EB518

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Press Tool Design (Combination Dies)

Actrac Products Ltd/ Australian National Training Authority 1997 1

MODULE TITLE P R E SS TOOL DE SIGN (COMBINATION

DIE S )

N o m i n a l Du r a t i o n Two Modules

M od u l e C o d e o r N u m b e r EB518

Mo d u l e P u r p o s e The pu rpose of this m odule is for t he pa rt icipan t

to design combina tion dies su ita ble for use in

single, double an d t riple action pr esses.

R e la t i o n s h i p t o

C om p e t e n c y S ta n d a r d s This m odule will be modified in line with th e

requirement s of th e Nat ional m etals and

En gineering Stan dar ds when t hey become

available.

The module cont ains t he kn owledge an d skills

identified and agreed by all sta tes/terr itories. It

ha s been developed on t he assu mpt ion t ha t t hese

will be reflected in t he sta nda rds.

P r e r e q u i s i t e s (EB517) Pr ess Tool Design (Simple Bend ing

Operations)

S u m m a r y of C o n t e n t 1. Compound and Combina t ion Dies .

- P rin ciples

- s ingle sta t ion opera t ion

- common centre l ine design

- basic compound die operations

- blanking

- piercing

- notching

- basic combination die operations

- blanking

- piercing

- bending

- forming- drawing

- Common design fea tures

- Des ign characte r is t ics

- inver ted

- convent ional

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2 Actrac Products Ltd/ Australian National Training Authority 1997

- Ejection and knockout systems

- shedding

- shedder

- st r ipping

- st r ipper

- eject ion

- ejector

- knockout cap

- shaft

- spreader

- t ransfer pins

- Cut t ing act ion of d ies

- op pos it e dir ect ion s

- sam e dir ect ion

- Bur r side effect- blank and slug

- pier ced open in g

- sin gle bur r side

- Cu t t in g clea r an ces

- t oolm a kin g fa cilit y

- reduct ion of cu t t ing force

- at t r it ion

- Die openings and angular clearance- d iffe ren t ia l cu t t ing clea rance

- s ize rela ted to d ie life

- Component character is t ics

- fla tness

- dim en sion a l a ccu r acy

- bur r sides

- Ut ility cons idera t ions

- die cush ions

- la rge com pon en ts

- use of solid die bols ter p la tes

- Shedding, st r ipp ing and pressure pads

- Compressive a rrangements

- k nock ou t pr op or t ion s

- sh edder pr opor t ion s

- spr in g select ion

- t ra nsfer m et hods

- spr ing loca t ion and confinement

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- Percuss ive a rrangemen ts

- k nock ou t pr op or t ion s

- sh edder pr opor t ion s

- Knockout-to-press re la t ionships

- adjustments- servicing

- op er a t or an d die sa fet y

- Shedding p ins and shedding vents

- r idda nce a ct ion

- pin a rr angement s

- locat ion

- pr essu r ised a ir ven t s

- P r essu r e pa d ar r a ngem en t s- bla n k h oldin g fu n ct ion

- pa d pr opor tions

- t ra nsfer m et hods

- Strippers , s tops and s tock guides

- ma ter ia l clamping funct ion

- spr ing loca t ion and confinement

- st r ipper bolt s

- st op loca tion

- st op ar r a ngem en t s for s pr in g

strippers

- Die b locks and punches

- Design a r r an gem en t s

- inver ted

- con ven tion al

- Const ruct ion methods

- one piece die cons t ruct ions

- compos ite d ie cons t ruct ions- punch pla tes

- bla nkin g pu nch

- pier cin g pu nch es

- for min g pu nch

- Location, a l ignment and retention

methods

- die a n d p un ch in set m ou n tin g

- dowelling

- t hr ea ded fa st en er s

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- Tool constru ction mat erials and service

conditions

- Die par t mate r ia l select ion

- Service condit ion

- t rea tment

- har dness value

- Die ca t egor ies

- Opera t ion and applica t ion

- Compound d ie types

- bla nk an d pier ce

- bla n k, p ier ce an d not ch- t r im and pierce

- sh ave a nd pier ce

- broaching

- Combina t ion die types

- blank and draw

- bla nk, dr aw a nd t rim

- dr aw, for m a nd pier ce

- r edr aw a nd pin ch tr im

- r ect an gu la r bla nk an d dr a w

- shell making- louver ing

- clip for ming

- bla n k, pier ce a n d ben d

- blank , p ierce and coin

- bla n k, for m an d p ier ce

- cu toff, form and pierce

- b lank , form, draw, t r im and p ie rce

- blank , p ierce and emboss

2. Design and draw combination press tools of

invert ed design for blank , pierce anddeform ing operat ions.

- Design principles and conventions

- Effect ive des ign concepts

- Select ion of pr ess

- Calcu la t ion of b lanking forces

- Es t imat ion of forming forces or

sprin g back allowan ces

- Repor t and ca lcu la t ion of work

design cost an d quotat ion estima tes

for tool const ru ct ion- Select ion of d ie s et .

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3. Design and draw combination press tools for

blanking and dra wing operat ions.

- Design principles and conventions

- Effective design concepts

- Select ion of p ress- Estimation of blank diameter, punch

an d die diamet ers

- Report a nd calculation of work design

cost an d quotat ion est imat es for tool

construction

- Selection of die set .

D e l i v e r y Pa rt icipant s should be encour aged to adopt a

project m an agement appr oach towards achieving a

tooling design solut ion for t he pr odu ctspecificat ion assignm ent .

To achieve this, the product specification should be

presented as a project wh ere part icipants m ust

un dert ak e resear ch a nd develop a tooling design

solution.

Pa rt icipants may work individually or in t eams

wher e th ey will be required t o use t heir

backgroun d knowledge of th e meta l Stam ping

Indu str y to recomm end th e use of appr opria te t ool

ma terials an d t he t ype of equipment to produce

th e product in a man ufactu ring environment .

The key focus of th e project is for t he pa rt icipan t

to be able to achieve a work able t ool design

solution for a given product specificat ion. In

completin g the pr oject, par ticipan ts should also

estima te t he costs of design a nd pu t in quota tion

estimat es to build the die. In addition th e

participant must undertake the n ecessaryresea rch, do all n ecessar y calculations, identify

design solutions an d compet e any as sembly and

detail drawing requirement s.

The design detail may be undert aken u sing

ma nua l drafting techniques an d or a comput er

aided design dr afting facility.

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S u g g e st e d o n -jo b t r a i n i n g f o r m a x i m u m s k i ll

a c q u i s i t i o n .

Work a s a dr aftsper son/tool design assist an t in a

tool design office.

These st ra tegies ma y also involve:

- co-operat ive registered off-job

provider/employer delivery sh ar ing a vailable

resources;

- delivery by an employer who is registered as

an off-job provider , with in-house qua lified

trainers using unique resources to facilitate

on and off-job deliver;

- off-th e-job objectives mu st focus on t he

indu st ry cont ext wh ile on-the-job object ives

will reflect a pplicat ion with in En ter prise

operations.

Assessment inst ru men ts will need to be developed

by th e module pr ovider wh ich will need t o reflect

consist ency with sta ted m odule learn ing out comes

and r elat ed assessment criteria.

Altern at ive assessmen t pr ocedur es will need to be

considered an d a pplied as appropriate t o

par ticipants n eeds.

This module is practical in na tu re an d

th eoret ically int egrat ed to complemen t t he

acquisition of practical design a nd dra wing skills

which h ave relevance to indu str ial applicat ions.

Inst ru ction an d tra ining should support a nd

consolidat e th e safety r equiremen ts a ssociated

with t he ha ndling of component s an d work ing

within a process man ufactu ring environm ent.

The qu alit y of the tool design solut ion will conform

acceptable indust ry stan dards.

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L e a r n i n g O u t c o m e s On complet ion of this m odule t he lear ner will be

able t o:

Learn ing Ou tcom e 1 O b s e r v e a n d i n v e s t ig a t e t h e p r i n c ip l e s o f

c om p o u n d a n d c o m b in a t i o n d i e s a n d

d e s c r i b e t h e e s s e n t i a l e le m e n t s in o r d e r t o

p r e p a r e a n d d e v e lo p t o o l d e s ig n s f or s p e c ifi ct a s k s i n cu t t i n g a n d d e fo r m i n g op e r a t i o n s .

Assessm ent cr it er ia Given pr act ical dem onst ra t ion , sam ple

component s, sample component dra wings, sam ple

dies or die part s an d sam ple die drawings.

1.1 Identify and define the principles of die

operation.

1. Single sta tion die.2. Designs pr oduced ar oun d a comm on

cent re line.

3. Distinction between compoun d and

combination dies.

1.2 List and describe the common design features

of compound and combination dies.

1. Design cha ra cter istics.

2. Ejection and knockout systems.

3. Die cut tin g an d form ing actions.

4. Component bur r side relat ionsh ips

5. Cutt ing clearan ces and retu rn ejection.

6. Die openings and angu lar cleara nces.

7. Component cha ra cter istics.

8. Ut ility consider at ions.

1 .3 Explain the principles and define the

essent ial design featu res of component

sheddin g and st ripping in single action dies

an d pressu re pa ds in combina tion dies forspecific t ask s.

1. Compres sive an d per cus sive kn ockout

and shedder ar rangements.

2. Knockout-to-press relat ionsh ips.

3. Shedding pins and shedding vent s.

4. Pr essure pad arra ngements for

combina tion dra w dies.

5. Str ippers, stops an d stock guides.

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1.4 Analyse die designs and describe the

funda men ta l meth ods of die block a nd pu nch

const ru ctions used for cut tin g and d eform ing

operations.

1. Design ar ra ngements.

2. Const ru ction met hods.

3. Locat ion, alignmen t and reten tion

methods.

1.5 Select tool constr uction mat erials and service

conditions.

1.6 Identify, list an d cat egorise examples of dies

by applicat ion t o specific t asks.

Condit ions Access to a suitable study environment .Sam ple component s.

Sample dies or die parts.

Sam ple die dra wings.

Reference sheets an d ha ndout sh eets for each

participant.

Access t o opera tiona l dies or s imu lat ion devices.

Assessment method Short answer quest ions.

Learn ing Ou tcom e 2 D e si gn a n d d r a w c o m b i n a t i on p r e s s t o o ls o f i n v e r t e d d e s ig n i n c o r p o r a t i n g b l a n k , p i e r c e

a n d d e fo r m i n g o p e r a t i o n s .

Assessment cr iter ia Given sample component par t s or sample

component drawings, produce an appropriate

combin at ion die tool design solut ion for a specified

product an d include:

1. Assembly drawing of th e tool design solut ion.

2. Conventional views.

3. Materia ls and parts l is t .

4. Selection of a suita ble proprieta ry die set or die

set component s.

5. Fully dimensioned and toleran ced detail

dra wings incorpora tin g all essent ial die

elements.

6. Calculat ions, written r eport on work design

costs a nd quota tion estimat es to produce th e

press t ool.

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Condit ions Access to a su itable study environment and

drawing equipment. Australian standards

AS1100 and AS1634.

Pr oprieta ry cata logues of die sets, presses an d

an cillar y equipm ent an d press t ool component s.

Reference ma terial a nd h andout sheets for each

par ticipant a s required.Sample dies or die part s.

Sam ple die design dr awing illustr at ing soun d

design features.

Assessment method Pr act ical design and dr awing exercise.

Learn ing Ou tcom e 3 D e si gn a n d d r a w c o m b i n a t i on p r e s s t o ols

i n c or p o r a t i n g b la n k i n g a n d d r a w i n g

o p e r a t i o n s .

Assessment cr iter ia Given sample component par ts or sample

component drawings, produce an appropriate

combin at ion d ie tool design solut ion for a specified

product an d include:

1. Assembly drawing of th e tool design solut ion.

2. Conventional views.

3. Materia ls and parts l is t .

4. Selection of a suita ble proprieta ry die set or die

set component s.

5. Fully dimensioned and toleran ce deta il

dra wings incorpora tin g all essent ial die

elements.

6. Calculat ions, written r eport on work design

costs a nd quota tion estimat es to produce th e

press t ool.

Condit ions Access to a su itable study environment and

drawing equipment. Australian standards

AS1100 and AS1654.Pr oprieta ry cata logues of die sets, presses an d

an cillar y equipm ent an d press t ool component s.

Reference ma terial a nd h andout sheets for each

par ticipant a s required.

Sample dies or die part s.

Sam ple die design dr awings illustr at ing soun d

design features.

Assessm ent m et hod P ract ical design an d dr awin g exer cises.

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S u g g e st e d L e a r n i n g

R e s o u r c e s - Suitab le s tudy environment .

- Drafting boards (A1 or larger) on stands.

- Draft ing machine to suit boards .

- Access to computer a ided design drafting

equipmen t (if available).

- Examples of different t ypes of bending dies.

- Sample die design drawings and components

for combin at ion dies.

- Manufactur ers cata logues or die parts , presses

and a ncillar y equipment.

- Au st r a lia n s ta n da r ds.

- Pa r t icipan t handou t sheet s .

- Wor ksh eet s.

All references should be of the latest edition.

- Au st r a lia n s ta n da r ds.

1. AS1100 Part 101-1984

Au stralian En gineering Draw ing

Handbook

2. AS1100 Part 201-1984

Au stralian En gineering Draw ing

Handbook

3. AS1654-1987

Lim its an d Fits for Engin eering

- OSTERGAARD D.E. Ba sic Diem ak ing

McGraw Hill Book Co. U.S.A. 1974

- ASTME Die Design H an dbook

McGraw H ill U.S.A. 1975

- F LI NN /TROJ AN En gineering Ma terials an d

th eir Application2nd Ed. Houghton/MifflinU.S.A. 1981

- ASM Metals Han dbook-Form ingASM

Handbook Committee U.S.A. 1981

- DONALDSON/Le CAIN/GOOLD T ool Design

McGraw H ill U.S.A. 1973

- P OLLACK H.W. T ool Design

Pr ent ice H all U.S.A. 1976

- OBERG/JONES/HORTON Mach in erys

Handbook 22nd Ed

Indu str ial Pr ess Inc. U.S.A. 1983

EB518

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