Press Tool Design (Combination Dies) MODULE TITLE Nominal Duration Module Code or Number Module Purpose PRESS

TOOL DESIGN (COMBINATION DIES) Two Modules EB518 The purpose of this module is for the participant to design combination dies suitable for use in single, double and triple action presses. This module will be modified in line with the requirements of the National metals and Engineering Standards when they become available. The module contains the knowledge and skills identified and agreed by all states/territories. It has been developed on the assumption that these will be reflected in the standards. Prerequisites Summary of Content (EB517) Press Tool Design (Simple Bending Operations) 1. Compound and Combination Dies. - Principles - single station operation - common centre line design - basic compound die operations - blanking - piercing - notching - basic combination die operations - blanking - piercing - bending - forming - drawing - Common design features Design characteristics - inverted - conventional

Relationship to Competency Standards

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) Ejection and knockout systems - shedding - shedder - stripping - stripper - ejection - ejector - knockout cap - shaft - spreader - transfer pins Cutting action of dies - opposite directions - same direction Burr side effect - blank and slug - pierced opening - single burr side Cutting clearances - toolmaking facility - reduction of cutting force - attrition Die openings and angular clearance - differential cutting clearance - size related to die life Component characteristics - flatness - dimensional accuracy - burr sides Utility considerations - die cushions - large components - use of solid die bolster plates Shedding, stripping and pressure pads Compressive arrangements - knockout proportions - shedder proportions - spring selection - transfer methods - spring location and confinement

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) Percussive arrangements - knockout proportions - shedder proportions Knockout-to-press relationships - adjustments - servicing - operator and die safety Shedding pins and shedding vents - riddance action - pin arrangements - location - pressurised air vents Pressure pad arrangements - blank holding function - pad proportions - transfer methods Strippers, stops and stock guides - material clamping function - spring location and confinement - stripper bolts - stop location - stop arrangements for spring strippers

Die blocks and punches - Design arrangements - inverted - conventional - Construction methods - one piece die constructions - composite die constructions - punch plates - blanking punch - piercing punches - forming punch - Location, alignment and retention methods - die and punch inset mounting - dowelling - threaded fasteners

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies)

Tool construction materials and service conditions - Die part material selection - Service condition - treatment - hardness value

Die categories - Operation and application - Compound die types - blank and pierce - blank, pierce and notch - trim and pierce - shave and pierce - broaching

2.

- Combination die types - blank and draw - blank, draw and trim - draw, form and pierce - redraw and pinch trim - rectangular blank and draw - shell making - louvering - clip forming - blank, pierce and bend - blank, pierce and coin - blank, form and pierce - cutoff, form and pierce - blank, form, draw, trim and pierce - blank, pierce and emboss Design and draw combination press tools of inverted design for blank, pierce and deforming operations. - Design principles and conventions Effective design concepts Selection of press Calculation of blanking forces Estimation of forming forces or spring back allowances Report and calculation of work design cost and quotation estimates for tool construction Selection of die set.

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) 3. Design and draw combination press tools for blanking and drawing operations. Delivery Design principles and conventions Effective design concepts Selection of press Estimation of blank diameter, punch and die diameters Report and calculation of work design cost and quotation estimates for tool construction Selection of die set.

Participants should be encouraged to adopt a project management approach towards achieving a tooling design solution for the product specification assignment. To achieve this, the product specification should be presented as a project where participants must undertake research and develop a tooling design solution. Participants may work individually or in teams where they will be required to use their background knowledge of the metal Stamping Industry to recommend the use of appropriate tool materials and the type of equipment to produce the product in a manufacturing environment. The key focus of the project is for the participant to be able to achieve a workable tool design solution for a given product specification. In completing the project, participants should also estimate the costs of design and put in quotation estimates to build the die. In addition the participant must undertake the necessary research, do all necessary calculations, identify design solutions and compete any assembly and detail drawing requirements. The design detail may be undertaken using manual drafting techniques and or a computer aided design drafting facility.

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) Suggested on-job training for maximum skill acquisition. Work as a draftsperson/tool design assistant in a tool design office. These strategies may also involve: - co-operative registered off-job provider/employer delivery sharing available resources; - delivery by an employer who is registered as an off-job provider, with in-house qualified trainers using unique resources to facilitate on and off-job deliver; - off-the-job objectives must focus on the industry context while on-the-job objectives will reflect application within Enterprise operations. Assessment instruments will need to be developed by the module provider which will need to reflect consistency with stated module learning outcomes and related assessment criteria. Alternative assessment procedures will need to be considered and applied as appropriate to participants needs. This module is practical in nature and theoretically integrated to complement the acquisition of practical design and drawing skills which have relevance to industrial applications. Instruction and training should support and consolidate the safety requirements associated with the handling of components and working within a process manufacturing environment. The quality of the tool design solution will conform acceptable industry standards.

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) Learning Outcomes Learning Outcome 1 On completion of this module the learner will be able to: Observe and investigate the principles of compound and combination dies and describe the essential elements in order to prepare and develop tool designs for specific tasks in cutting and deforming operations. Given practical demonstration, sample components, sample component drawings, sample dies or die parts and sample die drawings. 1.1 Identify and define the principles of die operation. 1. Single station die. 2. Designs produced around a common centre line. 3. Distinction between compound and combination dies. 1.2 List and describe the common design features of compound and combination dies. 1. 2. 3. 4. 5. 6. 7. 8. Design characteristics. Ejection and knockout systems. Die cutting and forming actions. Component burr side relationships Cutting clearances and return ejection. Die openings and angular clearances. Component characteristics. Utility considerations.

Assessment criteria

1.3 Explain the principles and define the essential design features of component shedding and stripping in single action dies and pressure pads in combination dies for specific tasks. 1. Compressive and percussive knockout and shedder arrangements. 2. Knockout-to-press relationships. 3. Shedding pins and shedding vents. 4. Pressure pad arrangements for combination draw dies. 5. Strippers, stops and stock guides.

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) 1.4 Analyse die designs and describe the fundamental methods of die block and punch constructions used for cutting and deforming operations. 1. Design arrangements. 2. Construction methods. 3. Location, alignment and retention methods. 1.5 Select tool construction materials and service conditions. 1.6 Identify, list and categorise examples of dies by application to specific tasks. Conditions Access to a suitable study environment. Sample components. Sample dies or die parts. Sample die drawings. Reference sheets and handout sheets for each participant. Access to operational dies or simulation devices. Short answer questions. Design and draw combination press tools of inverted design incorporating blank, pierce and deforming operations. Given sample component parts or sample component drawings, produce an appropriate combination die tool design solution for a specified product and include: 1. 2. 3. 4. Assembly drawing of the tool design solution. Conventional views. Materials and parts list. Selection of a suitable proprietary die set or die set components. 5. Fully dimensioned and toleranced detail drawings incorporating all essential die elements. 6. Calculations, written report on work design costs and quotation estimates to produce the press tool.

Assessment method Learning Outcome 2

Assessment criteria

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) Conditions Access to a suitable study environment and drawing equipment. Australian standards AS1100 and AS1634. Proprietary catalogues of die sets, presses and ancillary equipment and press tool components. Reference material and handout sheets for each participant as required. Sample dies or die parts. Sample die design drawing illustrating sound design features. Practical design and drawing exercise. Design and draw combination press tools incorporating blanking and drawing operations. Given sample component parts or sample component drawings, produce an appropriate combination die tool design solution for a specified product and include: 1. 2. 3. 4. Assembly drawing of the tool design solution. Conventional views. Materials and parts list. Selection of a suitable proprietary die set or die set components. 5. Fully dimensioned and tolerance detail drawings incorporating all essential die elements. 6. Calculations, written report on work design costs and quotation estimates to produce the press tool. Conditions Access to a suitable study environment and drawing equipment. Australian standards AS1100 and AS1654. Proprietary catalogues of die sets, presses and ancillary equipment and press tool components. Reference material and handout sheets for each participant as required. Sample dies or die parts. Sample die design drawings illustrating sound design features. Practical design and drawing exercises.

Assessment method Learning Outcome 3

Assessment criteria

Assessment method

Actrac Products Ltd/ Australian National Training Authority 1997

Press Tool Design (Combination Dies) Suggested Learning Resources

Suitable study environment. Drafting boards (A1 or larger) on stands. Drafting machine to suit boards. Access to computer aided design drafting equipment (if available). Examples of different types of bending dies. Sample die design drawings and components for combination dies. Manufacturers catalogues or die parts, presses and ancillary equipment. Australian standards. Participant handout sheets. Worksheets.

All references should be of the latest edition. - Australian standards. 1. AS1100 Part 101-1984 Australian Engineering Drawing Handbook 2. AS1100 Part 201-1984 Australian Engineering Drawing Handbook 3. AS1654-1987 Limits and Fits for Engineering - OSTERGAARD D.E. Basic Diemaking McGraw Hill Book Co. U.S.A. 1974 - ASTME Die Design Handbook McGraw Hill U.S.A. 1975 - FLINN/TROJAN Engineering Materials and their Application 2nd Ed. Houghton/Mifflin U.S.A. 1981 - ASM Metals Handbook-Forming ASM Handbook Committee U.S.A. 1981 - DONALDSON/Le CAIN/GOOLD Tool Design McGraw Hill U.S.A. 1973 - POLLACK H.W. Tool Design Prentice Hall U.S.A. 1976 - OBERG/JONES/HORTON Machinerys Handbook 22nd Ed Industrial Press Inc. U.S.A. 1983

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Actrac Products Ltd/ Australian National Training Authority 1997