IN-DIE TAPPING TOOLS - Danly · The special forming taps used in the in-die taping units are...

© 2004 Danly IEM, A Division of Connell Limited Partnership

IN-DIE TAPPING TOOLS

TECHNICAL INFORMATION MANUAL

CALL TOLL FREE: 1-800-243-2659FAX: 1-800-833-2659

1

www.danly.com

THIS MANUAL CONTAINS INFORMATION APPLICABLETO THE FOLLOWING IN-DIE TAPPING TOOL MODELS:

HY1024

ME1024

LP25M6

♦ PRODUCT SPECIFICATIONS 2

♦ ACCESSORIES 5

♦ TAPPING DEPTH/MATERIAL THICKNESS CHARTS 8

♦ FORMING TAP PRE-HOLE SIZE CHARTS 9

♦ APPLICATION DRAWINGS 11

♦ DESIGNING A CAM DRIVER 38

♦ RAPID T.A.P. CAM DESIGN SOFTWARE INTRODUCTION 39

♦ TROUBLE SHOOTING 40

(Patent #5173015)

TABLE OF CONTENTS PAGE NUMBER

2

www.danly.com

HY1024 Seriesfor Hydraulic Presses

The HY is the smallest and most compact of the tapping tools.The HY1024 is an economical solution for tapping from the top downin a hydraulic press. Since the HY1024 is not cam actuated, the presscontrols the acceleration and tap speed. The HY1024 will tap size#0 - #12 or up to M5 and typically runs at production rates between60 - 100 strokes per minute up to a maximum 200 (SPM) rate basedon strip material, tap size and tap pitch.

By utilizing multiple tools in place of one special tapping tool, youcan control flexibility in the stamping operation and greatly reducedowntime due to unscheduled maintenance.

Product Features

HY1024

HY1024 footprint dimensions

Notes: ♦ Tapping depth/maximum material thickness can be found on Page 8.♦ Metric dimensions are in italics.

NOTES:

♦ The HY1024 tapping tool cannot be used in a mechanical press. See the ME1024 or the LP25M6 forapplications requiring use in a mechanical press.

3

www.danly.com

The ME1024 is a simple and compact tool with a small footprintfor tapping top down in a mechanical or hydraulic press. The ME1024utilizes a cam driver to control tool acceleration. The ME will tap size#0 - #12 or up to M5 and typically runs at production rates between60 - 100 strokes per minute up to a maximum of 200 (SPM) basedon strip material, tap size and pitch.

The cam driver is designed as a separate functional piece to maximizedie design flexibility and take the sinusoidal motion that is inherentwith mechanical presses and turn it into a rotary tapping motion. Thecam driver mounts easily on a punch plate or upper die shoe above thetapping tool. The cam driver is application specific and can bemanufactured by using the free “Rapid TAP” CAD design software.


Product Features

ME1024 Seriesfor Mechanical Presses

ME1024

Notes: ♦ Tapping depth/maximum material thickness can be found on Page 8.♦ All dimensions are in inches.

A = TAPPING STROKE + 5.776

ME1024 footprint dimensions

4

www.danly.com

The LP is the most versatile tool with a simple and compact designfor tapping top down, bottom up or at any angle. The LP utilizes a camdriver to control tool acceleration and tap speeds. The LP25M6 will tapsize #0 - 1/4 or M6 and the LP516M8 will tap 1/4" - 5/16" or M8 whilemaking either right or left-hand threads. The LP typically runs atproduction rates between 20 - 60 strokes per minute up to a maximumof 100 (SPM) based on strip material, tap size and pitch.

The cam driver is designed as a separate functional piece tomaximize die design flexibility and take the sinusoidal motion that isinherent with mechanical presses and turn it into a rotary tapping motion.The cam driver mounts easily on a punch plate on the upper die shoeabove the tapping unit to provide the proper amount of tap accelerationand a positive return. The cam driver is application-specific and can bemanufactured by using the free “Rapid TAP” CAD design software.


LP25M6 & LP516M8 Seriesfor Mechanical Presses

LP25M6

Product Features

Notes: ♦ Footprint dimensions are identical for both units.However, performance variations exist between thetwo units. Consult the Rapid Tap software.

LP25M6 & LP516M8 footprint dimensions

NOTE A: Dowel pin holes ±0.001Fastener holes ±0.005

The shut height from the bottom of the upper shoe to themounting surface of the unit cannot be less than 3.775",unless modified (see installation manual).

ImportantNote

LP Cam Driver profile

♦ Tapping depth/maximum material thickness can befound on Page 8.

♦ All dimensions are in inches.

5

www.danly.com

Accessories andReplacement Parts

LP STANDARD EXTENSION

LP EXTRA LONG EXTENSION

Some applications require a wide strip width incorporating atapped hole located a distance from the edge of the material. The LPintegrates modular extensions in combination with a standard tool toprovide flexibility in design and off-the-shelf type components.

The standard Cam Extension provides over 9" of extra lengthwhile the extra long extension provides over 19". All components aremade from the best materials for maximum life and performance.

LP Extensions

Notes: ♦ All dimensions are in inches.

6

www.danly.com


The special forming taps used in the in-die taping unitsare available in inch and metric standard sizes listed below. Allforming taps are sold with a TiN coating as standard. Othercoatings for special material applications are available onrequest. Forming taps provide a superior quality and finish ofthread, with no chip formation.

Forming Taps —Product Features

R-006004 Small 2 - 56 - RH3R-006008 Small 4 - 40 - RH5R-006033 Small 4 - 40 - RH7R-006010 Small 5 - 40 - RH5R-006013 Small 6 - 40 - RH5R-006009 Small 4 - 48 - RH5R-006012 Small 6 - 32 - RH5R-006031 Small 6 - 32 - RH7R-006014 Small 8 - 32 - RH5R-006030 Small 8 - 32 - RH7R-006017 Small 10 - 32 - RH6R-006032 Small 10 - 32 - RH8R-006016 Small 10 - 24 - RH6R-006019 Small 12 - 28 - RH6R-006018 Small 12 - 24 - RH6R-006021 Medium 1/4 - 28 - RH6R-006090 Large 1/4 - 28 - RH6R-006020 Medium 1/4 - 20 - RH6R-006091 Large 1/4 - 20 - RH6R-006092 Large 5/16-32 – RH6R-006093 Large 5/16-24 – RH6R-006094 Large 5/16-18 – RH7

INCH SIZES

Part Number Shank Size1 Tap Size & D Limit

R-006042 Small M2.0 x .40 D5R-006044 Small M2.5 x .45 D5R-006045 Small M3.0 x .50 D5R-006046 Small M3.5 x .60 D6R-006047 Small M4.0 x .70 D6R-006049 Small M5.0 x .80 D7R-006050 Medium M6.0 x 1.00 D8R-006095 Large M6.0 x 1.00 D8R-006096 Large M8.0 x 1.00 D8R-006097 Large M8.0 x 1.25 D8

METRIC SIZES

Part Number Shank Size1 Tap Size & D Limit

Taps are sold in packs of 12.

Standard Stock Taps are TiN CoatedSpecial Tap Sizes, Pitches and Coatings are Available per Quotation

1 Tap diameter shank size application:♦ Small – 0 - #12 (M2 – M5) diameter taps: use in HY1024, ME1024, LP25M6♦ Medium – ¼" (M6) diameter taps: use in LP25M6♦ Large – ¼" – 5/16” (M6 - M8) diameter taps: use in LP516M8

7

www.danly.com

METRIC SIZESTap Part Part Part

Holder Number Number NumberPitch Size1 for for for

HY/ME1024 LP25ME LP516M80.40 mm Small R-002048 R-002068 —0.45 mm Small R-002047 R-002067 —0.50 mm Small R-002046 R-002066 —0.60 mm Small R-002045 R-002065 —0.70 mm Small R-002044 R-002064 —0.80 mm Small R-002042 R-002062 —1.00 mm Medium — R-002060 —1.00 mm Large — — R-0021161.25 mm Large — — R-002117

INCH SIZESTap Part Part Part

Holder Number Number NumberPitch Size1 for for for

HY/ME1024 LP25ME LP516M856 Small R-002005 R-002024 —48 Small R-002006 R-002025 —40 Small R-002007 R-002026 —32 Small R-002008 R-002027 —28 Small R-002009 R-002028 —28 Medium — R-002031 —28 Large — — R-00211224 Small R-002010 R-002029 —24 Large — — R-00211320 Medium — R-002030 —20 Large — — R-00211418 Large — — R-002115

Pitch inserts are interchangeable components of the tapping operation and are specific tothe tap pitch of the tapped hole. Each pitch insert contains a tap holder with a quick releasedepression collar. Taps can easily be changed within seconds in most applications.

For applications needing a little extra reach to tap inside an embossment, a pitch insertextension can be made specific to your needs. Our engineering department will work with youon your specific application.

Pitch Inserts/Tap Holders —Product Features


Pitch insert for non-standard sizes orpitches are by quotation.

1 Tap diameter shank size application:♦ Small – 0 - #12 (M2 – M5)

diameter taps: use inHY1024, ME1024, LP25M6

♦ Medium – ¼" (M6) diametertaps: use in LP25M6

♦ Large – ¼" – 5/16" (M6 - M8)diameter taps: use in LP516M8

8

www.danly.com

Maximum Tapping Depth/Material Thickness

NOTE: Maximum material thickness (T) includes extrusion height and .020 inch (or 0.5mm) gap betweenthe tip of the tap and the top of the material stock.

MAXIMUM MATERIAL THICKNESS (T) - INCHSize and HY & ME

Pitch 1024 LP25M6 LP516M8

2-64 0.080 0.168 —2-56 0.091 0.194 —3-56 0.091 0.194 —3-48 0.106 0.230 —4-48 0.106 0.230 —4-40 0.128 0.253 —5-44 0.116 0.280 —5-40 0.128 0.280 —6-40 0.128 0.280 —6-32 0.159 0.272 —8-36 0.142 0.261 —8-32 0.159 0.261 —10-32 0.159 0.261 —10-24 0.213 0.248 —12-28 0.182 0.248 —12-24 0.213 0.230 —1/4-28 — 0.230 0.3191/4-20 — 0.205 0.305

5/16x32UN — — 0.2775/16x24UN — — 0.3555/16x18UN — — 0.286

MAXIMUM MATERIAL THICKNESS (T) - METRICSize and HY & ME

Pitch 1024 LP25M6 LP516M8

M2 x .4 2.0 4.2 —M2.5 x .45 2.2 4.8 —

M3 x .5 2.5 5.4 —M3 x .6 3.0 6.6 —

M3.5 x .6 3.0 6.6 —M4 x .7 3.5 6.9 —M5 x .8 4.0 6.6 —M5 x .9 4.5 6.2 —M6 x 1.0 — 5.9 8.9M8 x 1.0 — — 8.9M8 x 1.25 — — 8.2

9

www.danly.com

65% THREAD 70% THREAD 75% THREADTAP SIZE/ THEOR. HOLE THEOR. HOLE THEOR. HOLE

PITCH (mm) SIZE (mm) SIZE (mm) SIZE (mm)M3 x 0.5 2.779 2.762 2.745M3 x 0.6 2.735 2.714 2.694

M3.5 x 0.6 3.235 3.214 3.194M4 x 0.4 3.823 3.809 3.796M4 x 0.7 3.691 3.667 3.643

M4.5 x 0.75 4.169 4.143 4.118M5 x 0.8 4.646 4.619 4.592M5 x 0.9 4.602 4.572 4.541M6 x 1.0 5.558 5.524 5.490

M6.3 x 1.0 5.858 5.824 5.790M7 x 1.0 6.558 6.524 6.490M8 x 1.0 7.558 7.524 7.490M8 x 1.25 7.448 7.405 7.363M10 x 1.25 9.448 9.405 9.363M10 x 1.5 9.337 9.286 9.235M12 x 1.25 11.448 11.405 11.363M12 x 1.75 11.227 11.167 11.108

METRIC COLDFORMING TAPS

NOTE: The shaded pre-hole sizes in the above table have been changed, as they wereincorrectly calculated in earlier versions of this manual.

PRE-HOLE SIZE CALCULATION

Hole size = Basic Major Diameter - Percent of Full Thread x mm Pitch

147.06

Example: Find the theoretical pre-hole punch size for M8 x 1.25mm to produce 65% thread:

Hole size = 8.00 - 65 x 1.25 / 147.06= 8.00 - 0.5525= 7.448mm

NOTE: Tapping an undersize hole may result in tap breakage due to excessive torque. As astarting recommendation, 65% thread should be considered.Tapping over 75% of thread is not recommended.

Pre-Hole Sizes

10

www.danly.com

INCH COLDFORMING TAPS

PRE-HOLE SIZE CALCULATION

Hole size = Basic Major Diameter - Percent of Full Thread

Number of Threads per Inch

Example: Find the theoretical pre-hole punch size for 1/4 - 20 to produce 65% thread:

Hole size = 0.250 - 0.0068 x 65/20= 0.250 - 0.0221= 0.2279 inches

65% THREAD 70% THREAD 75% THREADTAP SIZE/ THEOR. HOLE THEOR. HOLE THEOR. HOLEPITCH (in) SIZE (in) SIZE (in) SIZE (in)0 – 80 NC 0.0545 0.0540 0.05361 – 64 NC 0.0661 0.0655 0.06501 – 72 NF 0.0669 0.0633 0.06592 – 56 NC 0.0781 0.0774 0.07692 – 64 NF 0.0791 0.0785 0.07803 – 48 NC 0.0898 0.0890 0.08843 – 56 NF 0.0911 0.0904 0.08994 – 40 NC 0.1010 0.1000 0.09934 – 48 NF 0.1028 0.1020 0.10145 – 40 NC 0.1140 0.1130 0.11235 – 44 NF 0.1150 0.1141 0.11346 – 32 NC 0.1243 0.1230 0.12216 – 40 NF 0.1270 0.1260 0.12538 – 32 NC 0.1503 0.1490 0.14818 – 36 NF 0.1518 0.1507 0.1498

10 – 24 NC 0.1717 0.1700 0.168810 – 32 NF 0.1763 0.1750 0.174112 – 24 NC 0.1977 0.1960 0.194812 – 28 NF 0.2003 0.1989 0.19781/4 – 20 NC 0.2280 0.2260 0.22451/4 – 28 NF 0.2343 0.2329 0.2318

5/16 – 18 NC 0.2879 0.2861 0.28425/16 – 24 NF 0.2941 0.2927 0.29123/8 – 16 NC 0.3474 0.3452 0.34313/8 – 24 NF 0.3566 0.3552 0.3537

7/16 – 14 NC 0.4059 0.4035 0.40117/16 – 20 NF 0.4154 0.4137 0.41201/2 – 13 NC 0.4660 0.4634 0.46081/2 – 20 NF 0.4779 0.4762 0.4745

NOTE: Tapping an undersize hole may result in tapbreakage due to excessive torque. As astarting recommendation, 65% threadshould be considered.Tapping over 75% of thread is notrecommended.

Pre-Hole Sizes

11

www.danly.com

FIGURE #1

LOW PROFILE TOOLS TAPPING FROM THE BOTTOM UP

UPPER DIE

BOTTOM DIE

MACHINED POCKETS

CAM

FOR CAM CLEARANCE

DIEDIE

MATERIAL

MATERIAL

MACHINE POCKET INDIE SET FOR DESIREHEIGHT.

STRIPPERSPACER BLOCK

(IF NEEDED)

THIS DRAWING IS SHOWING THE LP25M6 IN THE CLOSED POSITION.

8 PLACES1/4 S.H.C.S.

MACHINE GROOVE TO ALLOWPASSAGE FOR GREASE GUN.

HEEL BLOCK

NITROGEN SPRING CAN BE USED

TO ELIMINATE TOO LONG OF A DIE SPRING.

SPRING TRAVEL IS BASEDON TAPPING STROKE, PLUSPRELOAD ON MATERIAL BEFORETAPPING. (PRELOAD WILL INSURE PROPER STRIPPING FOR TAPPING.)

STRIPPER INSTEAD OF A SPRINGSTRIPPER IF DESIRED.

CUSTOMER CAN USE A BRIDGE

D-04-1002

Application Drawings

12

www.danly.com

FIGURE #2

LOW PROFILE TOOLS TAPPING FROM THE TOP DOWN

UPPER DIE

BOTTOM DIE

DIE STRIPPER

MACHINED POCKETS

CAM

SUPPORT BLOCKFOR CAM CLEARANCE

THE SUPPORT BLOCK

BOLT

S.H.C.S. TO HOLD CAM TO DIE.

LP25M6 IS BOLTED TO THE STRIPPER AND

CAM

THIS WILL ALLOW A SMALLER SHUT HEIGHT.REMOVE BRIDGE PLATE, (1.00 inch THICK)

HEEL BLOCK

D-04-1003


13

www.danly.com

FIGURE #3

HEEL BLOCKS FOR LOW PROFILE TOOLS

0.9250

CAM TRACK

CAM FOLLOWER

SHIMS FOR CLEARANCE ON SET UP.

PARALLEL

0.3750

3.1000

0.5000

0.2500

1.0000

2.0000 2.6000

1.3000

0.50000.5000

45° X .02 (4PLS)

CLEARANCE POCKETS FOR CAM

0.65600.4000

0.8000

1.3120

0.2500

0.5000

X .02 (4PLS)45°

BACK HEEL BLOCK

FRONT HEEL BLOCK

BACK HEEL BLOCK

FRONT HEEL BLOCK

DRILL TAP 6-32 (3PLS)

DRILL TAP10-32 (3 PLS)

DRILL C-BORE FOR6-32 SHCS (3PLS)

DRILL C-BORE FOR10-32 SHCS (3 PLS)

1.3120

.125 RAD (2PLS)

.25 RAD (2PLS)

0.2500

0.2500

D-04-1004


14

www.danly.com

FIGURE #4

POSITION FOR CAM FOLLOWERS(RIGHT-HAND THREADING ONLY)

8.125

POSITON A

POLYGON DRIVESHAFT.

D-04-1005


15

www.danly.com

FIGURE #5

LP25M6 & LP516M8 CAM DRIVER MOUNTING INFORMATION

DRILL AND C-BOREFOR 1/2-13 SHCS(4PLS)

.500 DOWEL PIN(2PLS)

CAUTIONBOLTS AND DOWELPINS CAN`T MOUNTBELOW THIS SURFACE.

D-04-1006


16

www.danly.com

FIGURE #6

LOW PROFILE TOOLS MOUNTED ON A STRIPPER PLATE

TIP OF TAP SHOULD NOT EXTEND BELOW BOSS.

BOSS SHOULD NOT EXTENDBELOW STRIPPER PLATE.

BOSS

BRIDGE STRIPPERHEEL BLOCK

HEEL BLOCK

D-04-1007


17

www.danly.com

FIGURE #7

RECOMMENDED LUBRICATION SYSTEM OPTION #1

NOZZLE SHOULD BEWITHIN .02 TO .100

OF THE DIA OF TAP.

MACHINE SLOT OR DRILL POCKETFOR TUBE.

3/32 OD X .06 ID BRASS TUBING

STRIPPER PLATE

ALLOW 3/32 BRASS TUBING TO PASS THRU.

.093 ID X 1/8 OD TEFZEL TUBING

1,1,1 TRICHLORETHANE. THIS COMPOUNDUSE TUBING THAT WILL WITHSTAND

IS USED IN GOOD TAPPING FLUIDS.

SLOT IS PROVIDED IN PITCH INSERT TO

D-04-1008


18

www.danly.com

FIGURE #8

RECOMMENDED LUBRICATION SYSTEM OPTION #2

NOZZLE SHOULD BEWITHIN .02 TO .100

OF THE DIA OF TAP.

MACHINE SLOT OR DRILL POCKETFOR TUBE.

COMPRESSION FITTINGFOR 1/8 DIA TUBE1/8 MALE PIPETHREAD IS 5090K111/8 FEMALE PIPE THREAD IS 5089K11

1/8 OD X .097 ID BRASS TUBING3/32 OD X .06 ID BRASS TUBING

STRIPPER PLATE

IF TUBE NEEDS TO BE BENT, USE A TUBE BENDER

E-POXY (JB WELD)EITHER USE SOLDER OR

ALLOW 3/32 BRASS TUBING TO PASS THRU.SLOT IS PROVIDED IN PITCH INSERT TO

D-04-1009


19

www.danly.com

FIGURE #9

PITCH INSERT ASSEMBLY

BOSS ORSTRIPPER

TAPCOLLET

KEY STOCK

MIS-FEED SPRING

MALELEAD SCREW

FEMALELEAD SCREW

D-04-1010


20

www.danly.com

FIGURE #10

SHUT HEIGHT

THE END OF THE STROKE.

CLEARANCE HOLES WILLBE REQUIRED IN DIE SHOEFOR CAM SIDE PLATES.

MIMIMUM SHUTHEIGHT

3.775

0.050 OF CLEARANCE AT

D-04-1011


21

www.danly.com

FIGURE #11

FIXED CAM DIMENSIONS FOR THE LP CAM DRIVER(RAPID TAP SOFTWARE WILL SELECT EITHER CAM A OR CAM B)

5.5000

CAM TRACKHEIGHT

HEIGHTCAM TRACK

1.1250

CAM A CAM B

2.5500

4.1000

.50 OF STRAIGHT

.50 OF STRAIGHT

AB

C.005 ABC

.375 2PLS

1.000 2 PLS

4.0000

TAP AND C-BORE FOR5/16-18 X 1.00 S.H.C.S4 PLS

3/8 PRESS FITDOWEL PIN 4 PLS

4 PLS5/16-18 X 1.00 S.H.C.STAP AND C-BORE FOR

DOWEL PIN 4 PLS3/8 PRESS FIT

BREAK ALL SHARP EDGESFINISH: NONE

BOLTS CAN`T MOUNTBELOW THIS SURFACE.

ENGRAVE JOB NUMBER.

MATERIAL: 7075-T6 ALUMINUM

CAUTION

4.5500

0.50002.425

1.0000

.875 2 PLS

1.500 2 PLS

2.425.500

1.1250

.500

MATERIAL CAM BE REMOVEDTO ADD CLEARANCE. .500 MIN DIM FROM END OF CAM TRACKTO EDGE OF MATERIAL.

MINIMUM DIM

D-04-1012


22

www.danly.com

FIGURE #12

LOW PROFILE TOOLS MOUNTED ON A SPRING STRIPPER

SPRING TRAVEL IS BASED ONTAPPING STROKE, PLUS .25 OF PRELOAD. 4 NITROGEN SPRINGS EQUALLING3000 LB BEFORE CAMS MAKE CONTACT WITH CAM FOLLOWERS.

.500 DIA LOCATING PINS (4PLS)THIS WILL KEEP THE STRIPPERPLATE FROM SHIFTING WHEN

THE CAM FOLLOWERS.THE CAMS MAKE CONTACT WITH

D-04-1013


23

www.danly.com

FIGURE #13

TAPPED HOLE DETECTION(TO DETERMINE WHETHER THE TAP FULLY PENETRATES THROUGHT THE MATERIAL)

MATERIAL GUIDES

DIE PLATE

MATERIAL STRIPBRIDGE STRIPPER

DIE SPRING

GUIDE PINS

SPRING LOADED

CLEARANCE BETWEEN MATERIALAND PLUNGER IS 2.5 X PITCH

SWITCH

SPRING

SET SCREW WITHTHRU HOLE

D-04-1014


24

www.danly.com

FIGURE #14

EXAMPLE OF 13 LP TAPPING UNITSTAPPING FROM THE BOTTOM UP

D-04-1017


25

www.danly.com

FIGURE #15

EXAMPLE OF LP25M6TAPPING UP AND DOWN IN THE SAME STATION

D-04-1018


26

www.danly.com

FIGURE #16

CAM DRIVER TEMPLATE FOR ME1024

1

CAM PROFILE DETERMINEDBY PRESS STROKE ANDTAPPING STROKE

1

MODEL ME STANDARD CAMOPEN AND SHUT HIEGHTS

5.02

.75

1.875

4.396

9.785

6.150

.500

.375 RAD(4 PLS)

6.000

14.000

.750

1.875

1.000(2 PLS)

(2 PLS)

10.785 MIN

9.785

30(2 PLS)

2.00

.500

CAM TEMPLATE FOR ME1024

1.300DIA

.250

SHADED AREA TO BE MACHINED BYCUSTOMER BASED ON APPLICATION

NOTE:

1.822

GREASE FITTING (45 DEG ANGLE)

OIL HOLE

D-04-1019


27

www.danly.com

FIGURE #17

ME1024 CAMFIXED DIMENSIONS

.375 RAD(4 PLS)

.750

1.000(2 pls)

(2 pls)

9.785

30(2 pls)

.250

11.000

MATERIAL: 7075-T6 ALUMINIUM

FINISH: NONE

ENGRAVE JOB NUMBER

.375 RAD (2 pls)

14.000

R 1.000 (4pls)

6.000

1.0000

.6250 DIA

7.0000

1.875

.6000

2.00

D-04-1021


28

www.danly.com

FIGURE #18

ME1024 CAMON BRIDGE STRIPPER

MATERIAL GUIDES

DIE PLATE

MATERIAL STRIPBRIDGE STRIPPER

DIE SPRING

GUIDE PINS

SPRING LOADED

.630 CLEARANCE HOLE FOR DRIVE SCREW

D-04-1022


29

www.danly.com

FIGURE #19

CAM DRIVER MOUNTING FOR ME1024 CAMUSING A SPRING STRIPPER

1.00

END USER BASED ON PROPER HEIGHT REQUIREMENTS.

MATERIAL

DIE

THIS SECTION IS REMOVED BY

SPRING TRAVEL IS BASE ON TAPPING STROKE, PLUSPRELOAD ON MATERIAL BEFORETAPPING.

THIS DIM. IS THE SAME FORALL CAM`S, WHEN USED IN ASPRING STRIPPER APPLICATION.SUBTRACT AMOUNT OF PRELOAD TRAVEL USED BEFORE TAPPINGFROM THIS 1.00 DIM. IN MOST CASESUSE .05 TO .100 OF PRELOAD TRAVEL.

THIS WILL INSURE PROPER STRIPPINGFOR TAPPING.

MICRO SWITCH

CAUTIONIF USING A SPRING STRIPPER.

THAT THE STRIPPER COMES DOWN 100%. IF STRIPPERDOES NOT COME DOWN ALL THE WAY THE UNIT

TO BREAK.

THERE SHOULD BE A SENSOR TO MAKE CERTAIN

COULD BOTTOM OUT, CAUSING THE CAM ROLLER

D-04-1023


30

www.danly.com

FIGURE #20

MOUNTING THE ME1024 UNIT IN A HYDRAULIC PRESS

OPEN

.625 DIA X 1.35 DEEP RELIEF HOLE IN PUSH BLOCK FOR SCREW

1.250 .100 MINIMUMTHIS KEEPS PUSHERBLOCK FROM MAKINGCONTACT ON CAMPLATES.

CAM PLATE

CLOSED

D-04-1024


31

www.danly.com

FIGURE #21

TAPPING WITH MATERIAL LIFTERS

NITROGEN SPRINGS

.50 DIA SPRINGS

MATERIAL

STOP BLOCK TO OVERCOME NITROGEN SPRINGS

0.6250

MATERIAL LIFTERS

SUPPORT PAD

SPRING BRIDGE STRIPPER

APPROXIMATELY 1800 LB OF NITROGEN PRESSURE.

TRAVEL

D-04-1025


32

www.danly.com

FIGURE #22

SAMPLE LAYOUT FOR MULTIPLE TAPPINGWITH 3 ME1024 UNITS IN ONE DIE

AIR FEEDERAIR CLAMP

ME1024 TAPPING UNITS.

22.9537

48.6781

16.0000

4.1250 4.1250

NOTE: ALL DIMENSIONS ARE APPROXIMATE

D-04-1026


33

www.danly.com

FIGURE #23

TYPICAL WAY OF APPLYING TAPPING UNITS TO IN-DIE TAPPING

DIE

BOTTOM DIE SET

PARALLEL

FIRST HOLE

SECOND HOLETAPPED

THIRD HOLETAPPED

TAPPED

PUNCH HOLESFOR TAPPING

PART

MACHINED POCKET

TAPPING UNITS 1,2,3

THREE HOLESTAPPED 10-32

PART PUNCHED OUT

THIS DIM. IS FROM THE TOPOF THE MATERIAL OR EXTRUSIONTO THE TOP OF THE CAM

6.271

2.00

5.00

.600

2.00

3.00

5.00

1.00

THIS DIE HAS ONEMACHINED POCKET

FOR ALL TAPPINGUNITS

12.103

IN THE CLOSED POSITION

MOUNTING SCREWSFOR CAM

.771

9.300

3/8-16 S.H.C.S

MATERIAL

D-04-1027


34

www.danly.com

FIGURE #24

SUB-PLATE FOR LP25M6

1/2-20

1/4-20

SUB-PLATE

STOP BLOCK

GUIDE RAIL

GUIDE RAIL

D-04-1031


35

www.danly.com

FIGURE #25

SUB-PLATE FOR LP25M6 CAM

SUB-PLATE

RAIL STOP BLOCK5/16-18 S.H.C.S.

D-04-1032


36

www.danly.com

FIGURE #26

SUGGESTED LAYOUT FOR TAPPING BOTTOM UPWITH LOW PROFILE TOOLS AND USING A SUB DIE

DIE IN OPENPOSITION

DIE IN CLOSED POSITION

D-04-1033


37

www.danly.com

FIGURE #27

LP25M6 MOUNTED ON A SPRING STRIPPER

STOP BLOCKS OR NITROGENSPRINGS TO OVER RIDE3,000 LBS OF SPRINGPRESSURE.

APPROXIMATIELY 3,000 LBSOF SPRING PRESSURE.

MATERIAL LIFTER

FORMING TRAVEL

D-04-1034


38

www.danly.com

(Models ME1024 and LP25M6 only)

1. TOOL MODEL: ME1024 _______________ LP25M6 _______________

2. STROKE OF PRESS: _______________

3. TAPPING STROKE: _______________

The remaining stroke left after the material has advanced in its progression. Example: If a6" stroke press requires 2" to advance or progress, the tapping stroke would be (6" - 2") = 4".

4. SPEED OF PRESS IN STROKES PER MINUTE: _______________

5. TOTAL THICKNESS OF MATERIAL (include extrusion if applicable): _______________

Material thickness must include the gap between the tip of the tap and the top of material orextrusion. (Failure to do so could cause improper tap penetration.) (See Figure #15.)

6. MATERIAL TYPE: _______________

7. TAP SIZE: _______________

Designing a Cam Driver

39

www.danly.com

Rapid T.A.P. Software(Tapping Application Program)

Software that aids in thedevelopment of dies with DanlyIEM in-die-tapping tools. Thissoftware is designed to educatedie designers and stamping facilities on the benefits of In-dieTapping (IDT) and provide easyways to design dies thatincorporate the IDT tools. RapidTAP replaces Campro, an earlierDOS based computer program.

Rapid TAP produces neededCAD information for the IDT CamDrivers that are proprietary toDanly IEM tapping tools. RapidTAP’s program logic evaluates thesinusoidal acceleration that isinherent with mechanical pressesand converts it into a linear tappingmotion. This conversion is moreaccurate than altering gear ratios

Rapid T.A.P. Software

40

www.danly.com

1. DISTORTED THREADS

Threads are distorted and the go-gage will not go into the tapped hole. Check to see if anyportion of the die is hitting the top of the threads, such as the stripper plate, form block ora hold-down form pad. If this is the case, provide clearance for the hole by grinding ormachining a counter bore.

2. TAP BREAKS ON EVERY HIT

Make sure the hole is the correct size for a metal forming tap. If you are using a hole sizerecommended for a cutting tap, it is too small and will result in tap breakage. Ensure that thehole is being registered properly beneath the tap. See Mounting Procedures in the installationmanuals. For recommended pre-hole sizes, refer to the tables on pages 9 and 10 of thismanual.

3. TAP BREAKS AFTER ONE TO FIVE HITS

Tap height may be misadjusted and stocking out below the nose piece or boss. This conditionoften results in the tap catching on the material as at advances.

4. TAP BREAKS PREMATURELY

Check the lubrication. A discolored or black tap indicates that an improper level nor type oflubrication is being applied.

5. TAP SPINS BUT DOES NOT PENETRATE THE HOLE

The tap is backed up by a spring for “no hole” conditions. If this spring is weak there maynot be enough pressure to get the tap started. If a spring stripper or a spring loaded bridgestripper is used, adjust the tap so that is protrudes slightly from the nose piece. This will put apreload on the spring and increase spring pressure. If this does not correct the condition, astronger spring will have to be used. Call the factory for assistance if this is the case.

6. IF CHIPS ARE DEVELOPING

The pre-hole for the tap is too small. Opening up the hole by .002" to .003" will usually fixthe problem. Use 65% of thread to start with.

Trouble Shooting

© 2004 Danly IEM, A Division of Connell Limited Partnership DM109-1 8/04

6779 Engle Road Suite A - FCleveland, OH 44130-7926

VISIT US AT www.danly.comE-MAIL: [email protected]

TOLL FREE: 800.243.2659FAX: 800.833.2659

IN-DIE TAPPING TOOLS - Danly · The special forming taps used in the in-die taping units are...

Documents

Transcript of IN-DIE TAPPING TOOLS - Danly · The special forming taps used in the in-die taping units are...