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Die Design For Flat Parts - The Fabricator
Die Design For Flat Parts - The Fabricator
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In most cases in which parts must be flat, initial distortion is created during blanking, piercing, or trimming. During
these processes, stress is created, which forms strain planes along the surface of the part. These strain planes
are what cause your part to twist, bend, and distort. Therefore, the only realistic way to achieve part flatness is to
keep internal part stress to a minimum or to break up the strain planes after they have been formed.
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4.12.2018 Die design for flat parts - The Fabricator
The cutting and piercing clearance that is selected affects the amount of internal stress created. Depending on
the metal type and clearance between the upper and lower cutting steels, this stress can be significant enough to
promote part distortion.
Keep in mind that as you increase cutting clearance, more stress Figure 1:
will be introduced to your slug. If the slug is to be saved, Be sure to leave enough cutting clearance around a
blanking operation clearance should be decreased. pierce punch—it is critical in avoiding plastic
deformation.
Cut and Carry
A very popular way of achieving part flatness in a progressive die is to use a cut-and-carry process (see Figure
2). A cut and carry process holds the part flat during the cutting process and later ejects it from the carrier strip. In
a cut and carry process, the slug produced is the piece part. During the cutting process, the metal is squeezed
and held flat between the face of the cutting punch and a high-pressure pad. This pad is powered by a nitrogen
cylinder, die-draulic unit, or hydraulic cushion.
Figure 2:
In the cut-and-carry method, a piece is blanked about halfway through as metal is squeezed
and held flat, then is pushed through with a punch smaller than the cutting punch.
The part is blanked approximately 50 percent of the way through the strip and left in this position. The pressure pad
underneath also bottoms out on the die shoe.
The part later is pushed out with a punch that is slightly smaller than the previous cutting punch. It is very important to use
a reduced cutting clearance for cut-and-carry operations. This is necessary for two primary reasons—to hold the blank in
the carrier strip and to reduce the cutting deformation of the slug, or part.
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4.12.2018 Die design for flat parts - The Fabricator
Selection of the cutting clearance and penetration of the cutting punch are functions of a material's thickness and
mechanical properties. However, a good rule of thumb for most applications is to have the cutting clearance about 2 to 4
percent of metal thickness per side and punch penetration approximately 50 percent of the metal's thickness.
After the cutting operation is complete, try to avoid pushing the slug back into the strip, because this may cause
unnecessary distortion of the part. The part can be ejected later through the die with an ejection punch that has a slightly
smaller profile than the original cutting punch. A rule of thumb is to make the ejector punch 1 percent smaller.
This type of operation also allows the cut edge of the part to be burnished fully without fracture. This is highly desirable,
especially when you are manufacturing stamped parts such as gears or other items that require full edge contact.
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4.12.2018 Die design for flat parts - The Fabricator
Figure 5
Stippling. Let's say you have a part that needs to be flat, and the current die design does not incorporate a way of
controlling part stress. Don't worry—just stipple the blank.
Stippling the blank, a process that addresses internal stress after it has already been created, utilizes a cross-hatched
pattern that is coined into one or both surfaces of the part after all cutting and extensive metal deformation is done. The
stipple pattern breaks up internal part stress and destroys the part memory, allowing it to be rehit flat.
The depth of the stipple is relative to metal thickness, the mechanical properties of the material, and the stress that was
previously induced. Experimentation may be necessary to achieve the desired results.
There are more ways to hold parts flat. Processes such as grip flow and compound blanking are also very popular.
Attempting to make parts flat by using extreme tonnage or coining can ruin a die or press, especially if the equipment is
not designed for it.
With the exception of very thick or very soft metal, excessive tonnage generally will lead nowhere. The key element to
remember is controlling or breaking up internal part stress.
(/article/stamping/die-science-regaining-flatness-in- (/article/stamping/the-process-of-fineblanking)
stamped-parts)
Die Science: The process of fineblanking
Die Science: Regaining flatness in stamped parts
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stamped-parts)
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methods-used-in-stamping-operations)
DIEVESTIGATION: Designing stamped parts
Die Basics 101: Specialty metal cutting methods used in
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4.12.2018 Die design for flat parts - The Fabricator
stamping operations
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methods-used-in-stamping-operations)
Art Hedrick
Contributing Writer
Dieology LLC
10855 Simpson Drive West Private
Greenville, MI 48838
Phone: 616-894-6855
http://www.dieology.com (http://www.dieology.com)
Contact via email (mailto:dieology@pathwaynet.com)
Author of the "Die Science" column in STAMPING Journal®, Art also has written technical articles on stamping die design
and build for a number of trade publications. A recipient of many training awards, he is active in metal stamping training and
consulting worldwide.
Related Companies
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