Ask the Stamping Expert: The continuing

challenge of die maintenance

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  By Thomas Vacca 
 
  April 15, 2015
 
  Article
 
  Stamping
 
  0 Comments

Q: I have been trying to locate the die maintenance check list printed in a STAMPING
Journal® article several years ago, which also included the 10 Tooling Laws. I am
hoping you can lead me to it.

A: You will find the check list at the end of this article. But even with a maintenance check list
like this, stampers typically don’t understand the three primary end goals of the
process: consistency, documentation, and continuous improvement. This thought
process is driven home with the 10 Tooling Laws. You can find them
at www.thefabricator.com/article/stamping/10-design-laws-for-tool-designers. Post them in
your shop.

However, following the 10 Tooling Laws and driving toward the end goals will not get you
where you need to be without the 3 R’s. Be sure to consider these fundamental practices in
the design phase to prevent problems in the maintenance phase:

 Repeatability – Design components to prevent mistakes. Specify details to increase

repeatability. Define springs. If pilots need to be removed for tool servicing, make
sure they’ll go back in the same location. Add callouts for surface finish. Make sure
components can’t be put in upside down, backwards, or in the wrong location.
 Reliability - Tool builds that yield a lot of variation fall short on robustness. Die shoes
are too thin, resulting in forming variation. Down stops are not sufficient to maintain
consistent hits. The guidance pins and bushings are too small. Coil springs are used
when nitrogen are required. Pressure pads are missing. There aren’t enough pilots
and lifters. Stripper clamping pressure is insufficient. Slug retention is not designed
into the tool.
 Replication - Design a process or tool that is easy to duplicate. The design needs to
ensure you can make multiple spares, all exactly the same. I have seen complex
form inserts that required regrinding when serviced. After every service, adjustments
were required. If tool builders would split the dies into two stations and wire EDM the
components, it might add a few thousand dollars to the tool cost, but it would be
repeatable and prevent the expense of many hours every week over the life of the
program.

A best-in-class maintenance procedure will let you predict what needs to be serviced
and when. Your quality data will be consistent, and costs will be driven down.

20-point Tooling Maintenance Check List

1. Before cleaning a tool, visually inspect it for slivers, sludge, and black grease.
2. Visually inspect the last strip. Look for punch shear and brake lines, burrs,
tool marks, and slivers.
3. Inspect the slugs for correct penetration and tightness, as well as
irregularities.
4. Check and measure the die shoe guideposts. Inspect for tracking, galling, and
wear.
5. Check that all pilots are present and the right length. Always measure the first
one, as it does most of the work.
6. Check the punch length with a height gauge to make sure it is correct.
7. Make sure the punch float and pump in the punch holder are correct.
8. Check the height of the die inserts and forms with a height gauge.
9. Check and confirm the strip lifter height. Springs may collapse over time.
10. Make sure toe straps and clamps appear to be in good order.
11. Visually inspect die sections for chips and side galling.
12. Visually inspect the stripper face for signs of wear, hits, nicks, and other
damage.
13. Make sure the in-die stock pusher is working properly.
14. Inspect the scrap retainers.
15. Check all the miscellaneous items in the die maintenance card instructions,
such as the lace-up starting point and concerns and tooling demagnetization.
These should include general notes that toolmakers have entered regarding
specific historical problems to help prevent having to reinvent the wheel.
16. Check the safeties and air ports.
17. Complete the maintenance check list and file it in the die maintenance card.
18. Make sure the die maintenance card has been filled out for all work done.
19. Tag the tool with the proper storage tag, and put it away in the designated
location.
20. Make sure all orders for spare parts are submitted.