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Problem- Solving Guide

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Problem- Solving Guide Common Stamping Problems Problem- Manufacturers know that punching can be the most cost-effective process for making Dayton Progress Corporation holes in strip or sheet metal. However, as the part material increases in hardness to 500 Progress Road Solving accommodate longer or more demanding runs, greater force is placed on the punch P.O. Box 39 Dayton, OH 45449-0039 USA and the die button, resulting in sudden shock, excessive wear, high compressive loading, and fatigue-related failures. Dayton Progress Detroit Guide 34488 Doreka Dr. The results of some of these Fraser, MI 48026 problems are shown in the Dayton Progress Portland photos on this page. 1314 Meridian St. Portland, IN 47371 USA Dayton Progress Canada, Ltd. 861 Rowntree Dairy Road Woodbridge, Ontario L4L 5W3 Punch Chipping & Point Breakage Dayton Progress Mexico, S. de R.L. de C.V. Access II Number 5, Warehouse 9 Chips and breaks can be caused by Benito Juarez Industrial Park press deflection, improper punch Querétaro, Qro. Mexico 76130 materials, excessive stripping force, Dayton Progress, Ltd. and inadequate heat treatment. G1 Holly Farm Business Park Honiley, Kenilworth Slug Jamming Warwickshire CV8 1NP UK Slug jamming is often the result Dayton Progress Corporation of Japan of improper die design, worn-out 2-7-35 Hashimotodai, Midori-Ku die parts, or obstruction in the slug Sagamihara-Shi, Kanagawa-Ken relief hole. 252-0132 Japan Slug Pulling Dayton Progress GmbH Adenauerallee 2 Slug pulling occurs when the slug 61440 Oberursel/TS, Germany sticks to the punch face upon withdrawal and comes out of the Dayton Progress Perfuradores Lda Zona Industrial de Casal da Areia Lote 17 lower die button. Cós, 2460-392 Alcobaça, Portugal Punch Wear and/or Galling Dayton Progress SAS Die performance and longevity can 105 Avenue de l’Epinette be improved through the use of BP 128 Zone Industrielle regular maintenance, as well as the 77107 Meaux Cedex, France use of lubricants and leading edge punch designs. Dayton Progress Czech sro Hala G Punch Head Breakage Pražská 707 CZ-294 71 Benátky nad Jizerou Punch deflection leads to punch Czech Republic head breakage. Cutting shear, press tonnage, the type of backing This booklet deals with plate, alignment, and the types of punches and retainers all require several common punching careful consideration when problems; presents some designing a punch. Global leader in providing fabrication and stamping solutions Metal Stamping Solutions likely causes; and, offers solutions to these problems www.daytonprogress.com —including Dayton products. Form 992 10/12 www.daytonprogress.com Common Stamping Problems Problem- Manufacturers know that punching can be the most cost-effective process for making Dayton Progress Corporation holes in strip or sheet metal. However, as the part material increases in hardness to 500 Progress Road Solving accommodate longer or more demanding runs, greater force is placed on the punch P.O. Box 39 Dayton, OH 45449-0039 USA and the die button, resulting in sudden shock, excessive wear, high compressive loading, and fatigue-related failures. Dayton Progress Detroit Guide 34488 Doreka Dr. The results of some of these Fraser, MI 48026 problems are shown in the Dayton Progress Portland photos on this page. 1314 Meridian St. Portland, IN 47371 USA Dayton Progress Canada, Ltd. 861 Rowntree Dairy Road Woodbridge, Ontario L4L 5W3 Punch Chipping & Point Breakage Dayton Progress Mexico, S. de R.L. de C.V. Access II Number 5, Warehouse 9 Chips and breaks can be caused by Benito Juarez Industrial Park press deflection, improper punch Querétaro, Qro. Mexico 76130 materials, excessive stripping force, Dayton Progress, Ltd. and inadequate heat treatment. G1 Holly Farm Business Park Honiley, Kenilworth Slug Jamming Warwickshire CV8 1NP UK Slug jamming is often the result Dayton Progress Corporation of Japan of improper die design, worn-out 2-7-35 Hashimotodai, Midori-Ku die parts, or obstruction in the slug Sagamihara-Shi, Kanagawa-Ken relief hole. 252-0132 Japan Slug Pulling Dayton Progress GmbH Adenauerallee 2 Slug pulling occurs when the slug 61440 Oberursel/TS, Germany sticks to the punch face upon withdrawal and comes out of the Dayton Progress Perfuradores Lda Zona Industrial de Casal da Areia Lote 17 lower die button. Cós, 2460-392 Alcobaça, Portugal Punch Wear and/or Galling Dayton Progress SAS Die performance and longevity can 105 Avenue de l’Epinette be improved through the use of BP 128 Zone Industrielle regular maintenance, as well as the 77107 Meaux Cedex, France use of lubricants and leading edge punch designs. Dayton Progress Czech sro Hala G Punch Head Breakage Pražská 707 CZ-294 71 Benátky nad Jizerou Punch deflection leads to punch Czech Republic head breakage. Cutting shear, press tonnage, the type of backing This booklet deals with plate, alignment, and the types of punches and retainers all require several common punching careful consideration when problems; presents some designing a punch. Global leader in providing fabrication and stamping solutions Metal Stamping Solutions likely causes; and, offers solutions to these problems www.daytonprogress.com —including Dayton products. Form 992 10/12 www.daytonprogress.com Troubleshooting Guide to Extending Punch Life, Improving Performance, & Reducing Downtime Solutions for punch wear, Problem: Punch Chipping & Point Breakage Problem: Slug Jamming Problem: Punch Wear and/or Galling breakage, and other Cause Solution Dayton Products & Services Cause Solution Dayton Products & Services Cause Solution Dayton Products & Services The drawing below provides a quick reference Change punch materials Consider Dayton Versatile M2 & PS4, Tight die clearance Increase die clearance Ref. “The Engineered Clearance” & Dayton clearance testing service Tight die clearance Increase die clearance Ref. “The Engineered Clearance” & Dayton to the various parts of a punch die set, i.e., the problems come from both High impact or compressive Ball Lock PS4, or TuffPunch® PS4 clearance testing service failure Excessive land length Reduce land to 1-4 times stock thickness Consider Dayton XB alteration Change to a larger body diameter Coatings/surface treatments Ref. Dayton coatings brochure punch and the die button (the receptor). time-tested techniques (e.g., punch Change relief from counter bore to taper Consider Dayton Versatile & Kommercial Die Buttons Change punch materials Consider Dayton Versatile M2 & PS4, For additional adding a larger-than-normal Change from a Jektole® to solid Taper in the land of the Verify there is no reverse taper in the Ball Lock PS4,TuffPunch® PS4, or Versa/plus™ die button land of the die button Punch punch Punch entry too deep Reduce punch entry information on tool radius under the head) as Inadequate taper relief in Head Use guide bushings Consider Dayton Versatile product line Increase per side taper Consider Dayton XAR alteration die button Misalignment Check die & press alignment steels, coatings, well as consideration for Check for worn guide pins & Regrind burr Remove regrind burr—break sharp Fillet Misalignment resulting in lateral Worn die button Sharpen, replace, and/or change die Consider Dayton M2 or Versatile PS clearances, forces bushings—replace, if necessary corners on punch face a wide range of leading- forces button material Check for loose gibs in the ram of Worn or chipped punch Sharpen or replace punch Improper sharpening of Use flood coolant, and correct grind- on the punch, edge engineering solutions the press punch ing wheel speed & feed for steel type Use die buttons with smooth wire cut, and guidelines for Check overall die alignment Rough land in die button Shank (e.g., head alterations) and or ground land Improper punch material Change punch materials Consider Dayton Versatile M2 & PS4, Use gas or spring-guided stripper Consider Dayton MaxLife® Die Springs Ball Lock PS4, TuffPunch® PS4, or Versa/plus™ the selecting the Part material movement Use shear angle on punch and/or check Consider Dayton XS20 or XS21 on round ® Slug tipping specialty coatings designed Use a retainer or punch-mounted Consider Dayton DAYStrip or SMARTStrip™ punch-to-die alignment or shaped punches Sharp corners on shaped Increase clearance in the corners Consider Dayton “L” or “K” punches best product for stripper Urethane Strippers punches of the die button to maximize the life of the Check lubrication—consider lubricating your operation, Poor material control Review die, press, & feeder setup both sides of part material Punch surface too rough Consider punch finish improvements Contact Dayton Regional Manager punch. Increase punch-to-die button Ref. “The Engineered Clearance” & Dayton Use a Jektole® punch with a side vent hole Consider Dayton patented Jektole® punch Lack of lubrication on part Check lubrication Radius contact your local Excessive stripping force clearance clearance testing service and/or incorrect lubrication Blend Obstruction in slug relief hole Examine slug path Dayton Progress This troubleshooting guide Reduce punch-to-die entry Prepainted & coated part Increase die clearance to Consider increasing the size of the relief Contact Dayton Regional Manager material accommodate powdering & flaking representative. can help you determine Consider coatings to add lubricity Ref. Dayton coatings brochure hole in lower plate Point Back taper on punch point “B” the cause for your broken, Polish punch point Consider Dayton Versa/plus™ products Problem: Slug Pulling Punch point hardness Verify hardness is minimum of Request technical assistance
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