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Stamping Basics
� Die Components
� Class of Tools
� Cost Drivers
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Basic Types Of Tools
� Compound
� Progressive
� Draw
� Secondary Tools
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Compound Die
� Lower Volume
� Flatter Parts
� No Forms
� Burrs All One Direction
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Progressive Die
� Cuts
� Forms
� Sizes
� Coining
� Loose or Strip
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Traditional Class Of Tools
� Class “C” Tools
� Class “B” Tools
� Class “A” Tools
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Class “C” Tools
� Simple One Die Block
Construction
� Box Stripper
� Soft Punch Holder
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Class “B” Tool
� Some Guiding Of Punches
� Might Have Inserted Cuts
� Spring Stripper
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Class “A” Tool
� Higher Volume
� Inserted Cuts
� Hardened Back Ups
� Hardened Stripper Face
� Hard Punch Holder
� All Guided
� Insert Stripper
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DMI Class Of Tools Vol/Mat'l 1 2 3 4 5 6 7
100M LV LV LV LV LV LV HV
250M LV LV LV LV LV MV HV
500M LV LV LV MV MV MV HV
1MM LV LV MV MV MV MV HV
5MM LV MV MV HV HV HV HV
10MM MV MV HV HV HV HV SV
25MM MV HV HV HV HV SV SV
50MM HV HV HV SV SV SV SV
100MM HV HV SV SV SV SV SV
250MM SV SV SV SV SV SV SV
500MM SV SV SV SV SV SV SV
1 Billion SV SV SV SV SV SV SV
Tool Life
Tool Volume Construction Of Class "A" Dies
(Type Of Material / Estimated Life Of Tool In Parts)
1. Thin material of .004 or less will require one class upgrade
2. Tight tolerances of ±.001 or tighter may require one class upgrade
Material 1 = Brass, Aluminum, Phosphor Bronze
Material 2 = Beryllium Copper
Material 3 = Cold Rolled Steel
Material 4 = Nickel Silver
Material 5 = Stainless Steel
Material 6 = Nickel Alloys
Material 7 =Titanium
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Cost Drivers
� Holes
� Forms
� Flatness
� Edge Condition
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Cost Driver - Holes To Form
� Form will distort when formed
� Can perf with a cam after forming
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Cost Driver - Very Short Forms
•Difficult to form because of pressure on radius and
elasticity of material.
•Short forms can be cut after forming
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Cost Driver - Long Forms
•Harder to hold true
position at end
•Can add pre-forms
to help control
•Shipping may cause
parts to change
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Cost Driver - Shear Forms
� Extra Cutting Required
� More Maint.
� Tapered
� Can Lock Back Into Metal
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Cost Driver - Flatness
� Spring Stripper Will Hold Part
While Stamping
� Parting vs. Blanking
� Blank on Pad Will Allow
Flattening At Bottom
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Cost Driver - Edge Condition
� Square Edges
Are Not
Capable
� Can Give Up
To 80% Shear
� Shave
� Ball Size
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Materials
� Steel
� Brass
� Stainless
� BeCu
� Others
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Steel
� Cold Rolled Steel
� Most Common
� Many PrePlate Types
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Steel - Common Coatings
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Brass
� Mostly Available
� Good Electrical
� Can Get Pre-Plated
� Some Spring
� http://www.olinbrass.com/
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Stainless
� Good Spring
� No Secondary Process
� Can Have Many Nice Finishes
� http://www.olinbrass.com/stainlessdag.html
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BeCu
� Good Electrical
� Good Spring Forces
� Little Stress Relaxation
� Longer Lead-times
� Most Expensive
� http://www.brushwellman.com/www/homepage.html
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Others
� High Nickel
� Phos Bronze
� 7025
� Inlayed
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Plating
� Types
� Processes
� Post-Plate
� Pre-Plate
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AMP Presentation
29
Reel-to-Reel Plating Technology
Duplex ControlledDuplex Controlled
DepthDepthBelt MaskingBelt Masking
Multi StripeMulti StripeRotary Brush / ControlledRotary Brush / Controlled
DepthDepth
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Plating
� Nickel Thickness Drives Time
To Process
� Tin Can Contaminate Wire
Bonding Depending On
Proximity To Bond Area
� Gold
� Palladium
� Need Approximately .100 min
Separation
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AMP Presentation
31
• Brush•Control Depth•Mask Or Belt
NickelNickel - Electrolytic
- Electroless
* Ni Phosphorus
* Ni Boron
NickelNickel - Electrolytic
- Electroless
* Ni Phosphorus
* Ni Boron
TinTin - Pure
- All Solders
TinTin - Pure
- All Solders
GoldGold- Soft
- Hard
GoldGold- Soft
- Hard
PalladiumPalladiumPalladiumPalladium
SilverSilverSilverSilver
PalladiumPalladium
NickelNickelPalladiumPalladium
NickelNickel
CopperCopperCopperCopper
Plating
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Plating Processes
� Barrel
� Rack
� Strip
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Design For Inserts
� Shut off
� Tie Bar
� Hold Down in Plastic
� Tolerances
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Design for Inserts - Shut off Flats
� Size consideration
� Length of Tabs
� Width Tol.
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Design for Inserts - Shut off Flats
� Burrs
� Forms
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Design For Inserts - Tie Bar
� More Tie Bars Are Better
� Holds Parts Together
� Allows Tighter Location
Tolerances
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Design For Inserts - Hold Down in Plastic
� Coined Ears
� Holes For Anchors
� Semi-Perf
� Locking Tabs
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Design For Inserts - Continuous Strip
� Tie Both Ends
� Smaller Parts
� Ladder Strip
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Design For Inserts - Continuous Strip
� Ladder Strip
� Most Stable
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Packaging
� Bulk
� Plastic Trays
� Reel to Reel
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Proto-Types
� Laser
� Chem.. Etch
� Die Cut
� Wire Cut
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Proto-Types - Laser
� Short Lead Times
� Burr Free
� Cost Effective
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Proto-Types - Laser
� Material Thickness to be Between .001” min
to .500” max on all Steels. Coppers and
Brasses to be Between .001”min and .
160”max.
� Positioning Tolerances can be held to .00039”
and Repeatability of .00019”.
� Careful Consideration for Cross Section due to
Heat Effect Zone.
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Proto-Types - Chem Etch
� Hold Tight Tolerances
� Burr Free
� Work with Smaller Parts
� Some Edge Condition
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Proto-Types - Chem Etch
� Material Thickness Between .
0005”min to about .100”max.
� Etching Precision can be held to
within .0005”
� Lead Times about 5 - 10 Days.
The DiemastersManufacture Smarter