By Art Hedrick
November 21, 2002
Over time negative tonnage can cause significant press and die damage. Understanding the factors
that influence the amount of negative tonnage can help you control it.
Negative tonnage, often referred to as reverse or snap-through tonnage, is the undesirable result of
cutting operations. Basically, when a punch breaks through the metal during a cutting or piercing
operation, a negative force results that pulls down both the cutting punch and the top portion of the press
assembly.
Here is a good analogy to describe negative tonnage, one that I use when teaching seminars. Imagine
trying to push a Magic Marker® through the surface of a tautly held piece of paper. Now imagine trying to
stop the marker's penetration so that it does not travel beyond flush with the bottom surface of the paper.
It's nearly impossible, right? That's because for whatever positive force it took to make the marker
penetrate the paper, there is an equal and opposite force needed to stop it from going too far. This
opposite force is called negative, reverse, or snap-through tonnage.
Over time severe negative tonnage most likely will result in severe press and die damage. This article
discusses the factors how to control reverse tonnage by examining ways to reduce it, utilize it, or adsorb
it.
Several factors influence the amount of reverse tonnage generated:
1. Type, hardness, and thickness of the metal being cut
2. Selected cutting clearance
3. Sharpness of the cutting punch and die
4. Amount of cutting shear
5. Ram velocity of the press
Cutting Clearance
Tighter clearances require a higher force to fracture the metal. When the amount of clearance between
the cutting punch and the die is small, the metal must be sheared a greater amount of its thickness before
fracture begins.
Figure 1
Special operations, such as fineblanking and Grip Flow®, require high cutting tonnages to retain a fully
sheared edge. Figure 1shows parts made using a specialized Grip Flow® process. Although this special
process requires a great deal of tonnage, the reverse tonnage produced is not as great proportionally
because the process uses slower speeds than conventional blanking or piercing. Always try to use the
optimum cutting clearance for your particular cutting operation. Shoot for the old rule of thumb: One-third
shear, two-thirds break.
Figure 2
The amount of shear is usually calculated with respect to the metal's thickness as well as the length of
cutting perimeter. Avoid putting shear angles on small-diameter pierce punches such as quill-style
punches. Having a sufficient amount of cutting shear is undoubtedly the most influential factor controlling
reverse tonnage. Whenever possible, avoid cutting and blanking parts using dies without shear.
"Having a sufficient amount of cutting shear is undoubtedly the most influential factor controlling reverse
tonnage. Whenever possible, avoid cutting and blanking parts using dies without shear."
Ram Velocity
As the strokes per minute increase, so does the press ram velocity. As the velocity increases, so does the
force needed to stop the ram at the bottom and return it to the top of the stroke. The faster you run a
press, the higher the reverse tonnage. Because most stampers want to maximize output, slowing the
press down usually is not an option for reducing reverse tonnage.
Figure 4
Figure 4shows punch staggering. With punch staggering you reduce the punch contact area, as well as
adsorb the reverse tonnage of one cutting punch that you can use to create an additional hole. In a
sense, a free hole!
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Adding nitrogen cylinders and neoprene blocks to the die or press also will help adsorb negative tonnage.
However, be careful not to load the press with more tonnage than it has available at any point during the
stroke.
The causes of negative tonnage are numerous. Identifying the cause is the first step to resolving your
problem. First, do everything possible to reduce the needed tonnage, and if necessary, find a means of
utilizing or adsorbing it.