Guideline for Material Selection ‘Manufacturing Ease "= Materials Sélection | Manufsctarng Dificuty Material Tye. Catagory (Category? Category Category 4 [Carbon Stee! Low Carbon (C1006 - C1020) |b 45-75, 73-15 |Rb70-85,12 [RD 85-80,T1 —_|R 85-90, 71 lupto8mmtk. above 8 mm tk. |Carbon Stee! (Annealed) Medium Carbon (C1025 - C1035) Rb 75-85 (Carbon Steel (Spherodized Annealed High Carbon (C1036 - C1075) lup to 6mm tk. above 6mm tk. [Spring Steel (C1095 Rb 80-90) lup to 3mm tk, [above 3mm tk. [Alloy Steal (Spherodized Annealed) 18620, 8630, 4130, 4140, 4340, up to 6mm Tk. 15120, 5120H lem - 10mm Tk. Homm - 12mm Tk. High Strength Steel (HSLA) }040, 050, 060, 090 lup to 6mm Tk. lamm - 10mm Tk. 40mm - 12mm Tk. [Stainless Stoel (Annealed) 1200, 300, and 400 Series lup to 6mm Tk. |émm - tomm Tk. 10mm - 12mm Tk. [Aluminum 4100 lo, He, Ha He He '3003 lo, He Ha He, He 15052 lo H2, Ha H6, HB 12024, 6061, 7075 To IT3 i T6 Brass & Bronze Tae Tahar [si hard spring hard [Copper IF 45-75, soft Rb 88-95, Rb 96+, hard 2 hardGuideline for Presence of Die-Roll Expected bie Rol Expressed as Contour Feature Percent of Thickness: Rules of Thumb ‘Comers on inside Contours 2% - 4% Die-rollis sightly curved contour on the edge Straight Contours 4% - 8% lof one side of a component, created by a pull Curved Contours on Large Holes 6% - 12% Jdown as the component is extruded into the 90 Degree Comers 15%-25% die plate. ‘Acute Corners (< 90 degrees) 20% - 30% Die-roll is increased as corner angles decrease las comer radii decrease and with softer material, leline for Corner Ra Allowance ‘Type of Gomer Radius Requirement Expressed as Percent of Thickness Rules of Thumb: '80 Degree Comers Acute Comers (< 90 degrees) Obtuse Comers (> 90 degrees) 10% - 15% 15% - 20% 5% - 10% Larger radii results in: less tool wear less corer tearing less die-roll Harder material requires larger radi Guideline for General Tolerances greater than 6.4mm from +/- 0.038mm i Internal Contour Internal Contour Hole Diameters Material Thickness External Contours Spacing and Contours Tess than {mm -7-0.007mm + 0.01mm + 0.007mm mm - 1.75mm +1: 0.01mm 4/-0.018mm +-0.01mm 4.76mm - 8.2mm +-0.015mm +/-0.02mm, +/-0.013mm 3.3mm - 4.75mm + 0.02mm +¥/-0.025mm +/-0.015mm 4.76mm - 6.4mm +/- 0.028mm +/-0.03mm +/-0.02mm from +/-0.038mm | from +/- 0.025mm ‘greater than 0.25" from +/- 0.0015" Tess than 0.04" “#7 0.0005" +7 0.0004" 0.041" - 0.0 -+/- 0.0004" +/- 0.0006" 0.07" - 0.125" -+/- 0.0008" +/-0,0008" 0.126" - 0.187" +#/-0,0008" +/- 0.00 +/-0.0006" 0.188" - 0.250" +/-0.001" +/-0.0012" +/- 0.0008" from +/- 0.0015" from +/--0.001 [configuration of the part. tolerances to be achieved. [Tolerance range is influenced by material thickness, tensile strength of material, material structure, and [Tolerances on internal contours are easier to maintain than on outer contours. [As material gage increases, taper condition must be taken into consideration when applying tolerances. Thinner material will enable tighter tolerances to be achieved, Lower material tensile strength will enable tighter tolerances to be achieved.Guideline for Fiatness Tolerance Rules of Thumb (0.0mm - 0.02mm per em {0.001" - 0.002" per inch) The degree of flatness is affected by the condition of input material, configuration of the component, grain direction of material, and coil crown, Grinding processes following fineblanking can improve flatness, parallelism, and improve surface finish conditions.