UniPunch System

What if you could make your parts faster? The UniPunch system is a simple way to put holes in parts faster, and the UniPunch design team is available to
help you get started. Years of experience allow us to quickly recommend the tooling best suited for each application.

System Capabilities
The UniPunch system is a fast way to punch and notch a wide variety of parts and materials. Whether you have an application for round or shaped holes, in
aluminum or stainless steel, send the UniPunch Sales Department your drawing and we will help you select the hole punch tools best suited for your application.

A series punching units are the workhorse of the UniPunch product line. Available A series holder widths are: 1, 1 , 1 , 2, 2 , 3
, 5 and 8. Holder width is important because it defines the minimum hole to hole distance. The A series is widely used in industry to
punch mild steel up to 1/4" thickness. Depending on your material thickness, punch diameters are available from .0937 (2.38mm) to 5.000
(127mm). This series can punch up to a 3 diameter hole in 1/4" mild steel and up to a 5 diameter hole in 10 ga. mild steel. (For thicker
punching applications, see the AH and AD series.)

UniPunch A series holders up to 2 wide feature

economical two-piece punches.
The punch heads and bodies are separate which lets you
quickly change hole size or shape by simply changing the
inexpensive punch body and the die. The unique slipon retainer pin holds the punch in place without any special
tools. You can use and reuse the punch heads indefinitely.
Low-cost die buttons complete the punch system and offer
close tolerances for accuracy and interchangeability.
In addition to a wide range of standard round and shaped
punches and dies, UniPunch provides punch and die pairs
in shapes custom made to your specifications. Like most
other series, the A series is available with holder throat
depths of 4, 8, 12 and 18, which means the center of
the hole can be that distance from the edge of the sheet.
UniPunch units are rugged holders that allow you to punch
burr-free holes with minimal maintenance.
Various mounting methods are available including
dedicated templates for fast changeover at the press.

Dedicated Setups of UniPunch tooling

Typical Work Done

Round Holes

Shaped Holes

Edge Notchng

Corner Notching

Electrical Knock Outs

Shearing

Blanking

Louvers

Thread Loop

Countersinking

Pierce & Form

Emboss

Pierce & Emboss

Lance & Form

Cluster Tooling

Heeled Punching

Part

Double Lance

Trim and

Common Shapes

custom shapes
Some of the custom shapes we manufacture are shown below. A code number is provided for easy referencing when ordering. A fully
dimensional sketch should accompany all orders or inquiries. For shapes not shown below, consult the UniPunch Quotation Department.

Blanking

Blanking is the process of cutting a desired

shape out of a flat piece of sheet metal.
UniPunch tooling is used in applications
where the punch slug is the blank.
Curiously, a well-made punched hole is 2
sizes: On the side where the punch enters,
the hole is the size of the punch, and on
the other side of the material, the hole is
the size of the die. If the size of the hole is
important, the punch is made to size, and
the die is oversize. In blanking, it is the
size of the blank that is important so the
die is made to size, and the punch is
undersize to provide the
appropriate punch and die clearance.
The punch is supplied without shear to
maintain flatness of the blank.

UniPunch provides custom turn-key systems for progressive blanking including the mounting
system and gauging. Typical applications include washers, shims, identification tags and
nameplates. Compared to a die set, UniPunch tooling is a lower cost alternative for blanking
small parts or blanking and punching in the same operation.

Cluster Tooling
Cluster tooling is commonly used when multiple holes need to be punched close together
in one hit of the press. UniPunch provides cluster tooling with both shaped and round
holes, designed to your specifications. Depending on hole pattern and material type and
thickness, cluster punches can be supplied with replaceable punch inserts. When placing
an order or requesting a quote, please send us a drawing showing the hole shape, size, &
locations.

Examples

Corner Radius

Corner radius is commonly used for rounding the corners of a square part. The punch is provided with a heel
to engage in the die prior to the punch cutting thru, to insure line up between punch & die. The heel could be used to
gauge the part (if desired). When placing an order, or requesting a quote please indicate the degree of radius along with
the material type and thickness that is being punch. Also indicate whether or not the heel is to be used for gauging the
material.

Examples

Countersinking

Countersinking is commonly used for holes that need to accept a flat head screw or fastener. We offer 3
different styles of countersinking which is shown below. When placing an order or requesting a quote, please specify the
required dimensions based on the diagrams shown on the right side of the picture for each style.

Examples

Style 1 Countersink

Style 2 Countersink

Style 3 Countersink

Emboss

Embossing is a raised or sunken indentation in sheet metal without cutting the

material. This is commonly used to form one part to fit around another. A series units
with adjustable feed opening are recommended for easy removal of formed part. When
placing an order or requesting a quote, please send a drawing indicating the angle, overall
height and material type and thickness as shown below.

Example:

extruded holes
UniPunch tooling can be used to simultaneously punch a hole and extrude the material
down. Applications include for self-tapping sheet metal screws or, in thicker material, to
permit tapping for machine screws. Die buttons with oversized internal diameters,
typically with a .020" radius instead of a cutting edge are used to permit the material to
flow downward. This technique can be used in any UniPunch unit to make relatively
shallow extrusions; to accommodate deeper extrusions with standard UniPunch tooling,
the Feed Clearance Unit ("FCU") may be required so the part can be removed after
forming. When placing an order or requesting a quote, please specify type and thickness
of material and screw size.

Examples

Electrical Knock Outs

Electrical knock outs are used to create tabs in electrical outlet casings so they can be
pushed out when the hole need to be used. When placing an order or requesting a quote,
please provide a drawing of the part.
Single Knock Outs

Standard units with modified punches and dies are used for forming single electrical knock outs. The dies
have built-in strippers to force the slug out of the die for easy removal from the unit. The maximum
material thickness is 1/16 mild steel. When ordering, please specify the following:
Actual hole diameter
Thickness of material
Number of tabs (one or two)

Table of Punch Sizes

For Standard Conduit
Conduit
Size (I.D.)

Punch Size
of Slip Hole

3/8

11/16

1/2

7/8

3/4

1-1/8

1-3/8

1-1/4

1-3/4

1-1/2

2-1/2

2-1/2

3-5/8

double tab - single knockout

Single tab - single knock out examples:

Double tab - double knock out examples:

Double Knock Outs

Double Knock Out Units are made according to customer specifications.
When ordering, please specify the following:
Actual hole diameter
Thickness of material
Number and location of tabs

Forming
UniPunch tooling is commonly used for forming holes in metal, such as countersunk holes
or louvers. Punch and form in one hit of the press to eliminate secondary operations. With UniPunch tooling you can
also punch formed holes in formed parts and aluminum extrusions. UniPunch application engineers will design tooling for
your specific part, utilizing standard holders.
Typical Products

Typical Applications

Enclosures

Air vent holes

Furniture

Holes in sheet metal for tapping

Storage Racks

Recessed holes for flat

Head Screws
Shelving

 Hinges

UniPunch designs a wide variety of lance & form

tooling. The size, shape and depth of the lance
are required for quotation.

Shown here is a pierce and form operation typically

for air venting applications.
Send us your drawing showing the required
width, height and depth of the louvers.

With UniPunch tooling, you can punch and

countersink your material in a single press
stroke. Send us the screw or fastener
dimensions for a tooling quotation.

Another ideal application for UniPunch tooling is

the pierced and extruded hole to prepare sheet
metal for tapping. To Request a Quote, provide
screw sizes and material type and thickness.

Embossing is a raised or sunken indentation in

sheet metal without cutting the material, one of
many forming operations that can be done with
UniPunch tooling.Provide us with a drawing for
a fast quotation.

heeled punches
Heeled punches are used for notching the edge of sheet metal for medium or low
production runs. The heel of the punch would engage in the die prior to the punch cutting
thru the material, to insure proper line up between punch & die.

examples

Keyholes

Keyholes are commonly used for shelving. When placing an order or requesting a
quote, please provide the dimensions as shown in the drawing below.
Dimensions required for orders and quotes....

Lance and Form

Lance and form is used to cut all but one side of the shape and to form the material downward. This
application is commonly used to hook adjustable shelving or to hang parts. When placing an order or requesting a quote,
please provide a drawing of the part.

Examples

Louvers
Louvers are commonly used to create vents. When placing an order or requesting a quote,
please send a drawing indicating the dimensions as shown in the photo below.

EXAMPLE:

Trim and part

Trim and part tooling is used to cut a flat strip of material into two pieces and round the end of each part at the same
time. Trim and part tooling is supplied with 2 heels to prevent side loading when punching. Dies can be

supplied with a gauging system to help guide the part thru the unit. In addition to cut-off applications,
UniPunch also provides tooling to trim, part and punch within the same c-frame unit. Trim and part
tooling is commonly used for cut-off applications where a rounded end of the part is required. Torequest
a quote for tooling designed to your specifications, please provide a drawing of the part.

Examples

TUBE COPING

TP-2N

Tube coping is the process of putting a notch in the end of a tube often in order for one piece of tubing to fit against another, as for
example for welding. UniPunch tooling is used for end coping and edge notching and is custom designed for your specific tube size and
shape. Tooling is available for tube and pipe slotting, vee notching, shearing, staking and trimming.
Send us a drawing of your notch configuration and UniPunch will provide engineering assistance and promptly quote tooling for your part.

In addition to pipe notching, other common applications include:

End Coping
Slotting
V-Notching
Edge Notching
Shearing
Staking
Trimming
Flattening

Tube End Coping with Custom Angular

Drain Hole
Tube Notching

Tube End Coping

Tube Edge Notching

Rectangle Tube
Rectangle Tube Tube Slotting Coping with
EndCoping
Thick Wall
Drain Hole

Tube Slotting Thin Wall

Tube V-Notch

TUBE PUNCHING WITH A MANDREL

Tube punching is the process of making a hole in a tube with a die supported by a mandrel. This photo illustrates a hole that is uniform with minimal
distortion. (Tube piercing is the process of making a hole with a punch but without a die or die support. The resulting hole is dimpled.)

For dimple-free holes in tube or pipe, UniPunch provides custom mandrel style hole punching units. Mandrel punching units are offered for
producing round or shaped holes in single or multiple hole configurations in round, square or rectangle tubing or pipe. Due to the
style variations, Shut Heights and Die Heights are determined by individual mandrel unit designs.
For a prompt quotation, please send UniPunch a detailed drawing or sketch including tube or pipe size, hole size and hole location.

Examples

Fabricated AE Mandrel Unit

HZ STYLE MANDREL SETUP

AJ MANDREL SETUP

Quick Die Change and Clamping System

The UniPunch quick die change and clamping system is used on a press for faster changeover of setups of UniPunch tooling. The
system provides clamping for dovetail style templates so there is no need for external hold down clamps.

Short changeover time at the press is the prerequisite enabling capability for running small
lots for the more frequent deliveries that customers are coming to expect. More and more
factories are seeing the value in using dedicated setups of UniPunch tooling so they can
change over quickly from part to part. Below is a short video of UniPunch dedicated setups
being changed at a customer location.
With the UniPunch quick die change and clamping system you mount your dedicated setups on the
dovetail style template. Then simply slide the template into the quick die change system, tighten the
integrated front mounted clamps and begin making parts.
Slide, Lock and Punch.

Custom width and length systems are also available.

Die Clearance
Why does die clearance matter?
Proper clearance between the punch and die is essential for piercing a well-made hole
efficiently.

Too much punch and die clearance results in more rollover deformation where the
punch enters the material and a large burr on the die side.

With proper clearance between the punch and die, there will be minimal rollover
deformation around the hole where the punch enters the material. As the punch cuts
through the material, it creates a region of vertical burnishing until the fracture line
created by the punch meets the fracture line defined by the size of the die at which time
the material breaks creating the hole. On the die side there will be a minimal burr.
With too little die clearance the fracture lines of the punch and die do not meet, thus
requiring a secondary shear of the material to make the hole, and this secondary shear is
at the expense of requiring more tonnage, and in severe cases within the hole it results in
a second region of vertical burnish that will grip the punch as it is being extracted, thus
requiring (1) more stripping force to extract the punch from the hole and (2) additional
wear on the punch. Indeed the extra tonnage needed to make the hole and the additional
stripping force required to extract the punch can result in premature punch failure in the
form of chipping or breaking of the punch.
You can estimate proper die clearance with a die clearance calculator. To optimize the die
clearance, inspect the slug and hole. To correct an unacceptable burr on the die side of the
hole requires tighter clearance. Looking at the side of the punch slug, the top 1/3 should be
sheared and burnished and equal to the size of the punch; the remaining material is typically
dull and torn and the size of the die. If there has been a secondary shear, there will be two
regions of burnishing on the side of the slug. If on the side of the punch slug, more than
about 1/3 of the side is sheared and burnished, or if there are two regions where the slug is
sheared and burnished, die clearance is too tight. Die clearance can be made larger to
reduce tonnage and improve tool life.

How to Estimate Die Clearance Required

for Punching Mild Steel
Formula: MATERIAL THICKNESS X .2
Example: .250 x .2 = .050

How to Estimate Die Clearance Required for Punching

Stainless Steel
Formula: MATERIAL THICKNESS X .25
Example: .060 x .25 = .015
How to Estimate Die Clearance Required for Punching
Aluminum
Formula: MATERIAL THICKNESS X .15
Example: .250 x .15 = .0375

How to Obtain Tonnage Required for Punching Round Holes

Formula: TONNAGE IN MILD STEEL = 3.1416 X DIAMETER
OF HOLE X MATERIAL THICKNESS X 25
Example: 3.1416 X 2.000 X .250 X 25 = 39.26 TONS

Material Specification
Specifications for common materials and recommended die clearance.

STEEL
Hardness
Description

Shear
Strength
PSI

Shear
Strength
N/MM2

Material
Multiplier

Recommende
d
Die Clearance
In % Of
Thickness

Low Carbon HR
Steel

Rb 70

50,000

345

1.00

20%

Low Carbon C.R.

Sheet

Rb

40,000

276

.80

25%

ASTM A-36

BHN 119-159

58-80,000

1.20

20-25%

45-50 Carbon HR
Sheet

BHN 200

80,000

552

1.60

25%

Spring Steel 1074,

1095 Hardened to
Spring Temper

Rc 45-50

200,000

1,380

4.0

30%

COR-TEN Steel

BHN 120

55,000

379

1.1

20%

ALUMINUM BASE ALLOY(S) AND TEMPERS(S)

Description

Hardnes
s

Shear
Strength
PSI

Shear
Strength
N/MM2

Material
Multiplier

Recommended
Die Clearance
In % Of

Thickness
1100-0

BHN 23

9,000

62

.18

15%

1100-H14

BHN 32

11,000

76

.22

18%

2024-0

BHN 47

18,000

124

.36

18%

2024-T3

BHN 120

41,000

283

.82

20%

3003-0

BHN 28

11,000

76

.76

15%

3003-H14,
H16

BHN 40-47

15,000

103

.30

18%

3105-H25

BHN 47

16,000

110

.32

18%

5005-H34

BHN 41

14,000

97

.28

18%

5052-0

BHN 47

18,000

124

.36

18%

5052-H32

BHN 60

20,000

138

.40

20%

6061-0

BHN 30

12,000

83

.24

15%

6061-T6

BHN 95

30,000

207

.60

20%

7075-0

BHN 60

22,000

152

.44

20%

7075-T6

BHN 150

48,000

331

.96

20%

COPPER BASE ALLOYS & TEMPERS

Description

Hardnes
s

Shear
Strength
PSI

Shear
Strength
N/MM2

Material
Multiplier

Recommended
Die Clearance
In % Of
Thickness

-.050 mm GS

Rb 40

22,000

152

.44

15%

- 1/2 Hard

Rb 40

26,000

179

.52

20%

- Hard

Rb 50

28,000

193

.56

25%

Rb 55

35,000

241

.70

15%

110 Electrolitic
Copper

220 Comm Bronze

90%
- 1/2 Hard
230 Red Brass
85%

- 1/4 Hard

Rb 55

35,000

241

.70

15%

- .035 nn Gs

Rb 68

34,000

234

.68

15%

- 1/2 Hard

Rb 70

40,000

276

.80

18%

- Spring

Rb 91

48,000

331

.96

20%

342 A High Lead 1/2 Hard

Rb 70

40,000

276

.80

18%

675 Manganese
Bronze

Rb 65

42,000

290

.84

18%

Description

Hardnes
s

Shear
Strength
PSI

Shear
Strength
N/MM2

Material
Multiplier

Recommended
Die Clearance
In % Of
Thickness

202 Annealed

Rb 95

90,000

620

1.8 Thickness
(.024 - .048")

15%

302, 303, 304

Annealed

Rb 85

75,000

517

1.5 Thickness
(0.5-1.5mm)

15%

310 Annealed

Rb 90

90,000

620

1.8 Thickness
(.060 - .120")

20%

316, 321, 430

Annealed

Rb 90

75,000

517

1.5 Thickness
(1.5 - 3.0mm)

20%

410 Annealed

Rb 85

75,000

517

1.5 Thickness
(over .
120"(3.0mm)

30%

Hardnes
s

Shear
Strength
PSI

Shear
Strength
N/MM2

Material
Multiplier

Recommended
Die Clearance
In % Of
Thickness

345

1.20

25%

260 Cartridge
Brass

STAINLESS STEEL

Other
Description

Titanium -

Rb 23-29

50,000

Unalloyed

How to Obtain Tonnage Required for Punching Shaped Holes

Formula: TONNAGE IN MILD STEEL = PERIMETER X MATERIAL THICKNESS X 25
Example: (2 + 2 + 2 + 2) X .250 X 25 = 50 TONS

How To Reduce Tonnage

There are a variety of ways to reduce the required press tonnage.
Use Tonnage Compensator Caps Stagger the punch length so that the punches pierce
the material at different intervals
Add Punch Shear A shear angle ground onto the punch tip reduces the load or
tonnage unlike flat faced punches
Use correct die clearance This results in a balance of punching force, good hole
quality and increased tool life
Sharpen punches & dies often
Tonnage Compensator Caps
Are your punching capabilities limited by the tonnage
of your press or press brake? UniPunch has a solution.
Compensator caps stagger the punch length so that the
punches pierce the material at different intervals, reducing
the required punching tonnage. They are fastened to the
punch heads of A and AJ series units to reduce the total
punching load required for multiple holes.

UniPunch Unit

Compensator Cap
Part Number

A-1, A-1 1/4,

AJ-1, AJ-1 1/4

1040

A-1 1/2,
AJ-1 1/2

1041

A-2,
AJ-2

1042

For more information on tonnage, click here.

Punch Shear
Chisel shear on punches can considerably reduce required press tonnage. UniPunch offers
Chisel Shear, 4-Way Shear and Concave Shear.

Chisel Shear
Concave Shear

4-Way Shear

The chart below shows tonnage reduction factors for the shear depths listed. Multiply shear
factor times actual tonnage to obtain reduced tonnage per hole.

Tooling Maintenance

To optimize the performance of the UniPunch Tooling System, we recommend the

following tool maintenance procedures:

Sharpen punches and dies frequently.

Lubricate internal components during normal tool maintenance and at intervals

during punching operations.
Replace worn components such as springs and retainers as required.
Follow tool guidelines and operating instructions as shown in the UniPunch parts
book.

Lubrication

Slide 1: Disassemble unit. Clean and inspect internal components.

Slide 2: Externally lubricate outside diameter of guide body. Type GN metal assembly paste or die grease is recommended.

Slide 3: Reassembly of UniPunch unit. Place conical lifter spring over outside of guide body.

Slide 4: Re-assemble guide body with lifter spring into holder guide bore.

Slide 5: Align guide flat with retainer flat in holder.

Slide 6: Secure retainer and guide with fastener.

Slide 7: Insert punch body into stripping spring.

Slide 8: Externally lubricate punch body with GN metal assembly paste.

Slide 9: Align punch flat with retainer pin hole in guide. Insert punch retainer pin.

Slide 10: Tighten die fastener with hex key wrench.

Slide 11: Check pilot pin die adapter fastener securing it to holder.

Slide 12: Wipe all debris from bottom of unit machine surface before mounting.

Compile By Amjad Pervaz