Maintenance Manual Thick Turret, Trumpf® and Fab Tooling Maintenance, performance and troubleshooting guide for thick turret and punch users. Rev. 2.18.16 EG Table of Contents Introduction .................................................................................................................... 5 Mission Statement .......................................................................................................... 5 Punching ......................................................................................................................... 6 Three Phases to a Punched Hole .................................................................................. 7 Fracture Angle ................................................................................................................ 7 Parts of a Punched Hole ................................................................................................ 8 Reading Slugs ................................................................................................................ 9 Shear Amount Material Thickness Ratios ................................................................ 9 Shear percentages per material type: ....................................................................... 9 Tool Regrinding ............................................................................................................ 10 The Importance of Tool Regrinding ........................................................................ 10 Indicators That a Tool Needs Regrinding ............................................................... 10 Regrind Rules ............................................................................................................... 11 Grinding Coated Punches ........................................................................................... 12 Grinding Long, Narrow Punches ................................................................................ 12 Sharpening Tips When Grinding ................................................................................ 13 Material Removal ...................................................................................................... 13 Removing Galling ..................................................................................................... 13 Recommended Grinding Machines/Wheels ........................................................... 13 Other Style Tool Grinders ........................................................................................ 14 Tool Lubrication ........................................................................................................... 15 Machine Delivered Lubrication ................................................................................ 15 Manual Lubrication (non-machine delivered lubrication) ..................................... 15 Notes on Lubrication: ............................................................................................... 15 Lubrication for Large Station Guide Assemblies Manufactured by Wilson Tool ... 16 Calculating Maximum Regrind Life ............................................................................ 17 Maximum Grind Life Values for Punches .................................................................. 18 Maintaining Tool Life ................................................................................................... 20 Achieving Maximum Tool Life with Tool Lubrication ............................................... 21 Lubricating Series 80, Series 90 and HP (High Performance) Punches ................. 21 The WLS Tool Lubrication System ............................................................................. 21 Extending Tool Life with the Use of Shims ................................................................ 21 Maintaining Tool Life by Regularly Checking Turret Alignment .............................. 22 Shimming Old Style A Station Punches ..................................................................... 22 Rev. 2.18.16 EG 2 Shimming Old Style B Station Punches on Thick Turret, Thin Turret and Strippit® Machines ....................................................................................................................... 22 Adjusting B Station and 5/8” Drop-In Punches ......................................................... 22 Shimming Thick Turret, Thin Turret and Strippit® Old Style C, D, E and F Station Punches ........................................................................................................................ 22 The Problem of Over-Shimming Old Style Punches ................................................. 23 No Shimming Required: HP Punching Systems (Series 80, 80 Plus and Series 90 Tool Systems) ............................................................................................................... 24 Shimming and Adjustment .......................................................................................... 25 Thick Turret Tooling ................................................................................................. 25 HP Tooling ................................................................................................................. 31 Dies ............................................................................................................................ 32 Shimming Dies .......................................................................................................... 32 Achieving Maximum Tool Life by Using Suitable Die Clearance ............................. 33 Selection of Die Type ................................................................................................... 34 Standard Taper .......................................................................................................... 34 Positive Taper ........................................................................................................... 34 Negative Taper .......................................................................................................... 34 Slug Hugger® Dies .................................................................................................... 35 Slug Hugger® 2 Dies ................................................................................................. 36 Maintaining Tool Life by Regularly Checking Turret Alignment .............................. 36 Tool Maintenance ...................................................................................................... 36 Stripper Clearance Types ............................................................................................ 37 Closed Round Stripper ............................................................................................. 37 Fitted Shaped Stripper ............................................................................................. 37 Slip Fit Shaped Stripper ........................................................................................... 37 Calculating Punching Force ........................................................................................ 38 Punch Shear ................................................................................................................. 41 Interchangeability of Series 90, HP Punch and Guide Assembly ............................ 42 Punch Driver Assembly ........................................................................................... 42 Punch ......................................................................................................................... 42 Punch Holder ............................................................................................................. 42 Guide .......................................................................................................................... 42 Stripper ...................................................................................................................... 42 HP/Series 90 Identification Charts .............................................................................. 43 Standard HP/Series 90 ................................................................................................. 45 Problem Solving Checklist for Tool Failure ............................................................... 47 Piercing Tools ........................................................................................................... 47 Forming Tools ........................................................................................................... 47 Troubleshooting ........................................................................................................... 48 Rev. 2.18.16 EG 3 Thick Turret Tooling: Punch Body Breakage ............................................................ 53 C Station .................................................................................................................... 53 D Station .................................................................................................................... 53 Thick Turret Tooling: Punch Tip Breakage ................................................................ 53 Thick Turret Tooling: Die Breakage ............................................................................ 54 Coining Tools: Punch Insert Breakage ...................................................................... 54 Extrusion Tools: Insert Breakage ..............................................................................