COURSE OUTLINE NO.

1
 I. Introduction to Die Design
Punch
holder
1.1 Die assembly

The die pierces two holes

at the first station, and then
the part is blanked out at
Stripper
the second station. plate

Die
The material from which block
the blanks are removed is a
cold-rolled steel strip. The
Die
strip A is shown entering holder
the die at the right.
 I. Introduction to Die Design

1.2 Die components

These part names must be
memorized because we shall
keep referring to them many
times in future work.
A. Punch holder of die set
B. Piercing punch
C. Pilot nut
D. Square head set screw
E. Jam nut
F. Blanking punch
G. Punch plate .
Exploded view
 I. Introduction to Die Design

1.2 Die Components

H. Pilot
I . Stripper plate
J. Automatic stop
K. Finger stop
L. Back gage
M. Front spacer
N. Die block
O. Die holder of die set

Exploded view
 I. Introduction to Die Design

1.2 Die Components

Taken together the exploded view, show the
operation of a representative "pierce and blank" die.
The strip is advanced until it contacts the toe of the
finger stop K, which has been moved forward by the
operator.
The press is tripped and the piercing punches
B pierce two holes in the strip end. The finger stop is
then retracted and the strip is advanced until it
contacts the toe of automatic stop J,
Tripping the press again causes two holes to
be pierced in the strip at the first station,
 I. Introduction to Die Design

1.2 Die Components

while at the second station blanking punch F

removes a blank from the strip and pushes it into
the corresponding opening in die block N.

The acorn shaped pilots H engage the

previously pierced holes to register the strip
correctly before cutting occurs.
 I. Introduction to Die Design

1.3 Processing a die

Steps to be taken in processing a representative
die:

1. The Product
The product engineering department designs
the product considering the product to be
manufactured. In most plants, the work consists in
improving the product from year to year to meet
changing styles and changing requirements of
customers.
 I. Introduction to Die Design
Processing a die

1. The Product

After management has decided upon the

final form of the new or improved product, a
directive is sent to the process planning
department to route the various parts through the
appropriate manufacturing departments.

They request that the tool design department

produce designs of all jigs, fixtures, cutting tools,
and dies needed for efficient production of the
parts.
 I. Introduction to Die Design
Processing a die

2. The Part (Die)

The part which is to be machined, formed,

pressed, or inspected is called by one of three
names:
1. Part
2. Work
3. Workpiece

Part is the preferred term, but workpiece or simply,

work, are often employed as alternate names.
 I. Introduction to Die Design
Processing a die

2. The Part (Die)

The print on which this part, work, or

workpiece is represented is called a Part Print. It
may be a blueprint, or quite often it is a blue and
white print.

Therefore, in designing a die for producing a

stamping, the die designer works from a part print.
 I. Introduction to Die Design
Processing a die

3. Processing

Following is the sequence of operations or

procedure followed in processing a stamping through
the planning stages:

3.1 ROUTE SHEETS

The following information are usually included;
A. The Heading. This is located at the top of the
sheet and it contains the following information:-
Part name, Part number, Drawing number,
Number of parts required, Name of product,
Engineer and Date.
 I. Introduction to Die Design
Processing a die

3. Processing

3.1 ROUTE SHEETS

The following information are usually included;

B. The number of each operation required to

make and inspect the part.
Numbers are most frequently listed in
increments of 5, as 5, 10, 15, 20, etc., to
provide numbers in sequence for additional
operations which may be found necessary in
manufacture or when changes are made in the
design of the product.
 I. Introduction to Die Design
Processing a die

3. Processing

3.1 ROUTE SHEETS

The following information are usually included;

C. The name of each operation.

D. The name and number of the machine in
which the operation is to be performed.
E. Estimates of the number of parts which will
be completed per hour for every operation.
 I. Introduction to Die Design
Processing a die

3. Processing

3.1 ROUTE SHEETS

Route sheets are supplied to the following

departments:
* Tool design department
* Production department
* Inspection department.
 I. Introduction to Die Design
Processing a die

3. Processing

3.2 TOOL OPERATION SHEET

Is prepared from the route sheet and it usually

lists the following:

a. Number of each operation

b. Name of each operation
c. Machine data
d. List of all standard and special tools required
for the job
 I. Introduction to Die Design
Processing a die

3. Processing

3.2 TOOL OPERATION SHEET

e. Names and numbers of all special tools which

are to be designed and built. These numbers are
marked on tool drawings and later stamped or
marked on the actual tools for identification.

Tool operation sheets are helpful in planning and

developing a tooling program. Copies go to the
tool designers and to the tool purchasing
department.
 I. Introduction to Die Design
Processing a die

3. Processing

3.3 DESIGN ORDER

Is a slip of paper authorizing work on an
actual design. One is written for each die or special
tool required and the information is taken from the
route sheet. In addition, it may give instructions
regarding the type of die preferred.

The list of the information usually given on a design

order.
a. Department name
b. Tool name
 I. Introduction to Die Design
Processing a die

3. Processing

3.3 DESIGN ORDER

The list of the information usually given on a design
order.
c. Date
d. Tool number
e. Part name
f. Part number
g. Operation
h. Machine in which tool. is to be used
i. Department in which machine is located
j. Number of parts to be made.
 I. Introduction to Die Design
Processing a die

4. TOOL INSPECTION DEPARTMENT

A set of prints is sent to the tool inspection

department after a die has been designed. They will
inspect it to make certain that it was constructed to
specifications given in the tool print.

Procedures are followed to determine if stampings

produced by it are held to tolerances specified on
the part print.
 I. Introduction to Die Design
Processing a die

5. PRODUCTION

The set-up man for that department installs it

in the press where it will be operated and he
produces a few parts under the same conditions in
which the die will run in actual production.

After the production inspection department has

determined that the samples are satisfactory, a
form is issued and signed by the chief inspector
authorizing production with the die.
 I. Introduction to Die Design

1.4 DIE OPERATIONS

Following illustrated list of the twenty types of
operations which are performed in dies:
1.4.1 BLANKING

Stampings having an
irregular contour must be
blanked from the strip.
Piercing, embossing, and
various other operations
may be performed on the
strip prior to the blanking
station
 I. Introduction to Die Design
Die operation

1.4.2 CUT OFF

These operations are

those in which strip of
suitable width is cut to
length. Preliminary
operations before
cutting off include
piercing, notching, and
emboss.
 I. Introduction to Die Design
Die operation

1.4.3 COMPOUND

Compound dies pierce

and blank simultaneously
at the same station. They
are more expensive to
build and they are used
where considerable
accuracy is required
in the part.
 I. Introduction to Die Design
Die operation

1.4.4 TRIMMING

When cups and shells

are drawn from flat sheet
metal the edge is left
wavy and irregular, due
to uneven flow of metal.
This irregular edge is
trimmed in a trimming
die.
 I. Introduction to Die Design
Die operation

1.4.5 PIERCING

Piercing dies pierce holes

in previously blanked,
formed, or drawn parts. It
is often impractical to
pierce holes while forming
or before forming because
they would become
distorted in the forming
operation.
 I. Introduction to Die Design
Die operation

1.4.6 SHAVING

It consists in removing a
chip from around the
edges of a previously
blanked stamping. A
straight, smooth edge is
provided and therefore
shaving is frequently
performed on instrument
parts, watch and clock
parts, and the like.
 I. Introduction to Die Design
Die operation

1.4.7 BROACHING

Broaching operations are

similar to shaving
operations. A series of
teeth removes the
metal instead of just one
tooth as in shaving.
Broaching must be used
when more material is to
be removed than could
effectively be done with
one tooth.
 I. Introduction to Die Design
Die operation

1.4.8 HORNING

Horn dies are provided

with an a arbor or horn
over which the parts are
placed for secondary
operations such as
seaming, as illustrated.
Horn dies may also
be used for piercing
holes in the sides of
shells.
 I. Introduction to Die Design
Die operation

1.4.9 SIDE CAM

OPERATIONS

Side cams convert the

up-and-down motion of the
press ram into horizontal
or angular motion when it
is required in the nature of
the work. Piercing a
number of holes
simultaneously around a
shell is done in a side cam
die.
 I. Introduction to Die Design
Die operation

1.4.10 BENDING

Bending dies apply

simple bends to
stampings. A simple
bend is one in which the
line of bend is straight.
One or more bends may
be involved, and bending
dies are a large and
important class of press
tool.
 I. Introduction to Die Design
Die operation

1.4.11 FORMING

Forming dies apply more

complex forms to work
pieces. The line of bend
is curved instead of
straight and the metal is
subjected to plastic flow
or deformation.
 I. Introduction to Die Design
Die operation

1.4.12 DRAWING

Drawing dies transform

flat sheets of metal into
cups, shells, or other
drawn shapes by
subjecting the
material to severe plastic
defonnation. Shown in
the illustration, a rather
deep shell has been
drawn from a flat sheet.
 I. Introduction to Die Design
Die operation

1.4.13 CURLING

Curling dies curl the

edges of drawn shells
to provide strength and
rigidity. The curl may be
applied over a wire ring
for increased strength.
Example would be a
hinge in which both
members are curled to
provide a hole for the
hinge pin.
 I. Introduction to Die Design
Die operation

1.4.14 BULGING

Bulging dies expand the

bottoms of previously
drawn shells. Example,
the bulged bottoms of
some types of coffee
pots are formed in
bulging dies .
 I. Introduction to Die Design
Die operation

1.4.15 SWAGING

In swaging operations,
drawn shells or tubes
are reduced in diameter
for a portion of their
lengths. The operation
is also called necking.
 I. Introduction to Die Design
Die operation

1.4.16 EXTRUDING

Extruding dies cause

metal to be extruded or
squeezed out, much as
toothpaste is extruded
from its tube when
pressure is applied. This
shows a collapsible tube
formed and extruded
from a solid slug of
metal.
 I. Introduction to Die Design
Die operation

1.4.17 COLD FORMING

In cold forming operations,

metal is subjected to high
pressure and caused to
flow into a predetermined
form . In coining, the metal
is caused to flow into the
shape of the die cavity.
Coins such as nickels,
dimes, and quarters are
produced in coining dies.
 I. Introduction to Die Design
Die operation

1.4.18 PROGRESSIVE
OPERATIONS

Are those in which

progressive dies perform
work at a number of
stations simultaneously.
A complete part is cut
off, at the final station,
with each stroke of the
press.
 I. Introduction to Die Design
Die operation

1.4.19 SUB PRESS

OPERATIONS

Sub press dies are used

for producing tiny watch,
clock, and instrument
components,
represented by the
watch needles shown.
Sub presses are special
types of die sets used
only for such precision
work.
 I. Introduction to Die Design
Die operation

1.4.20 ASSEMBLY DlES

Assembly dies assemble

parts with great speed
and they are being used
more and more.

Figure represented is an
assembly operation in
which two studs are
riveted at the ends of a
link.
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