Design of Die plate

Presented By
Shaikh Kamaloddin
CTR Ludhiana

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Defining a die plate

 Die plate is the element that receives the punch.

 The terms used in the work place may also be "the male die", "the female
die“.
 It is the female cutting member of the press tool(shearing operation).
 It determines the blank size.
 Shearing dies are usually made up of HCHCr(D2).

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Calculating Die thickness

 For shearing
Fsh= KL t Ssh tonns
1000
 K = 1.1 to 1.5 ( normal narrow clearance )
 L = length of cut in mm
 t = thickness of stock in mm
 Ssh = shear strength of the material kg/mm2

 ( Td ) = Fsh 1/3

 Td - Die thickness

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Clearance and its effects

• Clearance is the gap between punch and die and is indicated by

‘C’.
• Clearance determines the shape and quality of sheared edge. As
clearance increases the edges become rougher and deformation zone
becomes larger.
• Furthermore, metal is pulled into the clearance area, and the sheared
edges become more and more rounded.
• In fact if the clearance is too large the sheet metal is bent and
thus subjected to tensile stresses.
• Clearance depends on the sheet thickness, tensile strength of th
stock, & dimensional accuracy of the product.

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 It is expressed as %age of stock thickness per side

C=ct
• Recommended clearance (2C) in terms of percentage of stock thickness
for various types of edges

 Type 1 – Large dished radius , Large burr , Only for structural rough
work.
 Type 2 – large radius/die roll , Normal burr , Max. tool life , For
average sheet metal work.
 Type 3 – Normal Radius/die roll , Normal burr , For components to be
formed later.
 Type 4 – Less radius , Normal burr , Signs of secondary shear , for good
quality components to be shaved/reamed/polished and

also for close tolerance

 Type 5 – Negligible radius , Normal burr , Complete secondary shear ,
Recommended for accuracy of stampings the die life reduces
considerably.

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 Material types of edge

1 2 3 4 5

Steel (SAE 1020) 21% 12% 9% 6½% 2%

Steel (High carbon) 26 ½% 18% 14 ½% 12% 4 ½%

Stainless steel 22 ½% 12% 10 ½% 4% 2%

Cooper (1/2 hard) 25% 11% 8% 3 ½% 2%

Cooper (annealed) 26% 8½ 6% 3% 1%

%

Brass (1/2 hard) 21% 9% 6% 3% 1%

 

Phospher Bronze 26% 13% 11 ½% 4 ½% 3 ½%

Lead 22% 9% 7% 0% 2 ½%

Aluminium (hard) 20% 14 ½ 10% 6% 2 ½%

%

Aluminium(260) 17% 9% 7% 3% 1%

Megenesium 16% 6% 4% 2 ½% 1%

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• Dimensional accuracy and die life depend upon ‘C’ . Its value should be
according to the requirements.
• In cases where cutting clearance is narrow there might be considerable
amount of increment in shearing force.

thus shearing force will be given by

KL t Ssh/1000 tonns

K = 1.1 to 1.5 ( normal narrow clearance )

L = length of cut in mm
t = thickness of stock in mm
Ssh = shear strength of the material kg/mm2

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• Effects of Die clearance
• Lower clearance value might result in Secondary shearing.
• In this case, the total separation of the sheet is obtained for a lower value
of punch penetration. If the cracks generated by the punch and die (A and
B) do not coincide, the formation of secondary cracks exists.

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 Excessive clearance

 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.

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Die land.

• The inner walls of the die opening are

not usually made straight through.

• If they are straight, the blanks or

slugs tend to get jammed inside the
die opening. This may lead to the
breakage of punch or die.

• To avoid this, the die walls are kept

straight only to a certain dimension
from the cutting edge.
• The straight wall is called as land.

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Why Die land?

 To ensure regrinding and enhancement in the die life.

 Optimum die land has to be selected.
 2-2.5 times of the sheet thickness, is what recommended.
 In cases where cutting clearance is more, we can go for increased land
length.

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Angular clearance
• The die walls below the land are relieved
at an angle for the purpose of enabling blanks or
slugs to clear the die.
• Soft material require greater angular
clearance than hard materials.
• The normal value of angular clearance is
1-1.5 Degree per side.
• Dies for materials like silicon steel and
stainless steel are privided with angular
clearance from the cutting edge.(no land is privided).
These materials are abrasive in nature and tend to bell-mouth the die opening rapidly if
land is provided.

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Die relief

In some cases a larger diameter hole is made in order to provide

convenience for scrap removal.

• This is more effective than the angular clearance, when the sheet
thickness is more then 2mm.

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 Die layout
◦ Strip layout.
◦ Arrangement of fasteners and locating.
elements arrangement.
◦ Stoppers and locating pins.

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Strip layout of a progressive tool

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 A – Front scrap
B – Bridge thickness
(space between parts)
B1- space between strip edge.
C – the distance from a point on one part to the
corresponding point on the next part.
H – Part width
l - Length of part
W – Width of strip
Y – Scrap recovery at end
N – Number of blanks
t– thickness of strip
L – Length of strip

B= 1.25t, when C is less than 2inch

= 1.5t, when C is more than 2inch
B1=2 times the sheet thickness
C=l+B
W = H + 2B
A = t + 0.015H
Y =L – Nc +B
N = L – B /C

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 Strip layout is important to have economy of press
tool operation.
Scrap strip layout gives an idea on the
positioning of various punches, stops and pilots.
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It ensures the ideal location of blanks in the stock strip.
Several trial layouts have to be made to confirm the
maximum percentage of utilization of stock strip. The
goal should be to have at least 75% utilization.

The percentage of stock used to calculated by the

formula:

% of utilization = Area of one blank X 100 /(Lead X Width)

Where, Lead = Length of component + Bridge thickness(B)

Width= Breadth of component + 2 X Bridge thickness(B1)

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 Arrangement of Bolts
and dowels.

D Dd B F
M4 Ø4 8 40±15

M5 Ø4 10 50±15

M6 Ø5 12 60±20

M8 Ø6 14 80±20

M10 Ø8 16 100±20

M12 Ø10 20 120±30

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 Relationship between die plate and screw size.

D T
M4,M5 13-15
M5,M6 15-22
M6,M8 22-27
M8,M10 27-32
M10,M12 32-42
M12,M16 42-57

Where ‘T’ is the thickness of die plate.

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Stoppers and locating pins.

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Die plate with inserts:-

• Insert type die is a generic name given to die using an insert

type plate.
• Very often dies using this type of plates are called precision
dies, and from the point of view of accumulation of error, the
positioning accuracy is lower compared to integrated dies.
The reasons why they are considered precision in spite of this are
the following.

• It is possible to machine the inserted components with high

accuracy.
• It is possible to adjust the positioning accuracy by moving the
insert plate.
• In the case of insert type dies, when the tip of a die gets worn
out, only the insert is grinded. The level is adjusted by putting
a shim corresponding to the extent of grinding.

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 In the case of insert type dies, by using materials with high wear
resistance (cemented carbide, etc.) for the inserts, it is possible to extend
the life of the dies.

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