Ask the Stamping Expert: Is there a check list for setting progressive dies?

Q: We are new to die setting. Do you have a check list that could help us with different progressive dies? Can you recommend any literature on the subject?

A: First, I do not know of any comprehensive literature. Most literature tends to focus on an individual subject rather than cover the overall topic of die setting.

Second, die setting involves too many variables for there to be one check list that can apply to all. The only way to get a full, detailed solution is through your own experience over time, running your dies and documenting a complete list to maintain repeatable setups for good parts. However, the following list of essentials and tips will help get you started:

1. Follow all OSHA safety and corporate safety requirements.
2. Pay attention to the die setting process information chart. This should list all equipment and tools needed to set the die.
3. Make sure the new die to be set is clean and has no burrs or nicks on the die shoes, on top or bottom.
4. Make note of the shut height and check to see if it has been revised since the last setting.
5. Set the press slide at top dead center.
6. Clean, stone, and oil the press bolster and slide to eliminate burrs.
7. When loading the dies into the press, make sure the right-to-left centerline of the press is in line with the right-to-left centerline of the die.
8. Position the die in the die space right to left so the die’s stations are balanced around the front-to-back centerline of the press. This typically requires a calculation. Note that it is not always good to position the die as close as possible to the feed; this placement might help the material press feed, but it can have a serious adverse effect on the press, die, and part quality. If not set correctly, the press slide will tip with each press stroke.
9. Adjust the press counterbalance pressure to suite the die size.
10. Set the press shut height. Be sure to establish a standard direction (up or down) of adjusting the adjusting nut and then stick to it. To check shut height, use die setting blocks (stop blocks) for the most accurate results.
11. Secure the upper die to the press slide. Secure the lower die to the bolster but leave the bolts loose (0.062-in. clearance on bolt heads).
12. Stroke the press several times to center the lower die with the upper die and press slide; then secure the lower die.
13. Set the press speed from the previous run or die setting chart. Note that changing the press speed during a production run will change the velocity of the upper die and press slide. Then you will have to revise the press shut height to maintain good parts and the die setting block (stop block) clearance. Remember, the press also has tolerances that will allow this variation. Die stop blocks should never tough; they can overload the press.
14. Set the stock guides in the die, press feed, and straightener to allow for maximum coil material camber. Note that if the guides are set too tight, they will not correct misalignment and will cause lost production and eventually a misfeed. The standard for coil slitting camber (to the right or left) is 0.25 in. per 10-ft. length when laid out flat on a surface.
15. Set all scrap removal.
16. Set feed progression and pilot protection.
17. Set all safety guarding.

Although this process is tedious, if you miss any one of these steps, you could increase your downtime and equipment maintenance and reduce your die life and part quality.

This is not a comprehensive list, and you can add items to suit your application. Experience over time will guide you on the points to note on your setting chart.