Die Science: Tooling and die training

Human Engineering

Human engineering is the single most important class a company can offer its employees. Having a tool roomful of die geniuses who don’t know how to communicate effectively is like having a Ferrari without gas. The potential is great, but you can’t realize it.

The success of an organization does not rely solely on it technical ability; it also relies on its working culture. It is important to train your employees to communicate effectively and to teach them what leadership really is. The principles of this course are learned behaviors, not instinctual.

Course outline:

A. Leadership principles

B. Conflict resolution

C. Listening

D. Effective communication

E. Team building

F. Basic human psychology

G. Creative thinking

H. Problem solving

Stamping Die and Press Fundamentals

We all have to start somewhere. Don’t assume that this basic information is unnecessary

Course outline:

A. Stamping die fundamentals

Line dies

1. Progressive dies
2. Transfer dies
3. Speciality dies

B. Cutting fundamentals

1. Blanking
2. Piercing/perforating
3. Lancing
4. Trimming
5. Notching

C. Forming fundamentals

1. Bending
2. Flanging
3. Coining
4. Ironing
5. Cold heading
6. Drawing
7. Solid forming/restriking
8. Embossing
9. Hemming
10. Curling

D. Die terminology

1. Cams
2. Dowels
3. Guide pin types
4. Buttons
5. Pierce punch types
6. Die shoes
7. Heels
8. Parallels

E. Press fundamentals

1. Press types
2. Counterbalance
3. Ram
4. Bolster
5. Cushion
6. Stroke
7. Tonnage

F. Basic precision instrument reading

1. Micrometers
2. Height gauges
3. Indicators

Sheet Material

Before you process, build, and try out a die, you need to understand the material you are dealing with to make a good, data-based decision. The objective is not to get side-tracked by the details of manufacturing the material, but rather to focus on how to select the material an dot understand how it behaves when it is cut and formed. Remember that you are the end user of the product, not the producer.

Course outline :

A. Ferrous and nonferrous metals

B. Yield strength

C. Stretch distribution

D. n value

E. r value

F. High-strength materials

G.Aluminium

H. Coil defects

Tool Steel Selection and Treatment

Make sure the diemakers indresadtand how to select the proper tool steel for the job. Make sure they also understand how to mill, drill, weld, and grind it properly.

A. Tool steel selectioN

B. Hardness measurement

C. Toughness

D. Wear resistance

E. Interface

F. Carbide

G. Welding

H. Grinding

I. Drilling

J. Milling

K. Stress relieving

L. Tempering

Safety

A small 250-ton press can exert 5000,000 pounds of pressure, and presses and equipment used in diemaking are completely unforgiving, so saftey is a very imprint issue.

Course outline:

A. Crane safety

B. Press safety

C.Basic first aid

D.HiLo reach and fork truck operation

Die setup

Many problems can be traced back to an improper die setup

Course outline: Shut height Press cleanness Pitch progression Press feeders and straightnessGas pressuresDie location and alignment Counterbalance Tonnage monitorsLubrication methods

Progressive Die Design

Most companies have or design progressive dies. A good die begins with a good process and design method.

Course outline:

A. Strip carrier designs

1. Solid
2. Stretch/flex

B. Strip starting and piloting

1. Pitch stops
2. First hit line
3. Smooth feeding techniques
4. Bar lifters/round lifters

C. Metal cutting

Cutting clearance selection

1. Wrap removal
2. Bypass burrs
3. Pinch trimming

D. Part flatness

1. Pressure blanking
2. Strippling

E. Flanging, bending, curling, and extruding

1. Stretch flanges/compression flanges
2. Holding bend tolerances
3. Hole flanging techniques

F. Pressure and stripper pads

G. Drawing in progressive dies

1. Draw ratios
2. Radii
3. Timing

H. Web carrier development techniques

Sheet Metal Forming Techniques

Forming problems are the most prevalent in stamping shops. Splitting in draws, inability to maintain or achieve been angles, and fracturing in stretch flanges and extrusions are common problems.

A. Bending

B. Stretch compression flanging

C. Embossing

D. Metal stretching

E. Drawing

1. Draw ratios
2. Calculations reductions
3. Radii selections
4. Friction and lubricants
5. Tool steel finishing/polishing
6. Pressure systems
7. Data-Based problem solving
8. Ironing
9. Draw beads
10. Metal gainers
11. Draw bars
12. Metal gainers
13. Draw bars
14. Surface problems
15. Binder development
16. Length of line analysis

Make it Your Own

These are just a few of the most commonly needed classes. You may find it necessary to add classes on statistical process control, math, heatreating, metallurgy, and other topics. Find out what training your company really needs, and don't be satisfied with a "canned" course from the local tech center that doesn't fit your requirements.

Don't forget that your own employees can be a great resource for leading the training. You might be surprised at the training talent in your own company.

Until next time... Best of luck!