INCREASE EFFICIENCY AND EXPAND YOUR OPERATIONS WITH FORMING

MATE SOLUTIONS TRAINING

AGENDA

• Why use forming?

• Forming basics

• Ways to use forming in your operation

• Summary

WHY USE FORMING?

• Increase efficiency

• Expand your capabilities

• Eliminate of secondary operations

• Increase machine time

• Reduce tool wear

• Secondary processing of machined countersinks is non value-added time

• Make them on the turrets, forming up or down, as required

EXAMPLE: ADDED COST AND PROCESSING TIME

• The ribs in this pane were nibbled, increasing machine time and tool wear

• Use a forming tool on the turret is a much better way

EXAMPLE: INCREASED TIME AND TOOL WEAR

FORMING VS. PUNCHING

• Punching– Makes a hole– Requires stripping– Stroke may not be critical– High speed

• Forming– Changes work from 2D to 3D– Stroke length critical to achieve

correct results– Lower ram speed– Station ranges are usually

reduced

7

Definitions

Special Assembly-

•Any tool that transforms the material to 3D

•Any tool that requires multiple holes in a single hit.

•Any tool that requires multiple forms in a single hit.

•Any tool that punches a non-standard shape or size hole.

FORMING BASICS

MATE SOLUTIONS TRAINING

WHAT LIMITS FORM HEIGHT?

• Machine Limitations– Maximum forming height is about 6.0mm

– Calculation:Maximum Form Height = (Turret gap/2) – Material Thickness – 1.0mm safety

– Forming should always be done last

• Not necessary with machines with forming cylinder

– Adjacent stations to the forming tool should not be used

• Sheet marking, bending, risk of tool breakage could occur

• Material Limitations– Emboss stretches material

– Some forms bend material like lance and form

– Material ductility

– Form geometry

MATERIAL TERMINOLOGY

• Ductility– Ability to be elongated in one dimension while becoming

thin in another dimension

• Elastic Limit– Point at which material will not return to original shape

• Plastic Deformation– Stretching metal enough to exceed its elastic limit and

stopping prior to fracture

• Spring back– Amount which material tries to return to its original

shape after forming

MACHINE CONSIDERATIONS FOR CORRECT SETUP

• Shut Height:– Measurement from ram bottom dead center to top

of new die• Amada 205 mm

• Finn Power 203 mm

• Murata Wiedemann (Variable by Model)

• Ram Operation– Mechanical– Hydraulic– Electro Mechanical– Ram stroke control

= Forming Tool

= Adjacent stations without tooling

20 Station Turret

STANDARD PUNCH PRESSTYPICAL TURRET LAYOUT

FORMING IN A TURRET PUNCH PRESS

• Because the forming die is higher than a standard die, the forming die must protrude above the material pass line on the conventional turret

• When the sheet is moved or the surrounding stations are used, then the forming tool may mark or scratch the sheet

CONVENTIONAL TURRET

CONVENTIONAL STATION VS.UPFORMING STATION

This lance and form could never be achieved in a conventional machine.

Machine with forming station makes it possible!

Forming die operated by forming cylinder

Die Line

15

Standard vs. Upforming

• Standard– Shorter form height

capabilities due to forming die height

– Form can be up or down.

• Upforming– Higher form height

capabilities: Use the entire feedgap

– Conventional forming dies sit at or below die line

– Special forming dies(Amada P&F)

– Form can be up or down.

DISADVANTAGES WITH CONVENTIONAL FORMING IN TURRET PUNCH PRESSES

Conventional Turret Finn-Power Upforming SystemB D B D

Example: 3mm material, 8mm forming

Example: 3mm material, 12mm formingTo perform any forming operation on a conventional turret:

• Forming die must be higher than a regular die• If a formed part’s height is more than ~12mm

(including material thickness), it will crash into the upper turret when it goes over the forming die

• A higher die also scratches the lower side of the sheet and may cause problems during sheet movement

NOTE: These conditions limit the forming height in a conventional turret solution to a maximum 5.9mm

Finn-Power upforming system:

• Allows formed heights equal to the feed clearance between turret plates

• Eliminates scratches and other problems

17

Finn-Power Upforming

•Optional in Series 10 and newer Finn-Power F, SG and LP model•Consists of an upper and lower hydraulic cylinder (250 kN, e-machines only 200 kN)•Forms as high as .590"(15mm) (higher with foot tool)•Lower ram travel .472"(12mm) max•Form tools manufactured for conventional stations will produce forms in the upforming station without any modifications, shims or spacers.

•To achieve maximum form heights, the die assemblies must be manufactured to these forming requirements. •These tools should not be used in conventional stations.

•Travel is limited by a mechanical stop at the bottom of the stroke. •Forming is typically done at mechanical bottom.

• Forms up to 13.0mm high.

• No contact with sheet by forming tool

• Form stroke controlled within 0.001mm

FINN-POWER UPWARD ACTING FORMING STATION

19

Amada P&F

Only for EM machines with Z-turret

20

Amada P&F

Amada P&F

21

‘Retractable’ Forming Station

Wiedemann and Euromac Forming Station

•Forming bar slides to activate forming•The sheet is lifted since the lower activates first.•Max form height same as standard

•Euromac = 6mm travel•Wiedemann = …

22

Calculating Maximum Form Height?

• Conventional Machines: (typical form 3mm above die line)

– Standard maximum form height is about 6.0mm

– Standard maximum form height is calculated:

TURRET GAP /2 - material thickness - (safety) 1mm = MAX FORM HEIGHT

• Upforming Machines: (typical form at or below die line)

– Upform maximum form height is about 14.0mm (dependent upon material thickness and gap between upper and lower turret, and machine type)

– Upform maximum forming height is calculated:

(TURRET GAP + UPFORM STROKE) /2 - material thickness – (safety) 1mm = MAX FORM HEIGHT

MINIMUM SPACING BETWEEN FORMS

Minimum = 3 x material thickness to sheet edge or form on sheet

Minimum = 6 x material thickness to like forms

3 x TMinimum

MaterialThickness (T)

6 x TMinimum

3 x T + RMinimum

Radius(R)

Radius= 1/2 x T

SPRING LOADED VS. NON-SPRING LOADED

Non-Spring Loaded

DieLine

Spring Loaded

DieLine

ULTRAFORM™ LENGTH ADJUSTMENT

Adjustments up or down in easy steps of 0.05mm

26

ULTRAFORM FX AND XT

• Ultraform FX and XT– Objectives:

• Incorporate interchangeability of Ultraform without all the features

• Improve price positioning over Ultraform

• Reduce holder complexity to leverage new press technology

27

Ultraform XT

• Low Cost• Adjustable Length• For bottom stroke

machines• B-E Station• Same inserts as Ultraform

today• OAL= 203 – Material (FP)

• OAL= 205 – Material (Others)

28

Ultraform FX

• Low Cost• Fixed Length• B-E Stations• For Precision controlled

Ram Machines• Same inserts as

Ultraform today• OAL=208mm !! (longer

than normal)

30

Forming Tool Recommendations

• Always form as far from the clamps as possible.

• Forming should be the last process on the sheet whenever possible.

• Additional Dwell Time may be necessary to allow tools to strip properly (Programming command)

• Forming tools should be run at a slower punching speed to allow material to flow/form.

• Stations next to the forming tool should not be used. It is recommended to have a die in the die holder in these stations. Roller or brush dies are recommended for both sides of a forming station.

• Lubricate the sheet and use machines lube system if available.

31

Forming Tool Recommendations

• Periodically remove the tool from the turret and check the sharpness of any cutting edges.

• Form down operations should be avoided because formed material can drop into dies, get caught and pull the work piece out of the work holders, or distort the form. If a form down operation is the only solution for a particular part, make it the last operation on the sheet.

• Machine stroke lengths are different from machine to machine.

• A tool that works in one machine may not work in another.

• Set up using the tools minimum length and adjust in 0.15mm steps to achieve a sharp form where the tool is properly bottomed. Keep a setup record sheet for all special tools to minimize setup time for each subsequent use of that tool.

SOME FORMING TOOLS IN DETAIL

MATE SOLUTIONS TRAINING

33

Most Common Special Assemblies

• Top 10 Special Assemblies explained in detail.

Rank Description

% of SA Items Sold

1 Clusters 43.9%

2 Extrusion: Round 8.9%

3 Undefined 8.5%

4 Lance and Form 5.4%

5 Knockout 4.2%

6 Countersink 3.6%

7 Emboss 3.3%

8 Louver 3.0%

9 Engrave Stencil Down 1.6%

10 ShearButton 1.3%

11 EasySnap 0.7%

84.3%

34

• USE: To produce multiple holes with minimal hits.Ideal to guarantee center-to-center tolerances.

• TYPICAL APPLICATION: – Material thickness from 0.020(0.50) to

0.157(4.00). – Other constraints dependent upon station size,

punch size and shape, press tonnage capacity, distance between the border of the holes (web).

• For greater hole uniformity and flatter sheets, spread the punches to avoid punching adjacent holes in the same hit.

• Complete the desired pattern with the technique known as bridge hitting.

• Do not re-punch through previously punched holes to complete a pattern, single hit tool may be necessary.

Clusters2 to 100+ holes round or shaped

Limited to press tonnage and station parameters

35

• TYPICAL APPLICATION: – Material thickness from 0.020(0.50) to

0.157(4.00). – Other constraints dependent upon station size,

punch size and shape, press tonnage capacity, distance between the border of the holes (web).

Clusters

2 to 100+ holes round or shaped – Limited to press tonnage and station

parameters

ULTRA AND ORIGINAL STYLE THICK TURRET CLUSTERS: GUIDED & NON-GUIDED WITH

INSERTS

Minimum/Maximum

• 0.5mm minimum, 4.0mm maximum thickness

• Other restraints dependent upon station size, punch size and shape and machine tonnage

Punch head must be within pattern

øS = cluster punch retainer

37

CLUSTERS

Replaceable InsertsFully Guided

Replaceable InsertsNon-Guided

(shape cluster)

Note: Round cluster uses backing disc, shape cluster

uses punch screws.

Solid Standardor Solid Fully Guided

Cluster punch

burned from solid blank

BENEFITS OF FULLY GUIDED• Guiding at punch point• Increases hole accuracy• Improves stripping • Point Size closer to material thickness

38

Insert Style

Clusters: Solid or Insert

Features Solid Insert

Fully Guided Available Yes Yes

Initial Cost Lower Higher

Replacement Costs Higher Lower

Punch Point Spacing Closer Farther

Pattern Size Larger Smaller

Punch Point Size Recommended Larger Smaller

Sharpening Easier Harder

Solid Style

Cluster Pitch Rounds

• The minimum cluster pitch is determined by the die in most cases

• Minimum is 3.0mm STEEL between holes in the die. Example; 5.0mm hole in 1.0 mild steel with die clearance of 0.2mm will have a center to center spacing of 8.2mm

• Cluster pitch with many holes is determined on a case by case basis based upon spacing and material thickness.

• In most cases double spacing recommended as this produces a stronger die and less sheet distortion.

39

Cluster Pitch Shapes

• 12.0mm is the minimum pitch between punch points on a shape cluster. This limit is imposed by the upper assembly screws used to hold the inserts in place.

• For some special applications the pitch spacing can be reduced to 10.0mm but will require a full Mate engineering review based upon complete cluster pattern and material being processed.

40

41

Clusters: Tips for Success

Tips for Success: (addressed in upcoming slides)

1. Slug Pulling

2. Sheet Flatness

3. Tonnage or Noise

4. Tool Life

5. Tool Maintenance

6. Press Maintenance

42

Clusters: Slug Pulling

1. Sharpen tools

2. Correct die clearance

3. Proper die penetration

4. Accurate station alignment-• Furthest punch point distance from

center is multiplied.

43

Clusters: Sheet

Flatness

1. Bridge Hitting improves part flatness.

2. Sharpen Tools

3. Proper die clearance

4. Move in one direction each sequence

5. Increase Station Size or Stripping force

44

• Start punching pattern away from clamps and work toward clamps

Clamps

45

Shorten half of the cluster punches by 50 – 60% of the sheet thickness in order to reduce noise, vibrations and required punch tonnage.

Example:

16 punch cluster of 10mm square punches

Perforating in 1mm mild steel

Insert Punch length 37mm

Shorten 8 Punches to length 36,5mm ( Balanced Shortening)

Clusters: Tonnage or Noise

For safety, plan on all inserts hitting at the same time for tonnage. Do not exceed 75% press tonnage.

Lowers the force on a die and could extend die life

Increases slug pulling,

decreases insert grind life.

46

CALCULATING CLUSTER TONNAGE

PUNCHING FORCE FORMULA = linear length of cut x material thickness x shear strength = punching force in kilonewtons (kN). PUNCHING FORCE SHOULD NOT EXCEED 75% PRESS

CAPACITY.EXAMPLE: Grid of .250(6.35) diameter holes. Area of punch covers 48 holes; punch every

4th hole (12 holes). Mild steel .060 (1.52) thick. (Linear length of cut = 3.14 x diameter x number of punches).

Spring pressure of the spring-loaded cluster assembly runs under a ton (9 kN) and can be ignored in calculations for machine capacity.

SHEAR STRENGTH IN US tons/in2 (kN/mm2):

Aluminum 5052 H32 = 15.0(0.2068) Brass = 17.5(0.2413)

Mild Steel = 25.0(0.3447) Stainless 304 = 50.0(0.6894)

Clusters: Tonnage

47

Clusters: Tool Life

• More tolerances with insert style. Try Fully Guided• Machine alignment critical• Turret bore wear• Guide wear• Sharpen Tools• Consider punch stagger if tonnage is high or die failure.• No Double Hitting DO NOT DOUBLE HIT HOLES. Because

of tolerances built into the punch press, using the cluster punch to finish missed holes in patterns will cause punches to

shave sides of previously punched holes. The great lateral thrust from this

shaving shortens punch life. Use a single -hole punch to complete the

pattern.

4848

Using cluster tools reduces the number of hits…and

machine and tool wear

Cluster tooling will produce patterns with just 172 hits vs.

current 2,064 hits

Clusters: Tool Life

49

Clusters: Tool Maintenance

• Sharpen before the tool requires it

• Lubricate guide assembly

• Remove galling from points in direction of punching. Find root cause and eliminate!

Sheet lube, maxima, alignment, clearance, guide, bore wear, double hitting,

50

Clusters: Press Maintenance

• Station Alignment

• Good condition bore. Select the best one you have.

• Turret bore key in good condition

• Work Holder Condition

• Die holder and shim condition.

51

Alignment

0.1 degree is too much

52

Clusters: Review

• Several Types of Tools: – Fully Guided 1 PC & Inserts, Standard 1 PC & Inserts

• Tips for Success:– Slug Pulling: Sharpen Tools, Proper Die Penetration, Alignment– Sheet Flatness: Bridge Hit, Move in 1 direction, Spring Force– Tonnage or Noise Limits: Stagger punch points– Tool Life: Use FG, Sharpen Tools, Align Station, No double

hitting.– Tool Maintenance: Sharpen Often, Lubricate, Eliminate Galling– Press Maintenance: Bores, Alignment, Workholders, Bore Keys

Piercing and Forming Clusters

Piercing and Forming Clusters

55

Extrusion

• USE: Threading for screws and increased bearing area for tubes, etc.

• TYPICAL SCREW APPLICATION: – Material thickness from 0.031(0.80) to

0.106(2.70). – Overall Height 2x to 2.5x material

thickness. – Diameter 0.374 (9.50) (M-10)

50mm diameter

•Maximum diameter can be increased by using an alternative

design.

Extrusion - Tapping

• Buy additional inverted dies to accommodate different material thicknesses.

• Maximum diameter can be increased by using an alternative design.

• Pre-pierce determines height.

Extrusion - Tapping

• Lubrication:- Ultra-Form can provide lubrication.- Lube the sheet (bottom if forming up).

• Problems:- Galling : use optional Maxima coating- Stripping : use PowerMax design- Smaller size die inserts can break : order spares

58

Extrusion

Most Common (95%)

59

Extrusions: Different Styles

One of 4 lower assemblies is used based upon the applicationMore Common

Less Common

• Standard design• Max

diameter 9.5mm

• Disc springs = Strong

• Replaceable insert

• ID is 9.5-15mm

• Disc springs = Strong

• Replaceable inserts

•ID up to 25mm•For low form

extrusions due to shoulder

•Coil springs = weaker

•Solid lower, no replaceable insert

•ID up to 16mm•Coil springs =

weaker•Replaceable insert•Most applications

that can fit the maximum diameter

have stripper requirements that

requires a C station.

60

Extrusion

General Limitations:– Overall Height 1.5x to 2.5x material thickness. Beyond

2.5 the material will likely fracture– Effective Range=Extrusion Height – thickness – radius

• Largest Range under 1.5 x thickness– Consider “PUNCH and SHAVE” vs Extrude!

Extrusion Height1.5 – 2.5 x thickness

Radius.015” (0.4mm)

Eff

ect

ive

Ran

ge

61

Extrude, OR …Punch and Shave

Finished hole size is the starting point.

Punch #1 = finished hole size – clearance (20%)Die #1 = finished hole size + 0.1 mm

Punch #2 = finished hole size (full mat’l contact : Maxima !)Die #2 = die #1

.

62

Extrusion: Extrude or Punch

• When is a tapping extrusion not the best choice for achieving the highest number of tapped threads and punching and shaving is a better option?

– Small diameter extrusions in thicker material would require an extremely small pre-pierce diameter to achieve a significant form height.

– Using a pre-pierce that is appropriate for the material thickness may not leave enough material to achieve a significant form height.

– For this reason, the largest number of useable threads may be available from punching and shaving the hole. This is more likely when the material thickness exceeds .078” (2,00mm) and the extrusion ID is less than .315” (8,00mm).

63

Extrusion: Tips for Success

Tips for Success

1. Use Pre-Pierce Calculator

2. Sharpen tools for pre-pierce hole (to avoid inside burr)

3. Form Height no more than 2.5 X Thickness

4. Tonnage= Slightly more than punching same size hole

5. Material thickness not practical to exceed 2.7mm 6. Buy additional inverted dies (Upper Insert) to accommodate

different material thicknesses.7. Pre-pierce controls form height.

8. Lubrication:- Ultra-Form can provide lubrication.- Lube the sheet (bottom if forming up).

9. Galling : Consider Maxima coating

10. Smaller size die inserts can break : order spares

11. Stripping Problems: Consider PowerMax design, larger station size, or down forming

64

Lance & Form

• USE: For air flow, decoration, card guides, location markers, shear tabs, wire harnesses or clip attachments.

• TYPICAL APPLICATION: – Material thickness from 0.020(0.50) thick to

0.118(3.00). – Maximum recommended top-to-top height is

0.250(6.50). – Other limitations include material type, thickness,

station size and press tonnage capacity.

• The inclusion of a 5° draft angle is recommended to assure reliable operation.

Ultraform B

Upper Insert

65

Lance and Form

The ‘form’ part of the operation takes place as

the work piece is squeezed between the lower unit and

an inverted die in the upper unit.

The ‘lance’ is normally performed by the lower

unit using an inverted punch.

66

Lance and Form Design Considerations

• Draft Angle: An important consideration for trouble free production.

• Made for a single material thickness, sometimes lighter material can be used.

TOP VIEW: Without Draft angle...

DRAFT ANGLE5º Minimum

TOP VIEW: With draft angle, showing effect as front edge of tab

moves back in die...

SIDE VIEW: Front edge of tab moves

back in die as it is formed.

67

Lance and Form: Design Considerations

SHEET METAL PARAMETERS

MaximumHeight

.250(6.4mm)

R = .060(1.5mm)Minimum

85º Maximum

MaximumThickness

.120(3.0mm)

OPEN END

85º Maximum

45º Maximum

OPEN END

CLOSED SHAPE

Lower tool travel is what

typically limits the form

height.

Spring Back

Thicker materials may break before

completing form and cause too

much abuse on lower insert.

Angle is typical, may

be increased if form height

decreased.

68

Lance & FormSnaplock™

• Self-locking spring loaded tab- fits into hole

• Eliminates spot welding, riveting or fastening with threaded hardware

69

Lance & FormSnaplock™

70

Lance & FormSnaplock™

71

Triple Lance & FormHexLock™

Positive retention

Common size bolts

Robust easy to use tooling

72

Lance and Form: Tips for Success

Tips for Success:• Use forming lubricant on the sheet• Replace the cutting components when they become dull• Confirm the tool was designed for the material type and

thickness being formed• Increasing the form radii• Decrease the form height• Sometimes requires pre-piercing around form, then

using an emboss. • Use a more ductile material for forms with sharp angles

or curves• Form up whenever possible• Avoid plastic coatings if possible

Avoid forms sticking, creating a burr, or becoming

damaged in processing

73

Knockout

• USE: Allows optional pathway for electrical cable.

• TYPICAL APPLICATION:– Material thickness from 0.024(0.60) to 0.118(3.00). – Maximum size dependent upon material type, thickness

and press tonnage capacity.

• The tool can be used with other material thickness within a range of + or - 0.016(0.40) from design thickness.

• Maintain minimum of 0.236(6.00) difference between diameters used for knockout.

74

Knockout: Sample

50 Ton Application

100

mm

75

Knockout

76

Knockout: Process

1. The knockout process uses a single tool to create a slug and the tabs.

2. The tabs are stretched and weakened when the slug is displaced.

3. Small tabs in thicker material may not be able to stretch enough to keep the slug attached to the sheet

4. Precise, consistent stroke control in the press is very important for producing high quality, consistent knockouts.

5. It is common for knockouts to be pressed back into the sheet (planished) to create a closed feature. Although this flattening process will not press a knockout completely flat back into the sheet it does prevent dust intrusion into the enclosure.

6. Planishing knockouts introduces stresses into the sheet that may result in a slight bowing of the knockout and/or the surrounding sheet.

77

ELECTRICAL KNOCKOUTS

SPLITTING PUNCHING FORCE WITH TWO HITS

DOUBLES…If punching force is over capacity, make first hit

single K.O. down, second hit single K.O. up with relief.

1.1 x materialthickness

1st Hit

2nd HitTRIPLES…Make first hit

single K.O. up, second hit double K.O. up with

relief.

1st Hit

2nd Hit

Thickness Variation: • Knockout tool assembly accommodates a + .016(0.4mm) range in material

thickness• Beyond + .016(0.4mm), penetration is affected and knockout performance

deteriorates

Planishing:• Planishing punch pushes knockout back to 75% material thickness, leaving 25%

still raised• Planishing the knockout further makes it difficult to remove and distorts the

sheet• Knockouts can be produced without planishing

1st Hit

2nd Hit

QUADS…Make first hit double K.O. up, second hit double K.O. up with

relief.

If diameter is closer than 6mm, this process helps too

78

Knockout: Beat Out or Fall Out

• Consistency is the key factor. – Machine repeatability– Good tool condition (sharpened)– Tool Length and Programmed depth

• The depth of planishing impacts force to remove.• The number, size and location of tabs are

important.• Material type impacts force required• The force is subjective. To you it was easy, for me

it was hard….

79

Knockout: Tips for Success

• Be aware of tonnage limits• Beat out or fall out• Use lubricant on the sheet• Confirm the tool was designed for the material

thickness range being formed• Sharpen or replace the cutting components when

they become dull. Note: Sharpening can change form height and tab strength.

• Review tab sizes, locations, and quantities• Confirm the form height is correct (1 to 1.1 times

the material thickness)• Form up whenever possible

80

Countersink

• USE: Allows screw head to reside flush or below the surface of the material.

• TYPICAL APPLICATION: Material thickness from 0.048(1.22) to 0.250(6.35), dependent upon press tonnage capacity.

• 2 styles:• Universal style: Prototype work• Shoulder style (dedicated), generally ordered

for one material thickness and screw size

81

Countersink

Countersink Up

Countersink Down

Solid body die available for

up.

82

Countersink: Dedicated

Shoulder (dedicated) Style•Designed for one material thickness and screw size•May be used with thicker material but not thinner•Coins the surrounding area producing a clean, flat countersink with minimum burring•Maximum 85% of material thickness•Very repeatable and accurate forms

Blank Die

Upper Insert

83

Countersink: Universal

Note: Use UltraTec instead of Ultra Form holder for pilot-nose Countersink down (universal).

UltraTec Fully Guided B station is recommended as slight stripper movement may cause breakage.

Universal style•Used for various material thicknesses•Maximum 60% of material thickness•Where precision and repeatability is not as important

84

Countersink: Material

Deformation

– The plastic deformation of the material is generally opposite to the direction of the applied force, moving material back into the sheet and down into a pre-pierced hole, typically causing the final hole size to be smaller than the pre-pierce hole size.

– This form can be done either to the top or the bottom of the sheet.

The area in yellow must be displaced to areas in red.

Only the angle can be controlled reliably.

Notice the finished hole is smaller than pre-pierce

85

Cuntersink: Dedicated vs Universal

Universal Style

Dedicated Style

Dedicated countersinks are preferred:

•Less material moving to the top of the sheet

•More material into hole (control via pre-pierce)

•One Die fits all

86

Countersink

Material Considerations and Maximum Depths

A=Major diameterB=Minor diameterC=Form angleD=Form depthE=Approximate pre-pierceT=Material thickness

Typical: Metric= 90, Inch=82, Rivets=120

87

Countersinks: Tips for Success

Tips for Success:• Confirm the material thickness is correct for the tool design• Check that the form is being sufficiently coined (witness mark

around shoulder diameter)• Adjusting pre-pierce size changes depth

– (smaller = deeper, larger = shallower)

• Final hole size is less than pre-pierce (use calculator supplied)• Use dedicated vs. universal when possible• If using Universal

– understand limitations of repeatability and capable tolerances– Use a new die with no shims always. Ground dies will not produce the

same result unless you modify length of upper or adjust program.

88

Emboss - Formed

• USE: – Provides a recess or a protrusion– Mounting locations and stand offs on electrical

cabinets– As a sump to collect condensation inside of

refrigeration units

• TYPICAL APPLICATION: Material thickness from 0.027(0.70) to 0.250(6.35), dependent upon press tonnage capacity.

• Best results are attained when the side wall angle is 45° or less.

• Optimum form height is 3 times the material thickness or less.

89

Emboss - Formed

90

Emboss - Formed

91

Emboss - FormedExample of emboss down

UltraTEC punch holder

with special punch

Special form-down die

92

Emboss – Tips For Success

Tips for Success• Lubricant will help reduce punching force and produce

a better emboss.• Decreasing the form angle• Decreasing the form height• Increasing the form radii• Pre-piercing a hole in the center of the emboss• Use material that is more ductile

93

LOUVERS

Use: • To provide air flow or ventilation.

Recommended:• 2.7mm material maximum• Maximum top height is 6.5mm• Length is unlimited if continuous• If non-continuous:

• Usually 12.7mm shorter than the station size used

General:• One tool cuts the sheet and produces

the form.• The tool is limited to one material

thickness.• Generally require tonnage equivalent to

punching a hole equal to the cut length of the louver.

Open End Louver Closed End Louver

94

Louvers

95

Louvers

• Closed End– Stronger design

– Smooth ends

– No exposed corners

– For exterior panels or outdoors

• Open End– Maximum air flow– Closer spacing– For interior panels or indoors– Shorter front edge and longer back

design allows sides to strip easilyDraft Angle -- 10º standard, 5º minimum. During

forming, the shorter front edge rises and the longer back edge bends to allow the sides to

strip easily.

96

Continuous:

• Prototypes.

• Short production runs.

• Extra long louvers.

Continuous louvers are made by forming a closed end louver and then gradually

advancing the tool along one axis to expand the opening.

LOUVERS

• Continuous louver tools are designed to produce smooth-edged, level-topped louvers

• Start in the center and form to one side and then the other in .030(0.8mm) increments

• If needed, complete the process by re-hitting the center for ultimate flatness

97

Louver Spacing

99

Louvers – Tips For Success

Tips For Success.

• Use forming lubricant on the sheet • Move material in opposite direction of openings• Continuous Louvers: Start in the middle (Hit A) and work toward

one end, go back to the middle (repeat Hit A) and continue to opposite end. Then repeat Hit A for the third and final time.

• Replace the cutting components when they become dull • Confirm the tool was designed for the material type and thickness

being formed • Decrease the form height • Use a more ductile material • Form up whenever possible

If problems are experienced with a closed end louver sticking, creating a burr, or becoming damaged in processing, improved

results can be achieved by:

100

V-Line Emboss

USE: To produce a logo / design / messages on a part.

TYPICAL APPLICATION:– A thin sharp line is produced outlining

the shape required and produces an etched appearance.

– Minimum 0.8mm thick, maximum can be up to machine capacity. Maximum size is dependent on station size and size of symbols or characters.

– Low punching force; complex shapes are possible; usually trouble free.

– Depth 0.3mm; does not disappear with painting.

An exact drawing, CAD file or sample of logo is required in order to produce this type of assembly.

101

V-Line Emboss

102

V-Line Emboss

103

V-Line Emboss – Tips For Success

Tips For Success• Relatively trouble free application• Proximity of adjacent lines (not too close)• Closed end features fill with material (tool stops

moving down)• Use enough punching force to get designed

depth without leaving “witness” marks• Required: good artwork with clean lines

– At least two times larger image than required

104

Shear Button

• USE: To position sheet metal parts for welding or as stops as for shear stops.

• TYPICAL APPLICATION: – Minimum material 0.9mm– Maximum material 5.0mm– A diameter of 5.0mm is

standard, but up to a diameter of 9.5mm is possible.

• Maximum height is 65% of the material thickness

105

Shear Button

106

Shear Button

One tool produces the form in each mating part.

Using shear buttons to square large sheets...

Conventional use of shear buttons...Shear buttons in lower plate fit

into matching holes in upper plate...

Shear buttons used as weld projections for precision placement of plates to be welded

together...

107

Shear Button

Use slotted for small diameter and

thin materials

Multiple Material Thickness Tool:

•Use slotted insert for up to 2.3mm material and non-slotted for material up to 5.0mm thick

•Slotted insert leaves a tab (like a knock out)

108

Shear Button

• Traditional wire style micro-joint.

– Sharp point needs to be removed, creating a secondary operation

– Material left may cause inaccurately formed parts

• Square Shear Button style micro-joint– Adjustable in length when strength

is required– It can be snapped off easily, leaving

a clean edge– Square shape allows it to be used

at both 0° and 90° without the need of an auto-index station

109

Shear Button – Tips For Success

Tips For Success• Low tonnage operation that’s relatively trouble

free• When using in Stainless Steel, the diameter

should be twice the material thickness• In thin material, a slotted tip insert may be used to

help buttons stay in place• Tools can and should be sharpened

110

EasySnap™

• V-line stencil from both sides creates snap-line

• USE: Like a micro-joint – but better!

• Can be snapped-off with no burr

• Reducing waste of skeleton

• TYPICAL APPLICATION:

– Material thickness from 1.0mm thick to 1.5mm MS and SS, and 2.0mm ALU

– Tool dedicated for 1 thickness only

– Max. recommended length 300mm

111

EasySnap™

– Using tool for proper (designed) material thickness allows easy breakage of parts in two

– Using tool on material too thin for design could shear through material

– Using tool on material too thick for design won’t allow easy breakage of parts

112

EasySnap™

Use for easy part removal and skeleton breakdown

Use when a formed flange needs extra material for gauging and forming. Snap off extra after form is made

114

EasySnap™ - Tips For Success

Tips For Success

• Designed for one thickness– Punch depth should be about 33% into

material, both top and bottom

• Run at a slower machine speed

• Use as last operation if possible

115

• Complex bending made easy

• V-line stencil creates line of weakness

• Allows subsequent bending by hand

• Suitable for MS or SS < 1.50mm and Al < 2.00mm

• Maximum recommended length 300mm

• Available for all tooling styles

Before punching.

After punching with EasyBendT.

Hand bend along bend line created with EasyBend™

Component after hand bending.

Mate EasyBendMate EasyBend™™

LIT 00002

LIT 00002

JOHN ALPHA NUMERIC MARKING

• Use standard, replaceable, economical inserts.

• Message or letter changed easily

CARD GUIDE

Use:

• As a retainer for printed circuit boards

Minimum/Maximum

• 1.0mm thick minimum 2.0mm thick maximum

CARD GUIDE

• Length of the card guide is dependent upon station size and machine tonnage

• Maximum height recommended is 3.2mm

Pre-pierce ends can be rectangular or rectangular with radiused corners

CARD GUIDE

• Two tools are required– Pre-pierce – One that forms the card guide

• Each tool is made for a specific material thickness

• Galling can be a problem– lubrication through the tool and

on the sheet is beneficial

• Mild steel give the best form– Aluminum is fair– Stainless can be a problem

due to spring back of the material

• A post dwell should be used to allow stripping

COLD FORGED EMBOSS

Use: • To produce a logo or design on a part.

Minimum/Maximum:• Minimum 0.3mm thick, Maximum 3.0mm thick,

depending on the tooling style, station size and the machines tonnage

• Can be used on varying material thickness (within a range)

• Best if made in 1.0-2.0mm thick material

General:

• Exact drawing or sample of logo required to produce

• Tonnage can be high dependent on design and material

• Usually simple trouble free operation

• Width of characters should be minimum of one material thickness, more is better

• Space between characters or lines should also be one material thickness minimum

• Tools are not designed to be sharpened

• Can be dusted to sharpen the emboss after the tool is older

UPPER INSERTUPPER INSERT

MATERIALMATERIAL

LOWER INSERTLOWER INSERT.016(4.0mm)

to.020(0.5mm)

For clear definition and readability, raise characters at least .016(0.4mm) to .020(0.5mm) above the surface.

This cut-away of the MATE logo shows how a complex form is rendered by the cold forged embossing process.

MAXIMUMSTATION PERIMETERS

B Ø .787(20.0mm)C Ø 1.575(40.0mm)D Ø 2.362(60.0mm)E Ø3.346(85.0mm)

COLD FORGED EMBOSS

HINGE TOOLS

Tool 1 makes 2 hits: Pre bending and rising the pre-bended tap with axis movement in between

Tool 2 makes one hit and finishes the hinge

Tool 1 Tool 2

HINGE TOOLS

Tool 1

Tool 2

Use: • Logos, messages or symbols• Produces an etched appearance

Minimum/Maximum:• Minimum 0.8mm thick, maximum

can be up to machine capacity• Maximum size is dependent on

station size and size of symbols or characters

General:• Thin, sharp line produced,

outlining the shape required and• Low to high tonnage, usually

trouble free

V-LINE CUSTOM INSCRIPTION

V-Line Stamping -- renders the image with a thin, sharp line stamped into the surface. It requires relatively small force. Large complicated images are possible.

V-Line Stamping:• Thin, sharp line

reproduces the outline of the shape for an etched appearance. Low punching force.

• Within press capability, figures may be any size up to station maximum

• When ordering, an accurate indication of each figure’s size, shape and depth below surface (0.30mm maximum) are required

• Typefaces may be specified or artwork may be furnished, depending on the requirements of the subject matter.

RAM CONTROL TOOLS

Press must be capable of holding the ram down while the sheet is moved in the X and or Y direction.

MATE ROLLERBALL™

• Rollerball™ provides the benefit of making forms not possible with single hit forming tools

• Takes advantage of punch press extended programming capabilities

• Machine must be capable of operating in the x and y axis with the ram down

Rollerball™ Capabilities:• Make stiffening ribs in light gauge sheet

metal• Cross-break operations on the punch

press• No secondary press brake operations • Form ribs, flanges and raised areas

across the entire work surface• Offsets and embosses not limited to

station range

•Max. thickness 2.7mm

•Rib width ~22 mm (fix)

•Max. height 3.7mm incl. thickness

Ribs

Offsets

MATE ROLLERBALL™

Rollerball Examples

Rollerball® Beading in 1mm mild steel

Detail inside corner Roller Ball Beading

Mate RollerBall DeburrMate RollerBall DeburrTakes away the burrs on every hole – even small diameters and in corners, also slitting lines on both sides

Machine must be capable of holding down he ram while moving the sheet

Can be used in combination with EasySnap to get a burr- free product

Up to 4.0mmthickness

SHEETMARKER™

Three springs, two points (120 & 150) allow control of depth and width of the line scribed

Flexible, programmable marking

Score Plastic Protection for removal before laser cutting

or fabrication ( bending lines etc.)

Cuts trough the protective plastic film without leaving any marks on the metal surface .

Mate EasyMarkMate EasyMarkSprings: 3 Types to be

used for diamond orBrass Inserts

Spacer: Use for dead weight on

top of InkMarker

Punch: for installing and removing

inserts

Ink Marker pen Insert Holder 3 Inserts (2 diamond, 1 brass)

Allen Wrench: for installing and removing inserts

Die: Used forSheetMarker

and InkMarker

Spacer: Use with

SheetMarker

A-station Holder

Mate EasyMarkMate EasyMarkApplications with Inkmarker Pen

MATE SOLUTIONS TRAINING

PROBLEM-SOLVING CHECKLIST

PROBLEM-SOLVING CHECKLIST

• Is the material correct for the tool that was ordered?

• Is the tool length set correctly?• Is the forming being done close to the clamps?• Does the tool require sharpening?• Is galling present on the tool?• Was the correct pre-pierce used?• Is there a delay in the program to allow stripping?• Is the turret aligned properly?• Is there any damage to the tool?• Was lubrication used on the tool and sheet?

MATE SOLUTIONS TRAINING

SUMMARY

SUMMARY

• Using forming in your operations will help you…

– Increase efficiency

– Expand your capabilities

– Eliminate of secondary operations

– Increase machine time

– Reduce tool wear

THANK YOU!

MATE SOLUTIONS TRAINING