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Aluminum Stamping Solutions

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Aluminum Stamping Solutions Select the Coating that Matches Commitment to Quality & Customer Satisfaction Aluminum Your Speci c Needs Dayton Lamina is a leading manufacturer of tool, die and mold components for the metal-working and plastics industries. As a customer-focused, world-class supplier of choice, we provide Stamping Abrasive Wear Adhesive Wear the brands, product breadth, distribution network and technical Regardless of the end product(s) your Common Abrasion, pitting, cavitation, striation, Galling, pick-up, sticking, welding, company manufactures, you can Names etc. etc. support for all your metal forming needs. Solutions improve the length of run time, reduce Processes Hard sheet material—jagged edges Soft sheet material Piercing, shearing, etc. Drawing, extruding, etc. Our goal is to give our customers the most innovative and value- changeover time, improve uptime, Sliding wear—along direction of Perpendicular to direction of forming added products and services. and get more for your stamping dollar forming by selecting the type of coating that Process temperature may be too high Process temperature may be too matches your individual operational or low high Clearances may be too tight Clearances may be tight capabilities. Solutions Increase surface hardness Increase lubrication The chart on the right describes the Increase clearances Choose lower coefficient coating causes, e ects, and solutions for abrasive Choose high thermal resistance Choose high thermal resistance coating coating wear and adhesive wear. The slider Increase clearances graph following shows the relative suitability for each type of treatment/ Abrasive Wear Adhesive Wear coating in both of those categories. The bubble chart shows the relationship be- tween service temperature, coe cient Uncoated XNP XCN CRN XNT Tool XNM XCD XCDP of friction, and hardness of the coating. 2,500°F Notes: Size of the bubbles indicates the hardness of the coating. 1,250°C Color of the bubbles indicates the color of the coating. * 2,000°F 1,000°C *Dayton Lamina’s line of Danly products is available only to North America. ] ] 1,500°F °C °F [ [ 750°C CRN XNT 1,000°F XNM 500°C XCN* XCD XNP 500°F *These bubbles overlap because of the 250°C Service Temperature Service Temperature XCDP similarities of the properties. (0.05) 0.05 0.15 0.25 0.35 0.45 0.55 0.65 Co-efficient of friction Dayton coated punches are heat treated, precision ground, and made with high performance steel, including, but not limited to, the following: I M2—triple tempered HSS for longer runs. Performs well at higher temperatures; ideal for high-speed applications. www.daytonlamina.com Reducing Downtime, I PS—triple tempered with high vanadium and carbon particles. Higher wear and impact performance. Increasing Pro t I www.daytonlamina.com PS4—with 4% vanadium it provides higher wear resistance and Special tool steels are available on request. improved toughness. © 2018 Dayton Lamina Corporation. All rights reserved. Form 781 1/19 a MISUMI Group Company XAR BB Galling Solutions back into the hole as the punch is The initial solution considers how Dayton Progress Understands the Issues Associated Optimizing Punch Performance for Aluminum extracted, creating drag and pull to offset the adhesive influence BB One of the most frequent on the punch. The tensile nature of of the aluminum. To counteract A° with XS20 with Stamping Aluminum problems encountered with the material must be considered the galling, we must reduce the • Aluminum Oxide buildup Chamfer Shear Angles perforating aluminum is punch in determining the correct die co-efficient of friction between XS20, XS25—Shear Angles are used XS20 XS25 galling. Aluminum, in general, button. Dayton’s Engineered the punch and aluminum. This can L • Perforating problems primarily to reduce slug pulling. This Y 90° possesses a gummy characteristic Clearance will aid in developing be accomplished through several • Accelerated die component wear feature has been proven effective to 0° which causes it to adhere to the proper clearance. venues. One is to use a low co- generate longer cycle life. A° a surface of the punch when efficient of friction coating on the The galling of aluminum on the • Galling (adhesive wear) it’s drawn, pulled, trimmed, punch. But coatings containing Studies show that the XS20 (round) and XS20 XS25 punch tip over time will cause the perforated, or pierced. This aluminum in their chemistry must Ultimately you have more downtime XS25 (shape) shear angle can improve A any angle 7.5°, 15°, 30°, 45° hole size to expand. This creates an 0.020” (0.5mm), 0.040” (1.0mm), accumulation of material on be avoided. The trace aluminum and increased maintenance costs; life cycles by 200-300%. Y 0.04” (1.0mm) out of tolerance hole quality issue 0.060” (1.5mm) the punch is known as galling will create an intense adhesive robbing your company of profit. on the part. Several remedies are Tolerance on all angles is +/-15 minutes. (adhesive wear). The galling occurs issue. OEM manufacturers have available for this situation. These You can rely on solutions from both on the initial penetration had great success with Dayton’s solutions may be incorporated Dayton Progress to increase profits. into the material and extraction XCDP coating. Jektole® Punch separately or used in conjunction from the material. The elastic Many aluminum material applications The benefits of using a Jektole punch are with one another to alleviate the nature of the aluminum collapses use lubrication throughout the die and twofold. The spring loaded Jektole pin galling and prolong punch life. The Dayton Progress Solution Punch Design: Features that some materials contain a wax coating. (extending from the face of the punch) We have developed punches perforate cleanly and eject slugs This combination acts a bonding agent is a method to retain the slug in the die specially designed for stamping efficiently. Perforating Considerations However, when perforating the Punch to die clearance is a key between the punch and slug. This button after perforating. The Jektole aluminum. The combination of The various grades of aluminum softer 3000 and 4000 aluminum factor when perforating aluminum. Punch Material: Durable tool steel, magnifies surface tension and increases punch also has a side vent hole which the right punch material, design, behave differently when grades, dramatic hole shrinkage The recommended die clearance heat treated in-house in our modern the possibility of slug bonding. allows air to get in, breaking the vacuum coating, and finish will improve your perforating holes. A selection of may be experienced. Again is directly related to the type of vacuum ovens. and lubrication seal between the punch day-to-day operations. M2 or PS4 or PS tool steel for the utilizing the proper die clearance, aluminum, its tensile strength, and and slug. Coatings: Dayton Progress uses long punch material generally achieves the amount of hole shrinkage can the aluminum sheet thickness. The lasting coatings that reduce friction very good results. When punching be managed. Edge radius punch die clearances can run within a and increase wear life. the 5000 and 6000 aluminum points for the softer aluminum range of 3% to as high as 20% per Grind vs. Polish Back Taper series, the perforated hole size grades should be avoided. A flat, side. Finishes: Precision micro finishes XAR—Round punches can be ground XAR movement is minimal. By using the sharp edged punch point without with a back taper to reduce stripping that enhance the performance of BB proper die clearance, the hole will any shear angle performs best. our coatings. pressure, heat, and material build up be slightly larger than the punch. The shear has a tendency to only on point. This precise change in the BB A° with XS20 deform the aluminum and cause size facilitates stripping material and is more rollover in the hole in the Options That Fit Your Situation and Budget much less likely to adhere to the punch. A <=10° This publication is part of softer aluminum grades. Grind life is not affected. The reduction BB tolerance ±0.015” / ±0.38mmXS20 XS25 a series of free technical L Production Good Better Best Callout in diameter is so small that the punch Y 90° self-study and classroom How to Select Engineered (Jektole®) Die Clearance and Tensile Strength remains within normal tolerances 0° courses designed to improve Punch Material M2 PS4 PS M2, PS4, PS Clearance per Side (∆), the Proper Clearance 3-7 % 7-13% 13-20% for both hole size and die clearance A° % Material Thickness→ your knowledge of the metal XS20 (round) or Identify the tensile strength from Chamfer — Yes Yes throughout its life. Al-Copper Alloys (2xxx, etc) stamping process. Other XS25 (shape) the last rows in the chart. Al-Manganese Alloys (3xxx, etc) types of Dayton technical Al-Silicon Alloys (4xxx, etc) Jektole — Yes Yes BJ_, DJ_, VJ_ Al-Magnesium Alloys (5xxx, etc) assistance include person- Determine the recommended Diamond-like Carbon Coating Al-Magnesium-Silicon Alloys (6xxx, etc) to-person consulting, online Back Taper — — Yes XAR (round) clearance from the shaded area for Al-Zinc Alloys (7xxx, etc) and printed catalogs, CAD- Diamond XCD—This diamond-like carbon XCDP—This super-smooth, polished alloys. Al-Other Alloys (8xxx, etc) Yes — — XCD coating combines high hardness with finish is combined with a DLC coating Tensile Strength compatible design software, Coating MPa 110 175 285 430 610 an extremely low coefficient of friction. for a very low coefficient of friction with Multiply the recommended and other materials Polished Diamond KSI 16 25 41 62 88 and programs. — Yes Yes XCDP Offering good protection against high wear resistance. It is excellent for clearance with the thickness *Many variables, such as hardness, thickness & chemical composition, can affect results.
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