Die Basics 101: Intro to stamping

Stamping (metalworking)
Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or
coil form into a stamping press where a tool and die surface forms the metal into a net shape.
Stamping includes a variety of sheet-metal forming manufacturing processes, such
as punching using a machine press or stamping press, blanking, embossing, bending, flanging,
and coining.[1] This could be a single stage operation where every stroke of the press produces
the desired form on the sheet metal part, or could occur through a series of stages. The process
is usually carried out on sheet metal, but can also be used on other materials, such
as polystyrene. Progressive dies are commonly fed from a coil of steel, coil reel for unwinding of
coil to a straightener to level the coil and then into a feeder which advances the material into the
press and die at a predetermined feed length. Depending on part complexity, the number of
stations in the die can be determined.
 
Operations of Stamping Press Machine
 Bending - the material is deformed or bent along a straight line.
 Flanging - the material is bent along a curved line.
 Embossing - the material is stretched into a shallow depression. Used primarily for adding
decorative patterns. See also Repoussé and chasing
 Blanking - a piece is cut out of a sheet of the material, usually to make a blank for further
processing.
 Coining - a pattern is compressed or squeezed into the material. Traditionally used to make
coins.
 Drawing - the surface area of a blank is stretched into an alternate shape via controlled
material flow. See also deep drawing.
 Stretching - the surface area of a blank is increased by tension, with no inward movement of
the blank edge. Often used to make smooth auto body parts.
 Ironing - the material is squeezed and reduced in thickness along a vertical wall. Used for
beverage cans and ammunition cartridge cases.
 Reducing/Necking - used to gradually reduce the diameter of the open end of a vessel or
tube.
 Curling - deforming material into a tubular profile. Door hinges are a common example.
 Hemming - folding an edge over onto itself to add thickness. The edges of automobile doors
are usually hemmed.[5]
Piercing and cutting can also be performed in stamping presses. Progressive stamping is a
combination of the above methods done with a set of dies in a row through which a strip of the
material passes one step at a time.
  
The Tribology process generates friction which requires the use of a lubricant to protect the tool
and die surface from scratching or galling. The lubricant also protects the sheet metal and
finished part from the same surface abrasion as well as facilitate elastic material flow preventing
rips, tears or wrinkles. There are a variety of lubricants available for this task. They include plant
and mineral oil based, animal fat or lard based, graphite based, soap and acrylic based dry films.
The newest technology in the industry is polymer based synthetic lubricants also known
as oil-free lubricants or non-oil lubricants. The term "Water-Based" lubricant refers to the
larger category that also includes more traditional oil and fat based compounds.
 
What Is a Stamping Die?
A stamping die is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a
desired shape or profile. The die's cutting and forming sections typically are made from special
types of hardenable steel called tool steel. Dies also can contain cutting and forming sections
made from carbide or various other hard, wear-resistant materials.
Stamping is a cold-forming operation, which means that no heat is introduced into the die or the
sheet material intentionally. However, because heat is generated from friction during the cutting
and forming process, stamped parts often exit the dies very hot.
 
How Many Die Types Exist?
There are many kinds of stamping dies, all of which perform two basic operations—cutting,
forming, or both. Manually or robotically loaded dies are referred to as line dies. Progressive and
transfer dies are fully automated.
Cutting
Cutting is perhaps the most common operation performed in a stamping die. The metal is
severed by placing it between two bypassing tool steel sections that have a small gap between
them. This gap, or distance, is called the cutting clearance.
Cutting clearances change with respect to the type of cutting operation being performed, the
metal's properties, and the desired edge condition of the piece part. The cutting clearance often
is expressed as a percentage of the metal's thickness. The most common cutting clearance used
is about 10 percent of the metal's thickness.
Very high force is needed to cut metal. The process often introduces substantial shock to the die
and press. In most cutting operations, the metal is stressed to the point of failure, which produces
a cut edge with a shiny portion referred to as the cut band, or shear, and a portion called the
fracture zone, or break line (see Figure 2).

here are many different cutting operations, each with a special purpose. Some common
operations are:
Trimming—The outer perimeter of the formed part or flat sheet metal is cut away to give the
piece part the desired profile. The excess material usually is discarded as scrap (see Figure 3).
Notching—Usually associated with progressive dies, notching is a process in which a cutting
operation is performed progressively on the outside of a sheet metal strip to create a given strip
profile (see Figure 4).

Blanking—A dual-purpose cutting operation usually performed on a larger scale, blanking is

used in operations in which the slug is saved for further pressworking. It also is used to cut
finished piece parts free from the sheet metal. The profiled sheet metal slug removed from the
sheet by this process is called the blank, or starting piece of sheet metal that will be cut or formed
later (see Figure 5).
Piercing—Often called perforating, piercing is a metal cutting operation that produces a round,
square, or special-shaped hole in flat sheet metal or a formed part. The main difference between
piercing and blanking is that in blanking, the slug is used, and in piercing the slug is discarded as
scrap. The cutting punch that produces the hole is called the pierce punch, and the hole the
punch enters is called the matrix (see Figure 6).
Lancing—In lancing, the metal is sliced or slit in an effort to free up metal without separating it
from the strip. Lancing often is done in progressive dies to create a part carrier called a flex or
stretch web (see Figure 7).
Shearing—Shearing slices or cuts the metal along a straight line. This method commonly is used
to produce rectangular and square blanks (see Figure 8).

Die Basics 101: Forming operations

Finding the balance between a material's formability and strength
All forming operations deform sheet material by exposing it to tension, compression, or both.
Most part defects, such as splits and wrinkles, occur in forming operations. Successful sheet
metal forming relies heavily on the metal's mechanical properties. The metal being formed must
have the ability to stretch and compress within given limits. It also must be strong enough to
satisfy the part's fit and function. This balance between formability and strength often is hard to
achieve.
Most forming operations involve at least two basic components: a punch, representing the male
portion of the die, and the cavity, representing the female portion.

Common Forming Die Types

Although many die types exist, this article focuses on those used in the most common forming
operations.
Embossing Dies
Embossing dies use tension to stretch metal into a shallow depression. The die set primarily is composed of
a punch and a cavity. The metal's thickness and mechanical properties, along with the forming punch
geometry, determine the depth that can be achieved (see Figure 1).

Solid Form/Dead Hit Dies

Solid form/dead hit dies—also called crash forming dies—deform the metal using only a punch
and cavity. These dies do not control metal flow and cannot prevent the metal from wrinkling or
buckling. They are used to form simple parts, such as brackets and braces, made from thick, stiff
metals that are more wrinkle-resistant than thinner metals. Because this operation also uses
tension to form the part, attempting to solid-form difficult part geometries using thin metal often
results in severe failure (see Figure 2).
Coining Dies
Coining dies create the part's shape by squeezing the metal under extreme pressure. Coining
also can reduce the metal thickness. Coins (metal currency) are created with the coining process.
A simple round metal slug is placed into the die and forced to flow into a given shape by
compressing it (see Figure 3).
Restrike Dies
The restrike die operation fundamentally is a solid forming operation. The main difference is that
a restrike die is used after most of the major forming already has been performed. The restrike
die's function is to finish forming features that could not be obtained in a previous operation.
Restrike dies add details such as sharp radii and small embosses. They also help compensate
for springback that occurred during the initial forming.

A restrike die operation often follows a drawing or trimming operation. These dies, also referred
to as qualifying dies, usually use tension to re-form the part; however, compression also can be
used.
Bending Dies
Bending can be defined simply as a forming operation in which the metal is deformed along a
straight axis. Items such as tabs and channels are created using the bending process. Achieving
the correct bend angle in a bending operation can be very difficult.
Among the various bending methods are wipe bending, V bending, and rotary bending. All three
are very popular, and each has its advantages and disadvantages. Both compression and
tension occur during bending. Compression occurs on the inside radius, while tension occurs on
the outside radius. Figure 4 shows the compression and tension. Figure 5 shows the three basic
bending types.

Flanging Dies
Flanging is bending metal along a curved axis. Two basic types of
flanges are tension, or stretch, flanges, and compression, or shrink,
flanges. Tension flanges are susceptible to splitting, and shrink
flanges are susceptible to wrinkling.
Flanges are created using a flanging die that wipes the metal
between a punch and a lower die section. Both tension and
compression occur during the flanging process (see Figure 6).
Figure 6
Flanging
Drawing Dies
Drawing dies are the most impressive forming dies. Oil pans, automobile doors and fenders,
cookware, and door knobs are just a few parts manufactured by drawing.
Draw dies create the part shape by controlling metal flow into a cavity and over the forming
punch. Draw dies utilize a special pressure-loaded plate or ring called a draw pad or blank holder
to control the metal's flow into the cavity. This plate prevents the metal from wrinkling as it flows
into the cavity. Increasing or decreasing the pressure exerted under the pad also controls how
much metal feeds into the die. Although compression can occur when the metal is drawn,
drawing uses mostly tension to obtain the part geometry (see Figure 7).
Ironing Dies
Ironing dies are similar to coining dies in that they deform the metal with compression. However,
unlike conventional coining, ironing squeezes metal along a vertical wall. This highly compressive
process unifies a wall's thickness and increases the drawn vessel's length. Items such as
beverage and soup cans are made using an ironing process. Ironing allows an aluminum can's
wall thickness to be reduced to as little as 0.002 in. (see Figure 8).

Extruding Dies
In extruding, the metal is flanged around the perimeter of a prepierced hole. Like during stretch
flanging, the metal is susceptible to splitting during forming. Extrusions also are referred to as
hole expansions or continuous stretch flanges. Often extrusions are tapped for holding fasteners
used in the part assembly process (see Figure 9).
Die Basics 101: Production methods to make stamped parts
Among the many factors to consider when choosing a production method are the production
speeds necessary to produce the required quantity within a given time frame; the material
consumption needed for each part; the production method cost; preventive maintenance
requirements; equipment availability; and the part shape, size, and geometric tolerance specified.
Line Dies
Line dies are tools that typically are hand or robotically loaded. Often each station that forms or
cuts the sheet metal represents a single operation die. Hand-loaded line dies usually lend
themselves to low-production parts or those that are too big and bulky to handle with automation.
Several line dies usually can be placed within a single press. This allows the operator to transfer
the parts from die to die to with a minimal travel distance.
Larger line dies often are placed in individual presses close together in a line, an arrangement
referred to as tandem line presses (Figure 1).

Some line die advantages are:

They often cost less than more complicated dies.
They can be timed to run together in a common press.
The operation's simplicity allows the part to be turned over or rotated in any axis by the operator
or robot if necessary. This often allows for more complex geometries to be created.
Smaller individual tools are lighter and can be handled with lower-cost die handling equipment.
Maintaining a single station does not require removing all the dies.
Common line die disadvantages are:
They often cannot compete with production speeds achievable with other methods, such as
progressive dies.
They require expensive robots or human labor.
They often require several presses to manufacture a single part.
Transfer Dies
Transfer dies are special line dies that are timed together
and properly spaced an even distance apart in a single
press. The distance between each die is referred to as
the pitch, or the distance the part must travel between
stations.
Unlike with conventional line dies, the piece parts are
transferred by special traveling rails mounted within the
press boundaries. These rails most commonly are
mounted on each side of the dies. During the press
cycle, each rail travels inward, grabs the part with special Figure 2
fingers, and then transfers it to the next die. Transfer Rails
Transfer systems can perform numerous motions.
However, the two basic types are 2-D (two-axis) and 3-D (three-axis). Two-axis transfers move
inward, grip the part, and slide it forward to the next station. Three-axis transfers move in, grip the
part, pick it up vertically, move it to the next station, and lower it down onto the die. This third-axis
movement allows the part to be placed within the perimeter gauging boundaries. Transfer
systems are popular for manufacturing axial-symmetrical (round), very deep-drawn parts (Figure
2).
Some transfer system advantages are:
Large parts can be handled at fairly rapid speeds.
Stamped parts can be turned over or rotated during the transfer process.
Servodrive-type transfers can be programmed to accommodate a large variety of parts, press
speeds, and stroke lengths.
Transfer dies do not tie each part together, often allowing for material savings.
Large volumes of parts can be produced in a fairly short time frame.
Some transfer system disadvantages are:
They often are quite costly.
They often require sophisticated electronics and
mechanical finger motion to function properly.
They require more die protection sensors.
They require a blank destacking system.
Progressive Dies
The progressive die is one of the most common, Figure 3
fastest methods available for producing piece parts. Progressive Die Strips
Unlike line or transfer dies, progressive dies tie the Sample strips courtesy of SURE Tool.
parts together by a portion of the original strip or coil, which is called a strip carrier. Different
types of parts require different carrier designs.
Progressive dies can produce as few as seven or eight parts per minute or as many as 1,500
parts per minute. Unlike transfer or line dies, all necessary stations are mounted on a single
common die set. These stations are timed and sequenced so that the piece part can be fed
ahead a constant given distance called the progression or pitch. Many parts can be tied together
allowing many parts to be made with each single press stroke.
Progressive dies most commonly are coil-fed, and if they contain the proper sensing system, they
often can run unattended. It is not uncommon for a single press operator to run two or three
progressive dies. The coil material typically is pushed through the die; however, systems that can
pull and push the coil material through the die are available. Progressive dies usually require the
use of a coil feeder and stock straightener (Figures 3 and 4).
Progressive die advantages are:
1. They can produce a great volume of parts very
quickly.
2. They often can run unattended.
3. They require only one press.
Progressive die disadvantages are:
1. They usually cost more than line or transfer Figure 4
dies. Progressive Die and Strips
2. They often require precision alignment and
setup procedures.
3. They require a coil feeder system.
4. They require an open-ended press to allow for the metal to feed into the die.
5. Damage to a single station requires removing the entire die set.
6. They often are much heavier than single-station line dies.
The production method you choose depends on many factors. Carefully consider items such as
the required volume of parts, your labor rates, and your existing equipment before choosing a
production method for your stamped parts.
Die basics 101: Common
stamping die components (Part 1
of 2)
While many specialty components can be
used in manufacturing dies, most dies contain
certain common components.
Die Plates, Shoes, and Die Sets
Die plates, shoes, and die sets are steel or
aluminum plates that correspond to the size
of the die. They serve as the foundation for
mounting the working die components. These
parts must be machined so that they are
parallel and flat within a critical tolerance. The Figure 1
machining methods are milling and grinding. Various die set types
Although grinding is the most popular, a milled surface now can be obtained that is as accurate
as a ground surface.
Most die shoes are made from steel. Aluminum also is a popular die shoe material. Aluminum is
one-third the weight of steel, it can be machined very quickly, and special alloys can be added to
it to give it greater compressive strength than low-carbon steel. Aluminum also is a great metal
for shock adsorption, which makes it a good choice for blanking dies.
The upper and lower die shoes assembled together with guide pins create the die set. The lower
die shoe often has machined or flame-cut holes that allow slugs and scrap created in the die to
fall freely through the die shoe onto the press bed. The holes also may serve as clearances for
gas springs and other die components.
The die shoe thickness is based on how much force can be expected during cutting and forming.
For example, a coining die, one that compresses metal by squeezing it between an upper and
lower die section, requires a much thicker die shoe than a simple bending die (see Figure 1).
Guide Pins and Bushings
Guide pins, sometimes referred to as guide posts or pillars, function together with guide bushings
to align both the upper and lower die shoes precisely. They are precision-ground components,
often manufactured within 0.0001 in. Although numerous specialty mounting methods can be
used to install these components, there are only two basic types of guide pins and bushings—
friction pins and ball bearing-style pins.
Friction pins are precision-ground pins that are slightly smaller than the guide bushing's inside
diameter. Pins are made from hardened tool steel, while bushings often are made from or lined
with a special wear-resistant material called aluminum-bronze. The aluminum-bronze may
contain graphite plugs that help to reduce friction and wear that occur to the pins and bushings.
Friction pins also help to heel the die shoes and prevent them from moving from side to side.
 Figure 2
Various guide pins and bushings
Precision or ball bearing-style guide pins comprise precision-hardened pins, ball cages, ball
bearings, and bushings. Unlike friction pins, these pins ride on a series of ball bearings contained
in a special aluminum ball cage that permits the bearings to rotate without falling out. These pins
have several advantages. First, friction is reduced so the die can run at faster speeds without
generating excessive friction and heat. Second, they allow the diemaker to separate the upper
and lower die shoes easily. Third, because they use ball bearings, they can be manufactured with
greater accuracy than friction pins (see Figure 2).
Remember, guide pins are meant to align the upper and lower die shoes, not to align a poorly
maintained or sloppy ram in a press! Some companies try to compensate for a poorly maintained
press by adding oversized guide pins or grinding the guide pin ends to a cone shape. Care must
be taken when flipping die shoes over so that the guide pins are not bent.
Heel Blocks and Heel Plates

Heel blocks are special steel blocks that are

precision-machined, screwed, doweled, and often
welded to both the upper and lower die shoes.
They contain components called wear plates and
function to adsorb any side thrust that may be
generated during the cutting and forming process.
They are especially important if the generated force Figure 3
is one-directional. Too much force generated from Heel blocks
one direction only can cause the guide pins to
deflect, which results in misalignment of critical cutting and forming components.
Most heel blocks have steel heel plates, and the heel block on the opposite shoe has a wear
plate made from aluminum bronze or some other dissimilar metal. The plate selection process is
critical. Using two opposing plates made of the same metal type can result in high friction, heat,
and eventually galling or cold welding of the wear plates.
Heel blocks can be used to heel the die in any or all directions. Box heels often are used to heel
the die in all directions (see Figure 3).
Screws, Dowels, and Keys
Screws fasten and secure the working components
to both the upper- and lower-die shoes. The socket
head cap screw is the most popular fastener used
in stamping dies. This hardened tool steel screw,
often referred to as an Allen head screw, offers
superior holding power and strength.
Dowels are hardened, precision-ground pins that
precisely locate the die section or component in its
Figure 4
Keys, dowels and screws
proper location on the die shoe. Although dowels have much heeling ability, their main function is
to locate the die section properly.
Keys are small, rectangular blocks of precision-ground steel that are inserted into a milled pocket
in the die shoes and sections called keyways. Keys locate and heel die sections and components
(see Figure 4).
While these are the most common, other components can be used in manufacturing stamping
dies. These will be discussed in Part V of this
series.
Die basics 101: Common stamping
die components (Part 2 of 2)
Many specialty components can be used in dies,
but the most commonly used are die plates, shoes,
die sets, guide pins, bushings, heel blocks, heel
plates, screws, dowels, and keys—all of which
were explained in Part IV of this series. This article
focuses on other common components—pads,
retainers, and springs.
Pads Figure 1
A pad is simply a pressure-loaded plate, either flat
or contoured, that holds, controls, or strips the metal during the cutting and forming process.
Several types of pads are used in stamping dies. Depending on their function, pads can be made
from soft low-carbon steel or hardened tool steel. Contoured pads must fit very closely to the
mating die section. Precision requirements determine whether the pads are positioned with guide
pins and bushings or left unguided.
Stripper Pads/ Plates. Stripper pads are flat or contoured, spring-loaded plates that pull, or strip,
the metal off the cutting punches. When it's cut, metal naturally tends to collapse around the body
or shank of the cutting punches; this is especially true during piercing. The stripper pad surrounds
the cutting punches and mounts to the upper die shoe. As the punch exits the lower die, the
spring-loaded pad holds the metal down flush with the lower die section, which allows the cutting
punches to withdraw from the sheet metal or piece part.
Often stripper pads are inserted with a small block of steel called a pad window. This pad window
usually is small and lightweight and can be removed easily to allow the die maintenance
technician to remove the ball lock-style pierce punch from the retainer without removing the entire
stripper pad. Stripper pads also function to hold the metal flat or to the desired shape during the
cutting process (Figure 1).
Pressure Pads/ Plates. During the wipe bending process, the metal must be held down
tightly to the lower die section before the forming punch contacts the metal. Pressure
pads must apply a force that is at least equivalent to the bending force. Most pressure
pads use high-pressure coil or gas springs (Figure 1). When loaded with very high-
pressure springs, contoured or flat pads also can form sheet metal. These pad types
often are referred to as power punches (see Figure 2).

Figure 2 Figure 3
Draw Pads. Draw pads control metal flow during the drawing process. In drawing, the amount of
pressure, or downward force, exerted on the sheet metal determines how much metal is allowed
to flow and enter the draw die cavity. Too much pressure may stop the metal from flowing and
cause splitting; too little downward force may allow excess metal to flow inward and cause loose
metal or wrinkling.
Draw pads, often referred to as binders or blank holders usually are made from hardened tool
steel. They can be flat or contoured, depending on the piece part shape. Most drawing dies use a
single draw pad; however, in special cases, some use two (Figure 3).
Spools, Shoulder Bolts, and Keepers
Spools, shoulder bolts, and keepers are used to fasten pads to the die shoes while
allowing them to move up and down. They are secured to either the top or bottom die
shoe with screws and often dowels for precision location. Of all of the components used
for securing pads, spools are the most common, especially in larger dies (Figure 1
and Figure 4).

Figure 4
Retainers
Retainers hold or secure cutting or forming die components to both the upper and lower die shoes. One of the
most popular retainers is a ball-lock retainer, a high-precision, accurately manufactured die component that
secures and aligns both cutting and forming punches. It uses a spring-loaded ball bearing to locate and secure the
punches, which feature a precisely machined teardropor ball seat. The spring-loaded ball bearing locks into the
teardrop shape and prevents the punches from coming out of the retainer.

Figure 5
The advantage of ball-lock retainers is that they allow the die maintenance technician to remove
and reinstall punches quickly. The punch is removed by depressing the spring-loaded ball
bearing and pulling up on the punch. Specialty retainers also can be made to hold and align
irregular punch shapes, as well as headed-style punches and pilot pins (Figure 5).
Springs
Springs supply the force needed to hold, strip, or form metal. Many different springs are used in stamping dies.
Spring selection is based on many factors, including the required force and travel, the spring's life expectancy, and,
of course, cost. Among the most popular are gas springs, which, when filled with nitrogen, can supply a great deal
of force. They also have an excellent life expectancy.

Figure 6
Other types are coil and urethane springs, often called marshmallow springs (Figure 6). Coil
springs are very popular when a reasonable amount of force is needed and budget constraints
are present. Urethane springs work well in short-run or
prototype stamping operations. They also are
inexpensive.
Die basics 101: Specialty die
components
Previous articles in this series discussed common
stamping die components. This article focuses on less
common specialty components found only in certain
dies, most of which are available from various
suppliers.
Figure 1
In-die Tapping Units
Many dies produce parts that contain holes or Inidie Tapping Units
extrusions that will be tapped or threaded to hold a Image courtesy of Danly IEM.
fastener. These holes often are tapped in the die rather than in a separate, offline operation.
In-die tapping units use a series of helix-style shafts and gears to transfer linear motion (press
ram) into rotary motion. The mechanical rotary motion can be press ram-driven, or it can be
created by special electronic servo-drive motors. Besides moving downward, the tap spins and
creates the threaded hole.
Unlike a regular cutting tap, an in-die tapping unit uses special roll forming taps. Instead of
removing chips, roll forming taps gradually deform the metal into the shape of a thread. Using a
standard cutting tap in an in-die tapping unit would create a cutting chip removal problem.
Because the work hardens during the metal deformation process, an in-die tapped hole's strength
can be similar to a standard cut thread's strength. The
difference is cost—using an in-die tapping unit instead
of an offline tapping process can reduce costs
significantly (see Figure 1).
Rotary Benders
Rotary benders, often referred to as rocker benders,
are specialty metal bending units that feature a rotary
action-producing V-grooved cylinder. This cylinder is
spring loaded and secured into a special retainer
Figure 2
called a saddle. As the die closes and the cylinder
Image courtesy of Danly IEM
makes contact with the sheet metal, it rotates about its
centerline and creates the bend. Rotary benders can be used to create straight-line bends only.
Unlike conventional metal bending equipment, rocker benders require no additional pressure
pad. Rocker benders can be easily adjusted and require less force than conventional bending
methods. When inserted with a special hard plastic, they are nonmarking and can overbend the
metal to create an acute or less than 90-degree angle. They also can create double bends
(Figure 2).
Pierce Nut Units
Fasteners, such as screws, nuts and rivets, can be inserted into a stamped part in various ways. Using a pierce nut
unit currently is a common method. This special mechanical unit (Figure 3) both pierces a hole and fastens a
threaded nut to the stamped part.

Figure 3
Pierce Nut Installation Unit
Image courtesy of Multifastener Corp.
Pierce nut units can feed fasteners in several different ways and can be incorporated easily in
progressive, line, and transfer dies. Unlike tapping, in which the hole relies on the amount of
thread engagement that can be achieved by the specific extrusion length, pierce nut units can
work with a variety of nut sizes, strengths, and thread series.
Pierce nut units can be used in almost any hole-piercing operation and are very popular in both
the automotive and other industries.
HYDROCAMs
Activated by press ram-driven hydraulic cylinders, HYDROCAMs (Figure 4) pierce holes and create special forms in
die areas that are inaccessible using standard cams. Using HYDROCAMs can reduce the number of stamping
operations necessary, as well as the die cost.

Figure 4
HYDROCAM Assembly
Image courtesy of Ready
Technology.
The drive unit can be placed almost anywhere beneath the press ram and can be used to
activate one of several cams. Because these cams run on hydraulics, they can achieve a great
force. HYDROCAMs also can be adjusted easily to fine-tune the timing to execute specialty
cutting and forming operations.
Thread-forming Punches/Buttons
Thread-forming punches and buttons (Figure 5) both pierce and form the metal into a special shape. The specially
shaped pierced hole functions to hold a variety of screws and increases the force necessary to pull the screw out of
the sheet metal.

Figure 5
Image courtesy of Danly IEM.
The punches and buttons can be incorporated into standard ball lock retainers, or they can be the
headed type. Because the metal simply is being pierced and formed, no press speed reduction is
necessary.
Holes created with special thread-forming punches and buttons have improved holding ability
over putting a screw into a flat piece of sheet metal.
Metal cutting and forming methods are virtually endless and limited only by the imagination. Each
die has its own special function. To list all commercially available and custom-made die
components available would be nearly impossible.
Part VII of this series will discuss sheet metal properties.
Die Basics 101: Metals used in stamping (Part 1 of 2)
Previous articles in this series focused on stamping dies and production methods. This article
discusses stamping materials—both ferrous and nonferrous.
To process, design, and build a successful stamping die, it is necessary to fully understand the
behavioral characteristics of the specific material to be cut and formed. For example, if you are
forming 5000 series aluminum and you follow the same process you use for deep drawing steel,
the operation most likely will fail—not because aluminum is bad, it's just different from steel.
Each metal has its own unique mechanical characteristics. The metal type that the die is forming
and cutting often determines the tool steel that must be used, as well as how many operations
are required. In addition, different metal types require different lubricants, press speeds, and
capacities. Because stampers are end users of metals, this article focuses on selecting and
understanding the end-product behavior only and not the metal-making process.
Two Metal Types
Although there are literally thousands of metals that can be stamped, all fall within two basic
categories—ferrous and nonferrous. Ferrous metals contain iron, and nonferrous metals are
those without iron. Steel is a classic ferrous metal because it is derived essentially from iron ore.
Aluminum, however, contains no iron and is classified as a nonferrous metal.
With the exception of a few exotic specialty metals, ferrous metals are magnetic and nonferrous
metals are nonmagnetic. Because nonferrous metals do not contain iron, they are less likely to
deteriorate through oxidation or rusting. Some commonly stamped nonferrous metals are
aluminum, brass, bronze, gold, silver, tin, and copper.
Aluminum is a very popular metal for applications in which strength, weight, and corrosion
resistance are factors. Aluminum is approximately one-third the weight of steel. Although
hundreds of alloyed steels exist, plain carbon steel is by far the most commonly stamped ferrous
metal.
Steel Basics
Carbon is a basic element of the steelmaking process. In its raw form, carbon could be described
as a chunk of coal or pencil lead. A piece of coal buried a mile or so beneath the surface of the
earth and subjected to intense heat and pressure for about a thousand years yields what? A
diamond. A diamond is nothing more than pure, compressed carbon. (Yes, "Carbon is a girl's
best friend." Just make sure that it's natural, highly compressed carbon that you are giving her.)
From this basic knowledge of carbon, it is easy to deduce that the more carbon present in the
steel, typically the stronger and less formable it will be. For example, tool steel used in
manufacturing dies contains far more carbon than the sheet
metal being processed. Keep in mind that the carbon content
of a particular metal does not fully determine the metal's
mechanical properties. Carbon content is only one factor.
Alloys
An alloy is a homogeneous compound or mixture of two or
more metals that enhances the metal's chemical, mechanical, Figure 1
or physical properties. When combined, the metals must be compatible and resist separation
under normal conditions. For example, two common alloys added to steel are chrome and nickel.
Chrome is very hard and resists oxidation, and so does nickel. Adding chrome and nickel to steel
produces stainless steel. These added alloys enable the stainless steel to resist oxidation.
If you have purchased stainless steel flatware recently, you may have noticed different grades
are available. These grades usually are designated as good, better, and best. The main
difference in the quality depends primarily on the alloy content. The numbers that you see on the
packaging, such as 18/8 or 18/10, refer to the percentage of chromium (18 percent) and nickel (8
percent or 10 percent) in the stainless steel. Chromium is known for its stain resistance, and
nickel is known for its high luster and shine. Higher alloy numbers mean higher quality and cost.
Alloys can be introduced into both ferrous and nonferrous metals. Many aluminum alloys are
available today. A very common steel type used in the
automotive industry is high-strength, low-alloy steel
(HSLA). Alloys are combined with medium carbon steel to
give the metal good load-carrying ability and reasonable
formability. These mechanical properties make HSLA a
good candidate for frame rails and other automotive
structural parts that require strength.
The number of alloyed metals used in stamping are far too
numerous to mention in this article. The thing to remember
Figure 2
is that alloyed metals are a combination or mixture of two or more metals that create a new metal
with special characteristics.
Plain Carbon Steel
Plain carbon steel can be defined as pure steel, meaning that it contains no intentionally added
alloys. Plain carbon steel—among the most popular steel types used in stamping today—usually
is assigned a four-digit number, such as 1006, 1020, 1050, and 1080. To determine the steel's
carbon content, simply place an imaginary decimal place between the four digits and read the
last two digits as a percentage of 1 percent. For example, 1010 steel contains 10 1/100 of 1
percent carbon, or 0.10 carbon (see Figure 1).
The more carbon in the steel, the harder it will be to cut and form. Metals with increased carbon
can be hardened further by heating them to a critical temperature and cooling them quickly in the
proper quenching medium. Processing harder metals requires dies made from tougher, more
wear-resistant tool steels. Also, greater force is needed to cut and form the metal. Knowing the
metal's carbon content can help you make a better decision about the appropriate tool steel and
press capacity. Figure 2 shows a few typical applications with respect to the steel's carbon
content.
This article covered very basic metal types and properties only. The
next article in this series will discuss the mechanical characteristics of
different metals in more detail. It also will explain how the metal
selection affects the die processing method and die materials.
Die Basics 101: Metals used in stamping (Part 2 of 2)
Part VII of this series introduced two basic types of metals used to
manufacture stamped parts—ferrous, metals that contain iron, and
nonferrous, metals that do not contain iron. This article discusses the
specific mechanical properties of these metals in more detail.
The metal's mechanical properties greatly influence the process
chosen to transform the flat sheet metal into the finished part's shape Figure 1
and profile. The mechanical properties often influence the tool steel and lubricants used to form
and cut the sheet metal. They also determine if offline processes, such as annealing or
hardening, are necessary.
Literally thousand of metals are used in stamping today, and it would be nearly impossible to
cover each material's specific mechanical properties. This article explains the fundamental
properties they all share and discusses methods for testing and defining some of these
properties.
Tensile Testing
Among the numerous methods used to test metal's mechanical capabilities, the most widely used
and accepted is the tensile test. In a tensile test the metal is carefully cut to a specific shape
according to a given testing standard. The cut sample is called the test coupon.
The test coupon then is placed into a special machine called a tensile tester, which grabs each
end of the coupon and stretches it. The metal is stretched until it fails (breaks). Factors such as
how much the metal stretched, how it thinned out, how it changed shape, and how much force
was required throughout the entire forming process are carefully measured and documented.
Mechanical properties such as elongation percentage, tensile strength, yield strength and nandr
valuescan be obtained using this test (Figure 1).
The tensile test also can generate a special graph called a stress/strain diagram (Figure 2). This
diagram shows the relationship between the force that is
needed and the deformation that occurs. In short, it shows
how the metal behaves when being deformed.
Ductility
Ductility is a very broad term that describes a metal's
ability to change shape without fracture. In flat-rolled steel,
ductility usually is measured by hardness or mechanical
properties in a tensile test. Generally speaking, the more
ductile the metal is, the more it can be deformed.
However, keep in mind that metal can be deformed in

Figure 2
more than one way. Better defining how ductility affects the forming process requires first defining
a few important properties that are obtained when the metal is subjected to a tensile test.
Elongation Percentage. Elongation percentage is one of the properties that affect metal
ductility. Elongation can be described simply as a numerical expression of how much the metal
stretched within a given boundary. The most commonly used boundary is 2 inches.
The metallurgical definition and mathematical equation for elongation can be expressed as the
extension of a uniform section of a specimen expressed as a percentage of the original gauge
length:
Elongation, % = (Lx- Lo) / Lox 100,
where Lois the original gauge length and Lxis the final gauge length.
For example, a material having 42 percent total elongation stretched 42 percent of its beginning
length within a 2-in. boundary before it fractured.
Tensile Strength. Tensile strength can be defined as the maximum stress that a material can
withstand. In tensile testing, the measurement is the ratio of maximum load to the original cross-
sectional area. Often it is also referred to as the metal's ultimate tensile strength (UTS).
Another definition of tensile strength is the maximum stretching that a material is capable of
withstanding without breaking under a gradually and uniformly applied load. Simply, it is the
measurement of the breaking or rupturing force.
Yield Strength. A metallurgist may describe yield strength as the point at which material
exhibits a determined deviation from the proportionality of stress to strain. While this most
certainly is a true statement, it is not one that's easy to understand. Think of yield strength as the
measurement of the force necessary to deform the material permanently.
Remember, before a material can permanently change its shape, it must first go through a
transition from elastic deformation (not permanent) to plastic deformation (permanent). Think of it
like this: Imagine suspending a flat piece of sheet metal that is 0.062 in. thick, 12 in. wide, and 24
in. long between your arms. The sheer weight of the metal will cause it to sag slightly in the
center. This change in shape is the result of elastic deformation, meaning that although you have
witnessed a change in the metal's shape, the change is not permanent. This can be proven by
placing the metal on a flat table, at which point it will
return back to a flat sheet.
However, if you severely bow the metal sample and
apply enough force, it will begin to take the shape of
the bow. The point at which the metal permanently
changes its shape is its yield point. Yield strength is a
measurement of how much force it took to get the Figure 3
material to deform permanently, give up, or "yield." Yield strength usually is expressed in pounds
per square inch (PSI), or megapascals.
Hardness. Hardness, which can be defined simply as a measurement of the metal's
penetrability, usually is tested with a special machine. The most common hardness testing
machine is a Rockwell/Brinell tester (Figure 3). This device applies a load or weight to a point that
penetrates into the steel's surface. The deeper the penetration, the softer the material. By
measuring the applied force and the penetration depth, we can obtain a numerical value that
expresses the metal's hardness.
Although hardness alone does not give enough data to determine the metal's formability, it can
be used for comparative analyses. Generally, with the exception of metals such as aluminum, the
softer the metal, the more ductile it will be. Materials such a copper, brass, gold, titanium, and
many other nonferrous metals often are categorized by their hardness.
This article discussed only a few mechanical properties that both ferrous and nonferrous metals
have. The next article in this series will cover even more properties.
Die Basics 101: Mechanical properties and behavioral characteristics of
metals
Part VIII of this series discussed some of the specific mechanical properties of metals—ductility,
elongation percentage, tensile and yield strength, and hardness—and how to derive these properties. This
article describes other important mechanical properties, as well as a few behavioral characteristics.
 Figure 1
Strain and Thickness Distribution
Strain
Strain can be defined simply as a measurable deformation of the metal. In other words, metal
must be "strained" in order to change its shape. Strains can be positive (pulling the metal apart,
or tension) or negative (pushing the metal together, or compression.) Strains also can be
permanent (plastic) or recoverable (elastic). The result of elastic straining commonly is referred to
as springback, or elastic recovery.
Remember, every metal type wants to return to its original shape when it's deformed. The
amount the metal springs back is a function of its mechanical properties. When engineers refer to
part areas that are "high strain," they typically are referring to areas that have been subjected to
substantial stretch or compression. Figure 1shows a simulation image of a part that has been
stretched. Each color represents a different type and amount of strain. Some of the strains are
positive and others are negative.
Stress
Stress is simply the result of straining the metal. When subjected to stress, metal incurs internal
changes that cause it to spring back or deform nonuniformly. Trapped stresses within a part often
result in a loss of flatness or other geometric characteristics. All cut or formed parts incur stress.
Stretch Distribution
Stretch distribution is a very important mechanical
property. A metal's stretch distribution characteristics
control how much surface area of the stretched metal
is permanently deformed. Stretch distribution is
determined primarily by checking the metal's thickness
when it's deformed in tension during the tensile testing Figure 2
process. The more uniform the thickness distribution, Stretch Distribution / Tensile Test
the better the stretch distribution. Stretch distribution
also is partially expressed in the metal's n value. Figure 2shows different stretch distribution
results. The red areas of the sample test coupon represent areas that have been stretched.
n Value
To understand n value, otherwise known as the work or strain hardening exponent, you must
understand that every time metal is exposed to permanent deformation, work hardening occurs.
It's the same thing that happens when you bend a coat hanger back and forth. As you bend the
hanger, it gets harder and harder to bend. It also becomes more difficult to bend it in the same
place. This increase in strength is the result of work or strain hardening. However, if you continue
to bend the hanger in the same spot, it will eventually fail.
Ironic as it may seem, materials need to work-harden to achieve both good stretchability and
stretch distribution. How they work-harden is the key. The n value of a material can be defined
fundamentally as the metal's stretchability; however, it also is an expression of a material's
stretch distribution characteristics.
Perhaps one of the most important mechanical properties to consider if the stamped part requires
a great deal of stretch, the n value is expressed numerically in numbers from 0.100 to 0.300 and
usually is carried out two or three decimal places. The higher the number, the greater the metal's
stretchability and stretch distribution. Higher-strength metals, such as spring steel, have very low
n values, while metals such as those used for making oil pans and other deep-formed parts
usually exhibit higher n values.
The metal's n value also is a key mechanical value used in creating forming limit diagrams. (This
will be discussed in subsequent parts of this series.)
r Value
The metal's r value is defined metallurgically as the plastic strain ratio. To understand this
concept, you must clearly know the difference between stretching and drawing. Stretching is a
metal forming process in which the metal is forced into tension. This results in an increase in
surface area. Items such as most automobile hoods and fenders are made using this process.
Drawing is the displacement of metal into a cavity or over a punch by means of plastic flow or feeding the
metal. Items such as large cans, oil pans, and deep-formed parts usually are made using this process.

Figure 3
Plastic Strain Ratio r Value
The metal's r value can be defined simply as the metal's ability to flow. It also is expressed
numerically using a value from 1 to 2, which usually is carried out two decimal places. The
greater the r value, the more drawable the metal
(Figure 3).
The metal's r value is not uniform throughout the
sheet. Most metals have different r values with
respect to the metal's rolling direction. Testing for a
metal's r value requires tensile testing in three
different directions—with the rolling direction,
against the rolling direction, and at 45 degrees to
the rolling direction. The test results usually are
averaged and expressed as the r bar, or average
of the r values.
Differences in the plastic strain ratio result in
earring of the metal when being drawn. For Figure 4
example, when drawing a round shell from a round Earring Caused by Differences in the
blank, the results will be a near square bottom on Metal's r Value
the flange of the cup. This effect (Figure 4) is
caused by different amounts of metal flow with respect to the metal's
Surface Topography
A metal's surface topography, defined simply as the metal surface finish, is created mainly during
the metal rolling process. Surface topography is an important metal characteristic. When being
drawn, metals often require a surface finish that has the ability to hold lubricant. Surface
topography is determined with a measuring tool called a profilometer.
This wraps up the discussion of sheet metal characteristics. The next article in this series will
focus on metal cutting.
Die Basics 101: Metal cutting process
Cutting is the most severe metalworking process that takes place in a die and shouldn't be taken
lightly.
Cutting Basics
Cutting metal requires great force. For example, it takes approximately 78,000 lbs. of pressure to
cut a 10-in.-diameter blank from 0.100-in.-thick mild steel. Consequently, the punch, die, and
press must absorb overwhelming shock.
Overshocking the press and die components usually is what causes them to fail prematurely. If
you work in a shop that blanks heavy metals, you know what I mean. You can hear and  feel the
press shock. Doing everything you can to reduce the unnecessary loading and shocking is
important. Factors such as cutting clearance and shear angles contribute significantly to the
amount of forcerequired. They also affect the amount of shock that is generated.
Piercing Misconceptions
If you participated in a tool and die apprenticeship, you probably were taught the following rules
for piercing punches:
The punch determines the hole size.
The cutting clearance always should be even (equal) around the punch.
10 percent of the metal's thickness is a good cutting clearance for each side of the punch.
These are good starting guidelines for cutting, but they aren't entirely true. Let's examine each
misconception.
The punch determines the hole size. Although the punch produces a hole that is very close to
its actual diameter, altering the clearance between the punch and the button (sometimes referred
to as the matrix) also affects the hole size. The simple truth is that a hole can be made slightly
larger or smaller than the punch diameter by increasing or decreasing the cuttingclearance. This
is because of the way that the metal deforms before the cutting actually takes place.
Think of the metal that you're cutting as Silly Putty® or a rubbery plastic. If the clearance between
the cutting punch and the button is insufficient, it will cause the metal to compress or bulge out
away from the punch before the cutting takes place. After the slug is created, the metal grips the
punch sides. This increased friction between the sides of the punch and the metal raises
theamount of force necessary to strip or pull the punch from the metal.
The insufficient clearance between the punch and the button means that a greater force is
needed to create the hole. Inadequate clearance also increases the load on the edges of the
punch and the matrix, which causes premature edge breakdown.
After the punch is removed, the metal that once was compressed decompresses and collapses
around the void area (the hole). The result is a hole that is smaller than the punch's diameter
(see Figure 1).
Keep in mind that changing the clearance does not affect the hole size to a great extent, about
0.001 in. to 0.002 in. Although it might seem small, this change can reduce the friction generated
during punch withdrawal significantly and extend the punch life see Figure 2).
The cutting clearance always should be equal around your punches. Once again, unless
you are piercing only round holes, this statement is not entirely true.
Cutting clearances should change around the punch perimeter with respect to the punch
geometry. Let me explain using this example: If you are piercing a square hole, you may notice
that the corners of the punches are the first areas to break down. Once the corners break down,
the entire punch must be sharpened. Ever wonder why the corners break down first? It's because
this is the area that issubjected to the highest cutting loads. Very simply, wherever there is a
small radial feature in a cut (nothing is worse than a dead sharp corner), the compressive forces
will be greater.
Excessive compression can be compensated for by increasing the cutting clearance in areas with
small radial features or sharp corners. Increasing the clearance in these areas helps to increase
punch and button life and reduce the probability of a large corner burr. A good rule of thumb is to
increase the clearance in the corners to approximately 1.5 times the normal clearance. An even
betterscenario is to avoid dead sharp corners whenever possible (see Figure 3).
10 percent of the metal's thickness is a good cutting clearance for each side of the
punch. Once again, this statement isn't always true. While 10 percent is by far the most
commonly used cutting clearance, it most certainly is not always the ideal cutting clearance.
Cutting clearances can range from as little as 0.5 percent up to as much as 25 percent of the
metal's thickness per side. Among the many factors that determine the best cutting clearance are
the metal's thickness and hardness and the punch size and geometry. For example, the ideal
cutting clearance for piercing a 0.500-in.-diameter round hole in a sheet of 0.100-in.-thick 300
series stainlesssteel is about 13 percent of the metal's thickness per side, or 0.013 in. per side.
This calculates to a total clearance of 0.026 in.
However, changing from a 0.500-in.-diameter punch to a 0.100-in.-diameter punch requires more
cutting clearance, from 13 percent to 20 percent per side. This is because the smaller punch has
a smaller radius, and compressive forces congregate at the smallest radial feature of a cut (just
as in the rectangular punch example noted above).
Metal type also affects cutting clearance selection. Harder, higher-strength materials require
more cutting clearance, while softer metals, such as aluminum, require smaller cutting
clearances.
As you can see, metal cutting is slightly more complicated than often perceived. Understanding
the many variables and how they affect the cutting process are key.
Die Basics 101: Common causes of slug pulling

Slug pulling is a serious problem in a stamping operation. Addressing the issue requires first
understanding why the slugs are pulling.
What Is Slug Pulling?
When a pierce punch creates a hole, it also produces scrap, usually referred to as a slug. Slug
pulling occurs when the slug sticks to the punch face upon withdrawal and comes out of the
button, or lower matrix.
If a slug falls off the punch and onto the strip or part, it can damage the part and die. Keeping the
slug down in the matrix or, better yet, completely pushing it out of the die is the desired scenario.
What Causes Slug Pulling?
Many factors contribute to slug pulling. Among them are trapped air; large cutting clearances;
extremely fast piercing operations; sticky lubricants; improperly demagnetized punches; and
fatigued or insufficient spring ejectors.
1. Trapped air/ vacuum pockets. The slug generated during the piercing process has some
curvature. The curved, void areas where air is trapped, creating a vacuum action. During the
perforating process, a tight seal is maintained around the punch perimeter. When the punch is
withdrawn, this seal prevents the slug from coming off the punch (Figure 1a). Keep inmind that
the only portion of the piercing punch that makes contact with the metal is a localized zone
around the punch's outside diameter. Even punches with angularity make only localized contact
with the metal (Figure 1b).
Trapped air must be allowed to escape to reduce the amount of vacuum. This is done by creating
a small air vent in the center of the pierce punch, which allows the otherwise trapped air to
exhaust itself from the vent hole and reduce the suction. Losing suction breaks the seal between
the slug and the pierce punch and allows the slug to fall (Figure 2a).
When piercing punches that are too small to vent are used, other means of addressing slug
pulling most likely will be necessary. Also keep in mind that addressing the trapped air probably
won't solve the slug pulling issue completely, but it will certainly help.
2. Larger cutting clearances. Although using engineered or larger cutting clearances can result
in much greater punch and matrix life, there is one drawback to doing so. As the clearance gets
larger, compression on the slug decreases, which increases the chances of slug pulling.
When smaller cutting clearances are used during the perforating process, both the slug and
metal outside the slug are forced into compression. After the slug is cut free, it decompresses
and remains in the matrix. This is because the decompressed slug now has an interference or
press fit into the matrix.
In simple terms, when greater cutting clearances are used, the slug will be slightly smaller than
the hole in the matrix, which means it may be pulled from the matrix by the punch, resulting in
slug pulling. Reducing the cutting clearance certainly can help this problem, but it also can
shorten punch life and increase sharpening frequency. Rather than reducing the cutting
clearance, it isrecommended stampers try a few methods that will be discussed in the next part of
this series (Figure 2b).
3. Oil / lubricant problems. Using heavy, thick, highly viscous oils and deep-drawing lubricants
only adds to slug pulling problems. Unfortunately, these compounds often are necessary for
forming dies to perform correctly.
Over time heavy oils and compounds can become coagulated and sticky. Thick, sticky
compounds can cause slugs to stick to punches. Periodically cleaning the cutting components
can help to resolve this sticky residue problem. Other methods to resolbe this problem will be
discussed in Part XII.
4. Magnetized punches. Punches and die sections often are sharpened with a surface grinder.
Most surface grinders secure the sections and punches to be ground by a high-power electro- or
conventional magnet (Figure 3). Any ferrous metal that comes in contact with this magnet
becomes slightly magnetized.
After the die components have been ground, they then must be demagnetized fully. This process
is accomplished by using a commercially available demagnetizing unit. Magnetized pierce
punches and die sections can cause slugs and other magnetic debris to be picked up and carried
through the tool.
5. Weak or fatigued spring ejectors. Spring ejectors often are used in piercing and cutting
punches. These small, spring-loaded pins push the slug from the punch face after cutting has
taken place. If the spring behind the punch fails or fatigues, slug pulling can occur. Periodically
inspecting and replacing springs is a necessary part of a good die maintenance program(Figure
4).
Slug pulling can have disastrous consequences. A single slug carried through a progressive die
can damage every tool in the station. The next part in this series will discuss methods for
resolving slug pulling problems.
Die Basics 101: Resolving slug pulling problems

Figure 1 Spring Ejectors and Air VentsImages courtesy of Dayton Progress

Slug pulling, which occurs when scrap metal—the slug—sticks to the punch face upon withdrawal
and comes out of the button, or lower matrix, is a serious problem that can damage parts and
dies. Various methods can help reduce the occurrence of slug pulling.
Air Vents
Putting air vents in cutting and piercing sections most likely will not completely stop cutting slugs
from pulling, but it's a good start. This is because trapped air that creates vacuum pockets is a
major cause of slug pulling. It is good die-building practice to drill air vents in all cutting punches
whenever possible, especially if they are piercing punches.
Spring Pins
A common, popular method for preventing slugs from pulling is to use a pierce punch with a
spring-loaded ejector pin. However, this method is effective only if the punch is large enough to
accept a spring pin.
The spring-loaded pin pushes slugs from the punch point and into the matrix. Keep in mind that
to maximize the spring pin's effectiveness, it must be accompanied by an air vent. This can be
achieved by drilling an oversized hole for the pin and allowing the trapped air to escape around
the spring pin.
Spring pins work well in large dies containing large pierce punches, but they do not lend
themselves well to small-die, high-speed operations. Many commercial punch manufactures can
provide these types of punches for you. Some commercially available punches even have a
special wire retainer that allows the maintenance technician to depress the spring pin, lock it in
place with a specialretention pin, and grind the punch with the spring depressed. This capability
allows the punch to have the same amount of spring travel as a new punch (Figure 1).
Reduce the Punch-to-Die Clearance
Although reducing the cutting clearance shortens the life of the punch and matrix, it helps
minimize slug pulling. This is because reducing cutting clearance forces the slug in compression
during cutting. After the cutting is completed, the slug decompresses in the matrix for an
interference fit.
For short-term runs and low-production parts, reducing the clearance may be your answer;
however, for high-production dies, it is recommended that you use an engineered cutting
clearance combined with an alternate method for slug retention.
Special Die Inserts, Buttons, and Matrix Alterations
Many commercially available inserts orbuttons can help address slug pulling problems. Some
common commercial names are "slug huggers" or "slug-control buttons" (Figure 2).
A slug-control button consists of two small slots machined at an angle in each side of the matrix.
These slots cause a burr to be generated on the slug. The burr is forced downward at an angle,
wedging the slug in the matrix.
A slug-hugger button has barbs in the matrix that impale themselves into the slug. Both of these
methods work well and are highly recommended.

Figure 2 Commercial Slug Control Buttons

A reverse-tapered "bell mouth" button also works well. Most die buttons have a bell mouth taper
machined into them, with the hole diameter increasing toward the bottom of the button. Although
it may seem strange to use a button with a hole in the matrix that gets slightly smaller as it nears
the clearance opening, this is an effective slug retention method. The reverse taper holds the
slugs incompression in the matrix. Keep in mind that in most piercing operations, 0.0005 inch to
0.001 in. is more than sufficient taper. Too much taper and compression can cause the matrix to
split (Figure 3).
Vacuum Units
Commercially available vacuum units can be incorporated in your piercing operation. These units
create a vacuum and pull the slug downward into the matrix. In a pinch, try a simple wet and dry
vacuum. In my experience, it works fairly well. However, keep in mind that these vacuums
typically are not meant to run for hours and hours. Even the higher-quality models burn up
quickly.
Other Ideas
Although it may be somewhat crude, using a weld spatter technique on the inside of a button can
be a relatively effective slug-pulling remedy. Commercially available deposit machines work best
to execute this application. These special deposit machines deposit tiny barbs on the inside of
the button. These barbs impale themselves into the slug and help prevent it from pulling upward.
These portable application machines have significant advantages over ordinary weld spatter.
First, they can deposit tungsten or vanadium carbide on the button surface, which decreases
button wear and increases slug-retention life. Second, the deposits can be made accurately with
as little heat as possible. This helps to reduce tool steel and button damage. Deposit amounts
can be carefullycontrolled.
Keep in mind that each cutting and piercing operation may require a different slug pulling method.
The key is to remember that one pulled slug is one too
many. Even a single pulled slug can result in
extensive die damage. Don't risk ignoring the issue:
An ounce of prevention is worth a pound of cure!
Die Basics 101: Specialty metal cutting
methods used in stamping operations
Various specialty metal cutting methods are used
in stamping operations. Among them are pinch,
breakout, and shimmy.
Pinch Trimming
Pinch trimming is a special method in which the Figure 1
vertical walls of a drawn or stretched vessel are cut by Pinch trimming die design
pinching the metal between two hardened tool steel
die sections. In most cases, the clearance between the die sections is as little as possible
(Figure 1).
Unlike a conventional metal cutting process, no
shearing or fracturing takes place in pinch trimming.
Items such as deep-drawn cans often are pinch
trimmed.
Although pinch trimming is a very popular method,
because the metal basically is pinched off, a very
sharp burr usually remains on the part (Figure 2). This
burr must often be removed by tumbling the parts in a
tub containing abrasives.
Pinch trimming also places a great load on the sides
of the die sections, which results in high wear. Most Figure 2
pinch trimming operations require a great deal of Result of pinch trimming
maintenance.
Breakout Trimming
Breakout trimming is a specialty metal trimming process in which the metal is forced to fracture or
break free from the vessel's flange. If you are accustomed to conventional cutting operations, this
process most certainly may look harebrained to you. Unlike a conventional metal cutting process,
the lower die section has a 45-degree angle ground on its edge. This angle has two basic
functions:first, to allow the cup to fully nest in the lower die, and second,. to force the flange to
bend upward slightly.
The cutting clearance also is much greater in breakout
trimming than the clearance commonly used in
conventional cutting operations. This additional
clearance causes leverage action, but does not allow
for the metal to be bent into a vertical wall. However
rest assured, this process works well, especially for
metals that severely work harden (Figure 3).
Breakout trimming takes advantage of the metal's
work hardening and reduced thickness in a given
localized zone. This method works best for round or Figure 3
axial symmetrical drawn parts. Break out trimming
For breakout trimming to work effectively, the drawn cup must be properly prepared for the
process. The inside radius on the cup's flange must be
reduced to a dead sharp corner before using this
method. This is achieved by drawing the cup deeper
in the drawing operation or compressing it back over a
dead sharp corner on the die section (Figure 4). Doing
so reduces thickness inthe radius and allows work
hardening to take place.
After the cup has been prepared properly, it can be
introduced into the breakout trimming process, in
which the cup flange will be forced upward, causing
the metal to breakat the dead sharp corner (Figure 5).
Because the cup flange is round, as it is pushed Figure 4
upward it is forced into Creating a small radius
radial compression. This compression works to your
advantage by forcing the cup to befractured out of the flange.
Breakout trimming does not produce a burr as large as that
produced by pinch trimming. Also, because the loads on the
tool steel sections are minimal, the die requires less frequent
maintenance. However keep in mind that this method can be used
only in situations in which the metal must be cut at the
intersection of the flange and the cup's vertical wall.
Shimmy Trimming
Shimmy trimming is a unique metal trimming process in which a
series of specially Figure 5 designed cams are used to force the part
to move side to side. Unlike conventional cam trimming, the part
does not remain stationary, but rather moves horizontally in the die. It moves in such as fashion
that it can be trimmed true to the surface of the vessel. Trimming 90 degrees or  true
tosurfaceresults in a much cleaner cut and considerably lower burrs than pinch trimming.
A great advantage of shimmy dies is that they can cut the entire perimeter of a part in a single
press stroke. Unlike conventional pinch trimming, a shimmy trimming operation is not restricted to
straight line cuts. Features such as notches, curved cuts, as well as a various other cuts can be
made. Many common items such as cigarette lighters and gun shells are made using the shimmy
trimmingprocess.
Shimmy trimming operations also can be designed
to cut metal as thick as 0.250 in. and, unlike
conventional pinch trimming, can keep the original
metal thickness in the trimmed area. Not like
conventional cutting operations, shimmy dies require
a pressure system such as a press cushion or a
nitrogen gas manifold (Figure 6).
Which metal cutting operation a die design engineer Figure 6
chooses is based on many factors, including Parts trimmed with a shimmy trim die
allowable burr height, parts volumes, metal type and Images courtesy of Vulcan Tool Corporation
thickness, and trim line geometry. No single
trimming operation is best for all scenarios. The next article in this series will continue the
discussion of metal cutting.
Die Basics 101: Fineblanking and GRIPflow

Figure 1Results of Conventional Cutting

Although fineblanking and GRIPflow® often are categorized as metal cutting operations, they
more closely resemble a cold metal extrusion process that creates what appears to be a blanked
part. The processes can be defined simply as methods in which a part is squeezedfrom the strip.
Unlike parts made with conventional metal cutting methods, the parts made using fineblanking
and GRIPflow have little or no fracture zone (Figure 1). In other words, these parts appear to
have smooth, square machined edges.
These processes also can produce parts with very close flatness and dimensional tolerances and
roughness of about 2 to 3 �m, which means that, in many cases, postprocessing operations
such as grinding and milling can be eliminated.
Parts commonly made using fineblanking and GRIPflow include gears and parts that require
close flatness tolerances or a square cut edge. These processes also can pierce holes with
diameters as small as one-third of the metal's thickness and very close to the part's edge.
Before these methods were available, the metal had to be shaved in one or several shaving
operations to achieve a smooth cut edge. Shaving in a die often produces slivers and debris that
can create tool problems and product defects.
Fineblanking
Invented in Switzerland in the 1920s, fineblanking, unlike conventional stamping methods, utilizes
a special triple-action hydraulic press called a fineblanking press. Fineblanking requires the use
of extreme-pressure pads. These high-pressure pads hold the metal flat during the cutting
process and keep the metal from plastically deforming during punch entry.
In fineblanking presses, a V-ring is incorporated into one of the high-pressure pads. This V-ring
also is commonly referred to as a stinger or impingement ring.
Before the punch contacts the part, the V-ring impales the metal. It surrounds the part perimeter
and functions both to trap the metal from moving outward and push the metal inward toward the
punch. This action reduces the rollover that occurs at the part's cut edge. Using high-pressure
pads combined with the stinger ring and close clearances keeps the metal from fracturing and
creates a smooth edge (Figure 2). Because the part is held extremely tight between the high-
pressure pads during cutting, part distortion is minimal.
Unlike conventional cutting operations that use approximately 10 percent of the metal's thickness
for the cutting clearance, fineblanking operations usually use clearances less than 0.0005 in. per
side. This small-clearance requirement combined with high pressure also contributes to the fully
sheared part edge.
Once again, don't confuse fineblanking with a cutting operation. It's not a cutting operation at all;
it is more like a cold extruding process. The slug (part) is pushed or extruded from strip held so
tightly between high-pressure holding plates and pads that the metal cannot bulge or plastically
deform during the process. These high-pressure pads fit precisely around all cutting components.
Fineblanking can be used to produce parts as thick as 0.5 in. from a variety of metals.

Figure 2Fineblanking Process

GRIPflow
Not to be confused with fineblanking, the GRIPflow process does not use a stinger or
impingement ring to stop outward metal movement but relies solely on hydraulically applied
pressure to the blank. The pressure is applied through precision-guided pressure pads.
Think of the GRIPflow process as similar to compound blanking. However, unlike a compound
blanking operation, GRIPflow uses very small cutting clearances between each of the cutting
components. This small clearance, combined with high blank holding pressures and precision
clearances between all moving components, produces a smooth-edged part that can be held to
very tight dimensional tolerances (Figure 3).
Once again, keep in mind that GRIPflow is not a metal cutting process but a cold extruding
process. The cutting sections do not have cutting shear ground on them.
It is difficult to tell the difference between a part that was fineblanked and one made using the
GRIPflow process just by looking at them. Unlike fineblanking, GRIPflow does not require a triple-
action press. Because it uses hydraulic cylinders mounted in the die, the process is best-suited to
a hydraulic action press.
Both fineblanking and the GRIPflow process now are being used to produce many parts
previously made by more costly processes, such as casting, forging, and machining. Because
other minor forming operations can be combined with these special processes, they both lend
themselves to many geometries. Keep in mind that each process has its own advantages and
disadvantages.
GRIPflow is a registered trademark of EBway Corp.
Die Basics 101: Bending methods--Wipe, coin relief, pivot, V bending

Figure 1
Part II of this series presented a basic overview of metal forming operations, such as bending,
flanging, drawing, ironing, coining, curling, hemming, and embossing. This and future
installments discuss these operations in more detail. We will look at factors controlling the
success of each operation, as well as tooling design guidelines. Let's begin with metal bending, a
process oftenperceived as the simplest.
Bending
Bending can be defined simply as a forming operation in which the metal is deformed along a
straight axis. Both compression and tension occur when bending sheet metal. The inside radius
of the bent metal is in compression, or being squeezed together. The outside bend radius is in
tension, or being stretched.
Because of the metal's elastic properties, it wants to decompress on the inside radius and return
to its flat shape on the outside radius (Figure 1), which causes springback. Also know as elastic
recovery, springback is present in all metal bending operations.
For a 90-degree bend angle, the metal must be bent to an acute angle (less than 90 degrees)
and allowed to spring back to its finished position, a difficult task given the fact that a press ram
typically travels vertically only. In addition, because of natural mechanical variability in the
material from coil to coil and from the beginning of the coil to its end, attempting to achieve
aconsistent, precision angularity in a bending operation can be very difficult.
If ultraprecision bend angles are required, one of the best things you can do to achieve them is to
design the tool so that it can be adjusted quickly, safely, and effectively to compensate for
incoming variables.; Changing the product design also can help reduce springback and
inconsistency problems. Incorporating darts, ribs, or gussets into the part design will enhance
stiffness and reducethe amount of springback (Figure 2).
Bending Methods
Several basic types of bending methods can be incorporated into a stamping operation—wipe
bending, V bending, and rotary bending. All three are popular, and each has its advantages and
disadvantages.
Wipe Bending. One of the most common methods used, but not always the most effective, is
simple wipe bending. Unfortunately, this method does not allow for much overbending other than
the very slight acute angle that can be achieved by wiping the side extremely tight (Figure 3).
Even though wipe bending effectively creates a bend, controlling the bend angle isvery difficult.
This method is not well-suited to bending high-strength metals or for parts requiring precision
bend angle tolerances. Wipe bending can be improved by capturing the outside profile of the
radius with the forming die section.
Figure 4shows a coin relief method. This process allows the outside radius to be coined, or
squeezed, near the lower tangent point, which causes under- or over -bending to take place. The
coin relief method works best when the metal is bent over a radius that is equal to or less than
one metal thickness, and the metal is not ultrahigh-strength. One advantage to this method isthat
by vertically shimming the forming section up and down, the gap, as well as the amount of
coining, can be adjusted. This allows for easy adjustments to be made for variability in the metal's
thickness and mechanical properties.
Figure 5shows a pivot-style bending method, which incorporates both wipe bending and cam
motion. This design works well both to create the bend and to adjust the amount of overbend.
Overbend is created by adjusting the lower driver block vertically up and down.
V Bending. A very good method for obtaining a given bend angle, V bending is undoubtedly the
most common method used with press brake bending. An acute angle ground on both the punch
and die can provide adequate overbending of the metal. Also, the bending amount can be altered
by adjusting the amount of coining the metal undergoes at the bottom of the press stroke(Figure
6).
 Figure 2 Photos courtesy of Batesville Tool and Die Company.
One disadvantage to V bending is that it often requires the part to be rotated in such a manner
that sometimes is difficult to incorporate in a progressive die. An advantage is that it often
requires less force to create the bend compared with conventional wipe bending.
Die Basics 101: Rotary and reverse U bending

Figure 1
Part XV of this series described several bending methods—wipe, coin, relief, pivot, and V. It also
discussed springback and how to compensate for it when using these methods. This article
focuses on other bending processes. Keep in mind that the key to success is to design the
bending process so that it can be easily, quickly, and safely adjusted to allow for material
variables.
Rotary Bending
Rotary bending perhaps is one of the most popular and effective ways of creating a precision
bend. Rotary benders, also know commercially as Ready Benders® or Accu-Bend™ benders,
have many advantages over conventional wipe bending methods. First, let's examine how they
work.
Rotary or rocker benders consist of a foundation block, often referred to as the saddle. The
saddle has a spring-loaded V-shape component called the rocker. This rocker rotates about its
centerline and performs the bending action. It acts as both a holding pad and the bending
mechanism.
Although this type of bender can be installed in almost any direction with respect to the ram
travel, it most commonly is fastened to the upper die shoe. As the bender moves down, the
rocker makes contact with the sheet metal. One contact point acts as a holding pad, while the
opposite contact point rotates, creating the bending action. After the bend is completed and on
the press's returnstroke, the spring forces the rocker to return back to its original or idle position 
Advantages. Rotary bending has some advantages over other methods. The most
advantageous feature is the simplicity of adjustment. Changes in the bend angle can be made
simply by shimming or grinding the height of the assembly. Doing so takes very little time, and
time is money.
Rotary benders can bend as much as 120 degrees and are well-suited to bending high-strength
material. One company in Sweden has successfully created two 90-degree return bends in steel
with yield strength of 980 megapascals. This translates into steel that by U.S. standards has a
yield strength of more than 142,000 pounds per square inch (PSI)—five times stronger than low-
carbon steel.Attempting to make such a bend in a conventional wipe-bending operation most
certainly would be impossible.
Another advantage is that, unlike conventional wipe bending, rotary benders require much lower
forces to create the bend. Anywhere from a 40 percent to 80 percent reduction in force can be
expected. This makes this method ideal for producing long, heavy-gauge, large parts, such as
truck and semi frame rails.
You can expect less hole distortion in rotary bending. Consider a hole that is pierced in a flat
blank and later bent into a vertical wall. During conventional bending, this hole can be subjected
to a great deal of tension, which causes the hole to distort. Because rocker benders fold the
metal around the punch, hole distortion is eliminated (Figure 2).
Inserting rockers with a special hard plastic called Delrin® can make them nonmarking, which is
desirable when bending cosmetic-quality stainless steel or prepainted materials.
Rotary benders can used to bend up or down. They also can be placed on cam slides.

Figure 2
Disadvantages. Despite the many advantages, rotary benders do have some disadvantages.
First, they can be quite expensive; however, consider the advantages of the reduction in
downtime and frustration. Overall, they often pay for themselves in a short period of time.
Also consider that you most likely will not need an external pad, which reduces die cost. Often
the true cost of designing and building a conventional wipe bending die is much greater than the
rocker bender. Don't confuse cost with value. In my opinion, rotary benders are worth every
penny.
Because these benders have moving parts, there is a risk of galling up and failing to rotate. This
can be prevented by periodically cleaning and lubricating them.
Remember that rotary benders can be used for straight-line bending only. Avoid using them to
bend special-shaped trim lines that do not allow for simultaneous punch contact. Angled corners
are not good candidates for rocker benders (Figure 3).
Overall, I highly recommend using rotary benders for appropriate applications. They are available
commercially from a few reputable suppliers.
Reverse U Bending
Reverse U bending is a unique but effective way of obtaining either a 90-degree bend or a bend
with a slight negative angle. This process utilizes a high-pressure pad with an insert that can be
adjusted in height by shimming or grinding it. The insert causes the part to bow upward in the
center of the punch where a void has been created. Raising or lowering the insert changes the
severity ofthe bow. Keep in mind that this bow must be created with the pressure exerted by the
pad. This often requires the use of high-pressure gas springs.
After the bow has been created, the pad moves downward and the bends are established. Upon
punch removal, the part has a tendency to spring back in the center, which causes the bends to
"toe in." This method works well with materials that exhibit a great deal of springback. If the metal
permanently deforms in the center bowed area, it may be necessary to push the part back flat in
order toachieve a 90-degree angle (Figure 4).
Remember that the true key to bending success is to design the tool in such a fashion that it can
be quickly, safely, and accurately adjusted with respect to ever-changing incoming variables.
Avoid using the grinding and welding process whenever possible.
Die Basics 101: Fundamentals of drawing and stretching

Figure 1 Click image to view larger

Part XVI of this series wrapped up the discussion of bending in stamping operations. This article
focuses on drawing.
What Is Drawing?
Drawing is a metal forming process in which a product is made by controlling sheet metal flow
into a cavity and over a punch. The process of deep drawing means that the part must be taller
than its minimum width.
Many people confuse drawing with stretching. True drawing results in very little stretching of the
metal. Drawing requires metal flow, while stretching does not. It is only through the drawing
process that objects such as oil pans, beer kegs, and oil filters can be made.
Drawing can be better defined as the process of displacing pre-existing surface into an alternate-
shaped vessel containing nearly the same surface area. Stretching can be defined as the
increase of surface area that results in a product with more surface area than the original surface
area.
Drawing requires the metal to feed inward toward the punch. Very little or no metal flow takes
place during stretching. However, keep in mind that because drawing does require tension to pull
the metal inward, some stretching occurs during drawing.
The key in deep drawing is to limit the amount of metal stretching and thinning that take place.
Items such as oil pans require significant drawing and stretching. Achieving a deep-drawn
product that exhibits very little metal thinning requires extensive knowledge of sheet metal
properties, drawing ratios, radii, and friction.Figure 1 shows the drawing process.
Basic Drawing Components
the deep-drawing process is not directional-specific. in other words, the direction in which the
drawing takes place really doesn't matter. you can draw a part up or down into a cavity. you can
even draw a part vertically using cams or special vertical-motion presses.
please keep in mind that i am in no way indicating that process engineers or die designers don't
pay close attention to the direction in which are drawing. drawing direction must be given careful
attention because it affects the ability to move, cut, and eject the part in the die. if drawing is
incorporated into a progressive die, the drawing direction also may affect the die and strip
carrierdesign.
Figure 2 shows a section view of a very simple single-action drawing die. this die is designed to
produce a round cup with a small flange. a basic drawing die consists of the following
components:
1. Die set or foundation. This could be made of mild steel cast iron or aluminum. It serves as
the guided foundation on which all of the metal forming sections will be mounted.

Figure 2 Click image to view larger

2. Draw cavity. The draw cavity represents the drawing die's female portion. Uually made from
tool steel or solid carbide, it serves as the cavity in which the metal is formed.
3. Ejectors and knockouts. These pressure-loaded components serve to push or eject the part
from the draw cavity. a high-pressure knockout must be timed properly so that it pushes the part
out of the cavity after the die has fully separated. If the knockout is timed incorrectly, the part can
be crushed during the return stroke of the press.
An alternate method to using a knockout is to use a small ejector pin and a lightweight spring.
this spring must have enough force to eject the part adequately but not deform it during the
press's return stroke. The pin and spring method does not require specific timing. However, keep
in mind that certain part geometries require a great deal of force to eject from the cavity. in such
cases, atimed high-pressure knockout may be necessary.
4. Air vents. Air can be trapped during drawing. This trapped air must be vented out of the tool.
Not venting the air can cause defective parts, splitting, and wrinkling, as well as make it difficult to
strip the drawn part from the cavity.
It is critical that both the cavity and punch contain air vents. Air vents in the cavity allow trapped
air to escape during the downstroke of the press; air vents in the punch allow air to be pulled into
the punch, which prevents suction during the part-stripping process.
5. Die face. The die face is the surface surrounding the cavity. it can be a flat or a contoured
surface. this surface interfaces with the sheet metal and keeps it from wrinkling during the
drawing process. the die face typically is made of tool steel or carbide and is highly polished in
the direction of metal flow.
6. Draw punch. This component represents the male shape of the drawn part geometry. Like
the cavity, it usually is made of tool steel. In most cases, it is polished to a mirrorlike surface.
However, there are times when a rough surface is desired.
7. Blank holder /draw pad / binder. This pressure-loaded plate, which serves to keep the metal
from wrinkling during the drawing process, typically is loaded with gas springs. However, certain
drawing dies can achieve the force needed to control metal flow through the use of a press
cushion.
8. Pressure system. The pressure system supplies the force necessary to control metal flow. It
may consist of gas, coil, hydraulic, or urethane springs. Certain drawing dies utilize a press
cushion to obtain the needed pressure. A press cushion is a plate or series of vertically moving
thick, flat plates mounted beneath the press's bolster plate. These plates transfer theforce to the
bottom of the draw pad using a cushion pin (Figure 3).
9. Equalizer block. This block functions to maintain a specific gap between the die face and the
draw pad surface. It also allows for minor adjustments to be made with respect to how much
pressure is being applied to the blank.