5 Steps to a Successful Punch and Die Manufacturer
There is no elevator or escalator to success, the only way is a step by step progression in the right direction. Any punch and die manufacturer understands and acknowledges this fact. Because doing each different step proficiently will not only put the punch and die manufacturer in the right direction to productivity and profitability, but it also helps them to stay on that path successfully. Just as a flywheel provides continuous energy even when energy is discontinuous, following these steps will ensure the forward momentum toward success for the punch and die manufacturer. Therefore, analyzing the tooling and examining the slugs that result will help you to continuously progress toward success.
1. Right tooling design
Punch, stripper, die and the tool holder are the four important components of tooling design.
Punch: The punching process puts the punch through tensile and comprehensive forces which scrapes the flanks of the punch. For successful punching, a punch and die manufacturer uses high-quality steel with metallurgical properties. And he perhaps chooses to use the back paper which reduces pressure on the flank of the punch.
Stripper: This holds the work-piece in place against the die and holds the punch tip right on spot.
Die: A precision fit for the punch and die is the key for effective punching. Concentric and angular punch and die alignment ensure that the punch enters the die without scraping the sides of the die.
Tool holder: Reliability, repeatability, and accuracy are important aspects of various tool holder systems.
2. Scratch free punching process
If the end product is not scratch free then there is some problem with the process. Punch and die manufacturers uses brush tables that provide soft support to the sheet and this prevents scratches. Additionally, they could use a specially coated stripper to prevent imprints and scratches on the sheets. They could use different methods to handle the material gently, such as conveyor belts which make the product landing smooth.
3. Optimize die clearance
Once you understand the punching process, optimizing die clearance becomes easier. Too large a clearance results in large burrs and bad quality at the same time, too tight results in poor quality, damage to the tool and leads to frequent replacement of the tool component. When the punch and die manufacturer ensure that the die clearance is optimized, then they are ensuring that the shear cracks join. In other words, it balances the punch force. This optimizes the quality of the part and improves tool life.
4. Implementation of skeleton free process
A punch and die manufacturer can increase sheet utilization by implementing skeleton free process. This not only reduces the material cost but also ensures that the smaller scrap material is generated. This operator-friendly skeleton free process ensures increased safety. It also saves operational time and energy. By implementing this process they can enhance their production and boost their returns leading to success as a punch and die manufacturer.
5.Proper tool maintenance
Consistency is the key to proper maintenance. It includes lubrication of parts, sharpening using the grinding equipment designed for the job, and consistent maintenance of punch press. The punch and die manufacturer could ensure that the tools are easy to disassemble adjust and grind because it encourages the employees to perform maintenance regularly.
The punch and Die manufacturer should ensure that the punch does not chip or crack. It is important to use the finest shock-resistant tool steels, machine them to the exact tolerance and harden and temper them under metallurgical procedures. Each of the steps above will help ensure a punch and die manufacturer’s success.
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