemaker or die technician.

Keeping Slugs Out of the Tee Slots

A few slugs always seem to bounce out of the finest of chutes and find their way into the tee slots. Figure 7 shows how inserts can be placed into a tee slot to prevent a buildup of stray slugs. Hardwood is a low cost popular material. Rectangular steel structural tubing is a better long-term choice if available in the sizes needed.

Figure 7. The use of inserts to keep slugs and debris out of unused bolster T-slots. Smith & Associates

Tools Required For Chute Construction

Good chute construction requires a sheet-metal shear and box-brake suitable for the metal thickness worked. The usual range of thicknesses is from 11 to 16 gage. Purchasing a sheet metal shear and brake capable of working the heaviest gage metal to be formed is actually an investment in good housekeeping. The alternative is to form poorly fitting chutes from whatever coil stock is on hand.

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

Figure 8. Sheet metal shear and box brake used for press and die chute fabrication. Smith & Associates

Proper Chute Storage

Keeping scrap and slug chutes in tip top condition requires everyone's cooperation. It does little good to be able to change dies quickly if several additional hours are required to construct replacements for missing chutes. Without a good system, chutes may be lost, damaged beyond repair or cannibalized for another job. A designated storage procedure is required for all chutes. Often the chutes can be left with the die provided it is possible to transport the die to and from the storage rack without damaging the chutes. If wall space is available, it can provide an excellent place to hang chutes for storage. Painting an outline of each chute together with the appropriate job or die number on both the chute and the wall is a very good method. Visitors to the shop can be expected to make favorable comments about such a system. Other systems such as storage in racks and tubs can also be used. Some highly automated stamping plants such as Ford Motor Company's Wayne, Michigan integrated stamping and assembly facility have automated storage and retrieval systems which operate with computer control to store change over items that cannot be stored with the dies. As a metalworking professional, the diesetter has a responsibility to help insure that all chutes and production aids are stored correctly. Helping management devise good storage systems is a natural outlet for a good diesetter's talents.

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

Centering the Load in the Press

Maintaining correct die clearances is a basic requirement for producing high quality stampings. If the load is not centered in the press, critical die clearances will be changed.

Centering the Load in the Press

Figure 8. An exaggerated view (A) of the press deflection that is a normal result of developing the tonnage needed to do presswork; the die offset to one side of the press (B) for operator or set-up convenience; unequal loading results in an out-of-parallel condition (C) when press deflection occurs; to correct off-center loading of a press, a simple production aid or stock guide (D) may be all that is required. Smith & Associates Off center loading actually results in an out-of-level condition much like that caused by setting a die on a slug. This is because the press must deflect in order to develop tonnage. If the load is centered the deflection is uniform and the slide remains parallel to the bolster. If the load is not centered, the greatest deflection occurs in the side of the press with the greatest load resulting in an out-of-parallel condition.

Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

In the case of cutting dies, too little clearance between the punch and die will result in excessive cutting pressures, which will break down the cutting edges quickly. Too much clearance will result in excessive burrs. Ram tipping will also result. This will cause rapid wear of the gib liners and other important press parts. Figure 8 (A) illustrates an exaggerated view of the press deflection that is a normal result of developing the tonnage. Just as a spring must change shape or deflect to develop pressure, a press must deflect to develop tonnage. The illustration shows a small die centered in a large straightside press. Not all of the press tonnage capacity is safely usable. As a rule, at least 70% of the press bed should be occupied with a centrally placed die shoe if full press tonnage is to be developed. Developing full tonnage with a small die can result in damage to the press slide and bed due to excessive localized deflection.

Reasons for Offsetting Dies

The most common reason for offsetting dies from the center of the press is for the loading convenience of the operator. Offsetting the die may satisfy ergonomic considerations. The operator does not have to reach or bend as far to place and remove parts from the die. Productivity and operator comfort go hand-in-hand. Another reason dies may be offset in the press is the lack of a proper coil stock guide. Figure 8 (B) illustrates a die offset to one side of the press to move closer to the coil feeder.

The Effect of Unbalanced Loading

Figure 8 (C) illustrates the result of unequal loading. The result is an out-of-parallel condition when the press deflects to produce force. The short-term effect is press misalignment under pressure. The quality of work and number of pieces produced between die sharpenings will be lower than would be the case if the load were centered. The long-term effect is uneven press wear. Bearings will not wear evenly, resulting in an out-of-parallel condition in the future. The gibbing will be subjected to high-localized pressures resulting in rapid uneven wear and scoring.

Solutions to Off-center Die Placement

A good solution usually requires a careful analysis of all factors. solutions may include asking the following questions: Common sense

1. Is a smaller press available so the operator won't need to reach as far to place the blank? 2. Can a production aid be constructed to permit the part to slide into correct location by gravity or automatic movement?

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Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

3. Is it possible to operate two dies in the same press to correctly balance the loading? 4. Is the placement of nitrogen cylinders on one side of the press to balance the load a practical solution? 5. Is there a good reason for offset loading such as placing a progressive die to one side to balance the force? Figure 8 (D) illustrates a simple stock guide used to correct the problem.

Figure 9. Out-of-location stock can cause die damage: (A) out-of-location stock in a die; (B) a partial cut results in the stock being flanged into a die opening causing the die shoes to be displaced sideways; (C) the damage that results. Smith & Associates

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Basic Good Diesetting Practices C121.doc 1993, 2005 REV June 29, 2005 Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943.

Avoid Mishit Damage

Many dies are designed with balanced cutting action. This is done in order to avoid side thrust, which can change die clearances. If the part design or stock layout will not permit balanced cutting action, very large guide pins or heel blocks are required to limit the side-movement to an amount that is acceptable. Mis-positioned stock can damage the die. The unbalanced loading can be so severe that the stock is flanged rather than cut. Figure 9 illustrates how this happens. Out-of-location stock (A) is flanged into a large cutting die opening due to the unbalanced cutting action resulting from mislocated stock (B). Because the cutting clearance is only 10% of the stock thickness, the side displacement is so great that the punch and die cutting edges hit upon die closure and are damaged (C). It is very important that everyone be aware of how this type of damage occurs and how it may be avoided. Honest reporting of any damage of this type is important also. The damage shown in Figure 9 C could be reported as a broken punch. Replacing the small punch in the press would not fix the damage to the other stations. Press time should not be wasted. A die damaged this badly should be taken to the dieroom for extensive repair.

Floating Lower Dies

Some diesetting is accomplished under less than ideal circumstances. In many shops, die shoes with guide pins and bushings are considered a luxury. For many punching, forming, embossing and drawing applications, the punch is simply fastened to the press slide and the die fastened to the bolster after careful alignment. Exact alignment requires considerable skill on the part of the diesetter. This procedure involves allowing a controlled side movement of the lower die before it is tightly clamped in place. This practice is usually necessary when tooling is not mounted in a dieset. Usually a part is in place when this procedure is followed. The lower die is permitted to "float" into position while the press is carefully inched to bottom. The lower die is then tightened into position. Never perform this procedure without first making sure that it can be done safely, and in accordance with plant and government safety rules.

Floating in Badly Worn Dies

The floating technique can sometimes be of value when problems such as worn guide bushing and press wear or poor alignment result in loose burrs on one side of a trim panel or uneven sidewall thinning in deep drawing operations. At best it is a stopgap measure because floating does not address the root cause of the problem. In addition, plant and government safety rules may not permit the procedure.

NOTES: _____________________________________________________

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