Chapter 8: Die Design and Operation
carrier strips remain after the part is cut from
the strip.
Figure 8-61e shows strip development for the
same part using a shear-type cutoff. The flange
is formed upward as the combination cutoff and
form punch descends. A spring-loaded pad sup-
ports the workpiece during forming and assists
in ejecting the part from the die. The progression
of this type of development is shortened by the
width of the cutoff slug.
Figure 8-62 shows another development in
which the stock is the same as the developed
width of the workpiece. The strip is pierced in
station 1; piloted and notched in station 2; and
piloted, pierced, and formed in station 3.
Die Design
The die elements used in progressive dies, such
as punches, stops, pilots, strippers, die buttons,
punch guide bushings, die sets, guideposts, and
guidepost bushings, are of similar design to those
used in other types of dies.
A progressive die should be heavily constructed
to withstand the repeated shock and continuous
runs to which it is subjected. Precision or anti-
friction guideposts and bushings should be used to
maintain accuracy. When also serving as guides for
punches, the stripper plates (if spring-loaded and
movable) should engage the guide pins before con-
tacting the strip stock. Lifters should be provided
in die cavities to lift up or eject the formed parts,
and carrier rails or pins should be provided to sup-
port and guide the strip when it is being moved to
the next station. A positive ejection method should
be provided at the last station. Where practical,
punches should contain shedder or oil-seal-breaker
pins to aid in the disposal of the slug. Adequate pi-
loting should be provided to ensure proper location
of the strip as it advances through the die.
Figure 8 62. Four station strip development.
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Fundamentals of Tool Design, Sixth Edition
Figure 8-61a shows a workpiece to be blanked
and formed at high volumes in a progressive die.
The first step in die design is the development
of the blank (Figure 8-61b). The grain of the
coiled metal is normally parallel to the length
of the strip. Where possible, forming operations
are performed perpendicular to the grain to
forestall any tendency to fracture. Therefore,
the workpiece is sketched with the bend line
perpendicular to the strip.
The a dimension appears to coincide with
stock width. A comparison is made between the
exact dimension with tolerance and available
purchased coil stock. If the a dimension is not
within the slitting tolerance of the purchased
stock, the part must be blanked from a wider
strip and perhaps shaved to the finished dimen-
sion. In this case, the a dimension is within the
slitting tolerance; the slit edge will be satisfac-
tory; and no additional work is needed to obtain
the dimension.
The b dimension is developed by adding the c
dimension, d dimension, and a bend allowance.
Tolerances must be carefully considered in de-
veloping the b dimension, which will determine
whether it can be achieved with a single shear
or whether shaving will be required. In this
case, the b dimension is not critical and is, for
the moment, accepted as the station-to-station
distance.
With the a and b dimensions established, a
centerline is drawn and the template of the blank
traced along the centerline (Figure 8-61c). The ar-
eas from which stock must be removed are clearly
indicated. The straight edges of the stock appear
acceptable for guidance. The absence of scrap stock
on either side of the workpiece determines that
the strip must be piloted by registering workpiece
features. Hole e appears most suitable for pilot-
ing. The dimensions of the hole are examined to
determine whether it can be pierced convention-
ally (hole diameter is not less than 1-1/2 times
stock thickness) or if a secondary operation may
be needed. Hole dimensions in this case are not
critical, so the hole can be pierced in the first sta-
tion and used as a pilot in subsequent stations. The
first station now can be drawn, which will include a
stock guidance method that establishes the height
of the punch and the die. The punch location can
be transposed to the other stations where it will
indicate the presence of a bullet-nosed pilot.
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