INFORMATION

SHEET

NAME :- RUSHIKESH INGLE TRADE :- Tool and Die maker ( Press tool, J & F )

REG. NO.......................................... UNIT NO................... LESSON NO......................... DATE............................

I PREPARATION
1. Title :- Shearing Theory

2. Objectives : At the end of this lesson the trainee shall be able to

a. state the purpose of piloting

b. state common nose contours of pilots

c. specify the size of pilots

d. select a suitable diameter for the pilot opening in the die

e. state different types of pilots

f. differentiate between direct piloting and indirect piloting

g. determine the application of direct and indirect piloting depending on the situation.

Topics Information
points

Purpose of The pilot positions the stock strip in relation with the die opening. This is termed as registering. The strip
Pilots is normally overfed more than the pitch length. When the press is tripped the pilot comes down and
engages the prepierced hole. The strip is dragged back into the registry position. When mechanical
feeding is employed the strip is underfed. The pilot pulls the strip into registry position. (Figs 1 and 2)

Pilot size: Pilot size: Diameter of pilot for average work, diameter of hole to be piloted – 0.05 to 0.1mm.
For close work, diameter of hole to be piloted – 0.03 to 0.05 mm.
For accurate work, diameter of hole to be piloted – 0.01 to 0.02mm.
Thick stock materials and materials like aluminium and copper need often a bigger tolerance between the
pilot and pierced hole.

Pilot length Registering of the strip should be done before the punches come and engage the strip. Therefore the pilot
should extend beyond the punch face equal to one sheet thickness. (Fig 3)

1. Top plate. 2. Backplate. 3. Punch holder

4. Piercing punch. 5. Pilot. 6. Blanking punch
7. Die plate. 8. Bottom plate. 9. Stopper.
10. Stripper.

1
 Topics Information
points

Pilot opening If the pilot opening in the die is larger instead of registering, the material will be drawn into the opening.
in the die Diameter of the opening = diameter of pilot + double clearence.

Pilot opening Through hole is provided in the bottom plate for the following reasons:
in the • Slugs produced due to misfeeding can be cleared - if by chance the strip jumps the stopper the pierced hole
bottom plate will be out of alignment with the pilot. The pilot will hit the strip and punch out a deformed slug.
• Accumulated burrs dislodged from the pierced hole cleared. - During piercing operation burr is formed on
the pierced hole. The pilots, while entering the prepierced hole, will dislodge the burr. (Figs 4 & 5)

Pilot nose Bullet nose: The most common pilot nose profile is bullet nose. The bullet shape is formed by radius ‘r’
profile which is equal to piloting diameter. For piloting in holes less than 6mm in diameter the length of radius r can
be increased to reduce the lateral force due to piloting. Bullet nose is strong, simple to make and smooth in
action. (Fig 6)

45° Conical stub nose: shorter nose profile. Used for piloting thick meterials. (Fig 7)
30° Conical stub nose: This is a compromise between bullet nose pilot and 45° stub nose pilot . (Fig 9)
15° Conical stub nose: Used for small pilots and for soft thin materials. (Fig 8)

2
 Topics Information
points
Pilot in Pilots mounted in punches are called punch pilot.
punches The pilot extends beyond the punch face by a distance of atleast one sheet thickness (minimum 1.5 mm).
These pilots are used for slow production and secondary operation tools. (Figs 10 & 11)

Types of Retractable pilots: Misfeeding may occur due to the overshooting of stock strip over the stoppers. In such
pilots cases pilots may buckle or break. To overcome this difficulty retractable pilots are used. They are spring
loaded pilots; they will be pushed up when they come into contact with unpierced area during operation.
(Fig 12)

Removable type pilots: Pilots break often due to misfeeding of stock strip. Changing of broken pilots
consume considerable time and leads to loss in production. Removable type pilots are used to overcome this
difficulty. The pilots are inserted through the top plate into the punch holder and fastened with screw. (Fig
13)

Methods of Direct piloting: Piloting in holes pierced in that area of the strip which will become the blank is called
piloting direct piloting. (Fig 14)

Indirect piloting: Indirect piloting consists of piercing holes in the scrap area of the strip and locating by
these holes at subsequent operations.Direct piloting is the preferred method, but certain blank conditions
require indirect piloting. (Fig 15)

Close Pilots can enlarge holes while pulling a heavy strip in position. (Fig 16)
tolerance on
holes

3
Topics Information
points
Holes too small: Fragile pilots can break or deflect during operation. (Fig 17)

Holes too close to the edge of the blank: Distortion can occur on the blank because of enlargement of
holes. (Fig 18)

Holes in weak areas: Piloting in projecting tabs is impractical because they may deflect before the strip is
pulled in position. (Fig 19)

Holes spaced too closely: Piloting in closely spaced holes does not provide an accurate relationship between
holes and relative edges of the blank. (Fig 20)

Blanks without holes: Piloting has done in the scrap area whenever the blank does not contain round holes.
(Fig 21)

Questions :

a. What is the pilot and what is the use of pilot ?

b. How many types of pilots nose ?

c. What is the direct pilot ?

d. How to work Retractable pilots ?

Ref Books : Tool and Die maker ( press tools and J & F ) 2nd year Theory Book By Nimi.

Title of Next Lesson is :- Side cutters.