DIE DESIGN AND CONSTRUCTION SPECIFICATIONS STAMPING - EUROPE MINIMUM CORE HOLE SIZE TO PULL PUNCHES WITH WINDOWS

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1 MINIMUM CORE HOLE SIZE TO PULL PUNCHES WITH WINDOWS THE MINIMUM DIMENSIONS FOR THE HOLE IN THE PD REQUIRED TO INSERT THE PUNCH-PULLER ND THE BLL-LIFTER RE GIVEN IN THE TBLE BELOW. C CORE HOLE ØB MIN. SECTION - PUNCH BODY DI. Ø10 & Ø13 Ø20 Ø25 Ø32 Ø40 DIM. "" MINIMUM CORE HOLE SIZE "B" Ø40 Ø45 Ø50 Ø60 Ø70 PGE: 4

2 PUNCH STRIPPER PPLICTION WITH WINDOW FOR PUNCH RETINER PD CLERNCE 10mm MSCHINED 20mm CST BUTTONS IN NY SURFCE OTHER THN FLT ND HORIZONTL ND/OR VERTICL MUST BE ENCOMPSSED BY SURFCE FITTED TO THE PROFILE. TYPICL SECTION PGE: 5

3 BUTTON WITH RETINER KEY FOR STNDRD ND MC-HOLES LL BUTTONS, LSO FOR MC-HOLES MUST BE FIT DIRECTLY INTO THE CST BCK. IF THE HOLE DIMMENSION IS SMLLER THEN 8mm USE N INSERT TO RETIN THE BUTTON TO BE BLE TO KNOCK OUT THE BUTTON FROM BELOW. PGE: 7

4 GUIDELINES FOR USING URETHNE PUNCH STRIPPER - PENETRTION OF PUNCH INTO DIE BUTTONS (OR STEEL INSERTS) HS TO BE PPROXIMTELY 6mm. - HOLES IN THE DIE BUTTONS HVE TO BE CLERED TO DISTNCE OF 5mm FROM THE CUTTING EDGE TO ELIMINTE SLUG BUILD-UP. - YOU CN USE URETHNE PUNCH STRIPPERS FOR PIERCING: WHEN MTERIL THICKNESS IS LESS THN 1,5mm FOR MILD STEEL ND 1.2 FOR HIGH STRENGTH STEEL WHEN THERE IS NO ROOM FOR WINDOW. WHEN THE HOLE BEING PIERCED IS NOT DJCENT TO NOTHER PUNCH, PRT WLL, ETC. THT WOULD BE CONTCTED BY THE URETHNE BULGE ND RESULT IN PUNCH BREKGE. UNLESS STEEL STRIPPERS RE REQUIRED DUE TO OTHER DIE CONDITIONS FOR INNER PNELS ND FOR OUTER SKIN PNELS BUT NOT ON CLSS ONE SURFCE RES. RE CHNGED - DO NOT USE STRIPPER IF THE PUNCH POINT IS LRGER THN THE PUNCH BODY DIMETER, ( NO INVERTED PUNCHES LLOWED ), ND WHEN THE PNEL IS TIPPED MORE THN 5. URETHNE PUNCH STRIPPER SEE W-DX5-60M PGE MX. BCKING & RETINER PLTE SEE W-DX5-60M PGE URETHNE STRIPPER FORCE SEE W-DX05-60M Page CUTTING FORCE (F)= PIERCING LENGHT x MT.THICKNESS x SHER STRENGTH ( SEE CURVE ON W-DX25-40M Page 5 ) 3. DIE CLERNCE = 5% OF MT. THICKNESS 4. STRIPPER FORCE = n% of CUTTING FORCE FOR MT.THICKNESS 5 0,75 mm 6 1,00 mm 7 1,25 mm 8 1,50 mm 9 1,75 mm 10 2,00 mm 11 2,25 mm 12 2,50 mm MY 2006 PGE: 10

5 SPECIL PIERCING INSERTS WIRE CUT E.D.M. WHEN PIERCING HOLE TOO CLOSE TO TRIM LINE OR EDGE ND STNDRD DIE BUTTON CNNOT BE USED, PERISHBLE DETIL WILL BE PROVIDED FOR ESY REPLCEMENT. USE BUTTONS WHENEVER POSSIBLE. INSERTS RE TO BE COMPLETELY DETILED ON DESIGN EXCEPT FOR TRIM LINE & PRT SHPE. TO FCILITE ORDERING OF SPRES (DO NOT FULLY DETIL). DIMENSIONS MUST PPER ON DESIGN IN 2 PLCE DECIML FORM. DIMENSION TO HOLE NOT TO CENTERLINE OF DIE. CONSTRUCTION SOURCE TO SUPPLY THE DESIGN SOURCE WITH FINL MCHINE DIMENSIONS FOR PERISHBLE DETILS. DESIGN SOURCE TO UP-DTE DESIGNS WITH THE INFORMTION SUPPLIED BY THE CONSTRUCTION SOURCE. R 3 MIN. B TRIM LINE R 11 PREFERED B 5 MIN. 5 MIN. 5 MIN. SCREW & DOWEL HOLES RE IN DETIL BEFORE HRDENING SECTION - SECTION B-B INSERT MTERIL: BRSTOCK PGE: 13

6 LOUVER PIERCING UNIT - BLDE TYPE B SKETCH 1 SEE PGE 2 PRTIL PLN OF DIE SKETCH 2 SEE PGE 2 B SEE PGE 2 PRTIL PLN OF PUNCH PGE: 14

7 LOUVER PIECING UNIT - BLDE TYPE SPCER SKETCH 3 LTERNTE METHOD USING SPCERS SECTION - SKETCH 4 BCKING PLTE RC PUNCH RETINER RC PUNCH BLDE SECTION B-B PGE: 15

8 BLL SET IN BLL LOCK PUNCH - HEVY DUTY ØD g5 1.6 / / * USE CHECKING GGES HGP- -- TO CHECK THE POSITION OF THE BLL SET DIMENSIONS "E" & "F". H 0.8 M±0,4 K C F * G±0,3 E * BLL DI. B P- -D- BLL SET RELIEF CN BE LOCLLY OR LL ROUND D FOR ROUND PUNCH POINTS R 0.01 P FOR SHPED PUNCH POINTS PUNCH BLL SET CONFORMS TO (NSI) MERICN NTIONL STNDRD INSTITUTE. FOR CHECKING THE POSITION OF BLL SET ND TRIM SHPE, CHECKING GGES HGP- CN BE USED. D B C E F G H K M R CHECKING GGE (LNE CORP.) HGP HGP HGP HGP-20 HGP HGP HGP-40 PGE: 16

9 BLL SET IN PUNCH RETINER HEVY DUTY 4.19 ± E2± ' 0 5' C2 ±0.2 H2 E1± ±0 5' 0.01 ØD H6 1.6 B BCKING PLTE NGULR TOLERNCE OF BLL SET IS TO BE WITHIN ±0 5' -- 6, C1 ±0.2 H1 41 REF. G F M4 LOCK POSITION (REF.) BLL DI. B±0.011 D B C1 E F G H C E H RE CHNGED MTERIL : DIN X155Cr V Mo121; BS 4659 BD-2; ISI, D-2 HRDNESS: MIN. HRC 54 PGE: 17

10 MULTI PUNCH RETINER SET GUIDE LINES Ø E Ø8 DOWEL * * * Ø9 SPECIL PUNCH RETINER HRDNESS: MIN. HRC 54 BCKING PLTE HRDNESS: MIN. HRC 54 LL SCREWS ND DOWELS MUST BE SHOWN IN THE SOLID MODEL. THE BLL SET MUST BE SHOWN IN THE PLN VIEW OF THE DRWING; BUT IS NOT NECESSRY IN 3D. THE CTUL MNUFCTURING OF THE BLL SET WILL BE DONE TO THE CURRENT PUNCH/ RETINER MNUFCTURING STNDRDS. SEE WDX05-42M PGE 17. B D E G H Ø MIN. M8 MIN. M10 MIN. M SCREW * * THE MOUNT ND SIZE OF SCREWS MUST FIT TO THE MOUNT ND SIZE OF PUNCHES USED. FOR M5x12 FLT HD.SCR. DIN EN ISO 2009 (2) REQUIRED G ØD B BLL DI. 6 H 41 RE CHNGED ORDERING EXMPLE FR XW4F R.H. (1) REQUIRED DETIL NUMBER DIE TYPE DIE NUMBER EXCLUDING DRWING CLSSIFICTION ND CTIVITY CODE. FORD SPECIL RETINER ECH SPECIL PUNCH RETINER MUST BE PERMNENTLY MRKED WITH FORD PRT NUMBER ND MNUFCTURER'S BRND. MY-2006 PGE: 18

11 QUICK CHNGE RETINER PIPING REQUIREMENTS THIS SCHEMTIC IS ONLY N EXMPLE QUICK CHNGE RETINER SEE WDX5-60M PGE 24 NOTE: IF ELBOWS OR TEES RE REQUIRED IN DESIGN, THESE ITEMS MUST BE ORDER SEPRTELY MNUL CONTROL IR VLVE SEE WDX5-60M PGE 23 IR COUPLING BRCKET SEE W-DX35-70M PGE 10 MY-2006 PGE: 19

12 GUIDELINES FOR DIES WITH PIERCING OPERTIONS DEFINING THE PUNCH SIZE FROM THE PRT DRWING PUNCH DIMETER WILL BE THE DIMENSION OF THE PRT DT PLUS MXIMUM TOLERNCE MINUS 0,1mm, ROUND UP OR DOWN. PRT DT ON DRWING PUNCH SIZE ( IF PIERCING IS 90 TO SURFCE ) EXMPLES: = 15,2 15 ± 0.23 = 15,1 15-0,3 = 14,9 MC-HOLES: MNUFCTURING TOLERNCE PUNCH SIZE = PRT DT DIMS PIERCING ON NGLED SURFCES WITH ROUND PUNCH IS PIERCING ONTO N NGLED SURFCE THE TRUE SIZE OF THE HOLE MUST BE INSIDE THE TOLERNCES. IF THIS CN NOT BE CHIEVED WITH ROUND PUNCH THERE RE 3 POSSIBILITIES TO BECOME ROUND HOLE. 1. THE PUNCH FORM HS TO BE DEVELOPED. SEE SHEET DEPRESSION HS TO BE SKED FOR BY ENGINEERING. 3. PIERCING HS TO BE DONE BY CM. d1 ØPunch FORMULS FOR HOLE DIMETERS ON NGLED SURFCES α x s d1 = DIMETER OF PUNCH [mm] L = TRUE LENGTH OF HOLE ON SURFCE [mm] s = MT. THICKNESS [mm] 90 x = tan α * s (d1) cos α = d1 / (L + x) d1 = cos α * ( L + tan α * s ) L = ( d1 / cos α ) - tan α * s ) L PGE: 21

13 TBLE OF ELONGTION EXMPLE WITH MTERIL THICKNESS 0,91mm THE ELONGTION XIS CN DIFFER POSITIVE OR NEGTIVE, DEPENDING ON MTERIL THICKNESS ND NGLES. FOR LL OTHER MTERIL THICKNESSES ND OTHER DIMETERS NOT SHOWN IN EXMPLE TBLE USE FORMUL. IF THE DIFFERENCE BETWEEN THE "Ø OF HOLE ON SURFCE" ND THE CLCULTED "ELONGTION XIS" IS NOT WITHIN THE HOLE TOLERNCE, TRY GRPHICLLY N OBLONG SHPED PUNCH POINT. IF THIS IS NOT WITHIN THE HOLE TOLERNCE FORMHOLE HS TO BE DEVELOPED. SEE SHEET 24. HOLE DIMETER ON SURFCE EXMPLE CLCULTION FOR HOLE Ø12 d1 = Elong. xis NGLE ELONG. XIS DIFF NGLE ELONG. XIS DIFF NGLE ELONG. XIS DIFF X b c = L * cos α = 12.0 * = mm b = s * sin α = 0.91 * = 0.16 mm ELONGTION XIS OF PUNCH: d1 = b + c = = c L = Ø of Hole on Surface c = Dim. of Hole in Piercing Direction b = Elongation a b Detail X 12 s L=12 α=10 c s=0.91 α PGE: 22

14 NGULR PIERCING METHOD SPECIL PUNCH SIZE & SHPE PUNCH SIZE DEVELOPMENT FOR NGULR PIERCING TRUE SIZE ND SHPE OF HOLE ON PRT PRINT NGLE DIRECTION OF PIERCING THE BOVE METHOD OF DEVELOPING SHOULD BE USED TO DETERMINE THE PPROXIMTE RDII FOR PUNCH, PIERCING HOLE T GIVEN NGLE & REQUIRING THT THE HOLE IS ROUND ON THE FCE OF THE METL. IN THIS DEVELOPMENT LL NECESSRY POINTS ON PERIPHERY HVE TO BE GIVEN WITH "X" ND "Y" COORDINTES. THEY CN BE LISTED IN TBLE. RE CHNGED PGE: 24

15 PUNCH DEVELOPMENT METHOD OF DETERMINING TRIM TB PUNCH SIZE PUNCH DIM. LLOW 2` NGLE FOR ESE IN STRIPPING SUBTRCT 2 TIMES STOCK THICKNESS FROM PRT PRINT DIM. (WHEN DIM. IS GIVEN TO THE OUTSIDE OF STOCK) THEN DD 0.12mm WHEN STOCK THICKNESS IS LESS THN 1.5mm OR 0.24mm WHEN STOCK IS 1.5mm TO 3mm. WHEN PRT PRINT DIM. IS GIVEN TO INSIDE OF STOCK SUBTRCT ONE STOCK THICKNESS ONLY. EXMPLE: PRT DIM TWO TIMES STOCK THICKNESS DD CONSTNT PUNCH DIM. METHOD OF DETERMINING EXTRUDED HOLE PUNCH SIZES WHERE FLNGE HEIGHT MUST BE HELD T R B E W C P F H B = (0.25T + R) USE R = 0.5mm UNLESS PRT PRINT SPECIFIES RDIUS W = C - 2 (B + F) IF "W" IS LESS THN 1.5T USE POINTED EXTRUDING PUNCH P = HIGH LIMIT OF PRT PRINT HOLE SIZE E = 4T OR W, WHICH EVER IS LESS INSIDE DI. OF BUTTON = P + 2T PGE: 25

16 EXMPLES HOW TO ORDER SPECIL BUTTONS (PUNCHES) USE EXISTING FORM (DIN 3) "SPECIL PUNCH & BUTTON" SEE PGES 26/27. DIE NUMBER: 69 Z1K XW4F HO Z1K XW4F F05 07 BUTTON NO.: FB XW4F HO FB XW4F HO FB XW4F FO FB XW4F F B* 69 Z1K XW4F HO1 06 B* 69 Z1K XW4F F05 07 FB XW4F HO FB XW4F HO FB XW4F FO FB XW4F FO5 O7 353 C 69 Z1K XW4F C 69 Z1K XW4F F05 07 FB XW4F (2X) FB XW4F FO (2X) B* / B*: 2 SHEETS "SPECIL - PUNCH & BUTTON" RE TO DRW PGE: 26

17 EXMPLES HOW TO ORDER SPECIL BUTTONS (PUNCHES) USE EXISTING FORM (DIN 3) "SPECIL PUNCH & BUTTON" SEE PGE 26/27 DIE NUMBER: 69 Z1K XW4F FO Z1K XW4F FO2 07 BUTTON NO.: FB XW4F FO FB XW4F F B* 69 Z1K XW4F FO Z1K XW4F FO2 07 FB XW4F FO FB XW4F F C 69 Z1K XW4F FO Z1K XW4F FO2 07 FB XW4F FO1/ B*: 2 SHEETS "SPECIL - PUNCH & BUTTON" RE TO DRW PGE: 27

18 EXMPLES HOW TO ORDER SPECIL PUNCHES & BUTTONS USE FORM SPECIL PUNCH & BUTTON (BELOW) FORMT IN CTI VILBLE: SK DIE DESIGN OFFICE. Special-Punch Special-Die Button Material/Werkstoff DIN S Spezial-Schnittbuchse BS 4659-BM2 Hardness/Haerte HRC 63 1 Material/Werkstoff DIN X155CrV Mo BS -BD2 ISI - D2 Hardness/Haerte HRC 61 2 Die Clearance = 1/2 Total Die Cleareance Schnittluft = 1/2 Schnittspiel T D C (TOTL DIE CLERNCE) Versetzt gezeichnet Shown relocated "Z"-XIS TO BE USED S DTUM XIS BEZUGSCHSE IST DIE "Z"-CHSE Piercing Hole = Profile-Punch Lochform = Prof!!-Stempel Profile Scale/Masstab: 2:1 Section Profile + Die Clearance Profil + Schnittluft Profil Profile Schni!! - Profile Profil Die Clearance Schnittluft = +0,08 / +0,09 FORD ORDER NUMBER / NUMMER FP XW4F HO1 06 ITEM/POS. 381 S SHOWN/ WIE GEZ. 90 VIEW NSICHT "W" Punch/Stempel FP XW4F HO OPPOSITE/ SPIEGELB FP FB XW4F HO RH / LH S SHOWN S SHOWN/ WIE GEZ. 270 Die Button Schnittbuchse FB XW4F HO OPPOSITE/ SPIEGELB. Ballseat o Kugelsitz Locating Flat Verdrehsicherungsflaeche o FB RH / LH S SHOWN Ballseat see/ Kugelsitz siehe W-DX5-60m Page 5 Heavy Duty Die Number/ Werkzeug Nummer RH. 69-Z 1K XW4F HO1-06 Sht.Bl. Ballseat see/ Kugelsitz siehe W-DX5-70m Page 13 Light Duty Die Number/ Werkzeug Nummer LH. 17 Cross required version Benoetigte Version ankreuzen 69-Z Tolerance Toleranz j6 DTE/DTUM : NME : H.P.LOCHER STMPING ENGINEERING Special Punch Button BLL SET OF PUNCH ND LOCTION FLT OF BUTTON TO DESIGN REQUIREMENTS. SEE TBLE UPPER RIGHT CORNER (THIS SHEET) EXMPLE: MT. THICKNESS 1.5, TOTL DIE CLERNCE +0.16/+0.18, DIE CLERNCE +0.08/+0.09 COMPLETE DIMENSIONING REQUIRED: TO BE SCLED FOR CLRIFICTION (IF NECESSRY). MNUFCTURING TOLERNCES TO BE CONSIDERED WHEN DETERMINING THE PROFILE DIMENSIONS. COMPLETE DIMENSIONING REQUIRED S SHOWN ON W-DX5-70M PGE DO NOT USE HEVY DUTY PUNCHES WITH LIGHT DUTY RETINERS ND CONVERSELY. COMPLETE DIMENSIONING REQUIRED S SHOWN ON W-DX5-70M PGE 1-4 HEVY DUTY (NEW) PGE 5-8 LIGHT DUTY (OLD) W-DX5-70M PGE 9-12 HEDED PUNCHES. PGE: 28

19 EXMPLES HOW TO ORDER SPECIL PUNCHES & BUTTONS PUNCH/BUTTON ORDER NUMBERS RE PRT OF DIE NUMBER/S. WITH THE ITEM NUMBER DDITIONLLY. INFORMTION REQUIRED ONLY WHEN SME PUNCH/BUTTON IS USED IN OTHER DIE UNITS OF THIS DIE OR IN OTHER DIES OF THIS DIE SET. General Information : -Only in exceptional cases punch dimension G may be larger than shank- -Each punch/button must be stamped with the full order no. and manuf.brand. -This Item is identical with ITEM(S).../... on 385/6 355/6 DIE(S)... /... 07(same Die Set). FORD ORDER NUMBER / NUMMER FP XW4F HO1 06 Punch/Stempel FP FP XW4F HO1 06 Die Button FB XW4F HO1 06 Schnittbuchse FB FB XW4F HO1 06 Die Number/ Werkzeug Nummer RH. 69-Z 1K XW4F HO1-06 Die Number/ Werkzeug Nummer LH. ITEM/POS S SHOWN/ WIE GEZ. OPPOSITE/ SPIEGELB. RH / LH S SHOWN S SHOWN/ WIE GEZ. OPPOSITE/ SPIEGELB. RH / LH S SHOWN Sht.Bl Z STMPING ENGINEERING Special Punch & Button TO BE USED ONLY WHEN THE SME PUNCHES/BUTTONS RE USED FOR RH- ND LH-DIE. SEE EXMPLE C TO BE USED ONLY WHEN PUNCHES/BUTTONS RE SYMETRIC OPPOSITE. SEE EXMPLE "I " PGE: 29

20 CONNECTION LYOUT WHEN USING PIERCE NUTS IN LINE DIES IN THE BEGINNING OF DIE CONSTRUCTION CONTCT THE MNUFCTURER OF THE PIERCE NUT UTOMTION THE DIE DESIGN GROUP ND DEPRTMENT NY/FF-16 LOCTION OF NUT HOSES ND ELECTRIC CBELS ND ELECTRICL BOX HS TO BE DETERMINED IN THE SET-MEETING DOUBLE IR BRCKET FOR CL SEE WDX35-60M PGE 2. SENSOR:SHEET METL PRT SEE WDX19-70M PGE 1 SENSOR PIERCE HED SUPPLY PLUG E-BOX WITH HN 16 SEE WDX19-70M PGE 2 PIERCE NUT SORTING ND FEEDING UNIT PRESS CONTROLED IR CLOSED CONTROLED IR OPEN ELECTROMGNETIC VLVE HN 24 PERMNENT IR SINGLE IR COUPLING BRCKET.SEE WDX35-60M PGE 1. PGE: 30

21 SMLL DIES PGE: 31