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1 This PDF document is a sample chapter from the book Item Code BK90PUB4 click here to order on line or complete and print out the order form ocument. Then mail, fax, or phone in your order. Society of Manufacturing Engineers Copyright 1990

2 SECTION 2 STAMPINGS DESIGN No stamping-design work can be considered optimum until, in the judgment of the pressworking department or custom stamper, it holds out the strong probability of achieving the following: I. A die. or set of dies, that combines maximum production and least maintenance with lowest feasible life cost. 2. Maximum utilization of the least expensive stamping material that will serve satisfactorily. 3. Most efficient pressworking practices. 4. A stamped product that consistently meets sales and service requirements of shape, dimensions, strength, finish, style, and utility. Design alteration. except to meet changed product or press requirements, or to utilize existing dies with reasonable modifications, is to be avoided as being expensive and time-wasting. Therefore, even preliminary die sketches should be examined in the light of the following data. GENERAL DESIGN PROCEDURE The design planning of a new stamped part or assembly should take into account the following steps: 1. Determine exactly what the product is to accomplish in its application. 2. Convert or reduce any vague or generalized specifications to specific descriptions of materials, mechanical units, and dimensions. 3. See that all dimensions have the broadest permissible tolerances, and that initial allowances are made for overtravel, temperature and pressure variations, and other physical factors encountered in product service. 4. Set overall size limits with references to mounting upon or attachment to a machine. a control, or other cooperating parts. These limits may indicate the need of slotted holes, spacers, or similar devices. 5. Are weight limits imposed by the conditions of service? If so, consider reduction of the weight by such means as punching out unneeded material, or by resorting to lighter or thinner-gage material strengthened by stiffening ribs or bosses. 6. Check all critical points, such as bearing points, where high mechanical stresses or excessive wear may occur. Are parts as designed able to resist deformation during ejection from dies, tote-box handling, tumbling, or heat treatment? 7. If very high and fast stamping production is in view, see to what extent the physical proportions, the appearance, or the finish can be altered or compromised to achieve such production. 8. Find out whether there are any unavoidable limitations in available press equipment, fabrication and assembly facilities, or other production factors! and alter stampings design as far as possible to meet the limitations.

3 REDESIGN OF EXISTING PRODUCTS When a stamped part or assembly has been in production for some time. it may become feasible or necessary to redesign the product. because of market demands of appearance, functioning, or cost factors. It is especially desirable to consider product redesign if the worn press tools or stamping operations have proven unsatisfactory. The followin, 0 are good examples of integrated product and die redesign. Television-tube Electron Gun. The redesign of four electron-gun components shown in Fig. 2-1 resulted in 60% to 75% reduction in manufacturing costs. Top views show original parts design; lower views show them redesigned. 1 -Four pieces, welded 2-Seamless 3-Tubing and 4-Tubing and tubing, stamping, stamping, cut welded welded 1 -One-piece 2-Flat strip formed 3-Drawn in 4-Drawn in stamping, with lock seam, one operation, one operation, 48% saving 53% saving 55% saving 55% saving - Fig Components of television-tube electron gun: (A) original design; (B) redesign. (Joliti Vdkert Metal Starnpings, Iric.) The anode (No. 2) was previously made from stainless-steel tubing cut to shape; in redesign it is formed from flat coil stock and lock-seamed in a Multislide machine. The grids (Nos. 3 and 4) were also made from tubing. to which separately blanked and formed lens caps were welded; in redesign they are drawn in one piece from flat stock. The flange spacer or spider (No. 1) was originally fabricated from four pieces welded together; in redesign it is now stamped at the rate of 75 per minute in a six-station progressive die (Fig. 2-2) from automatically fed coil stock. The spacer was improved in redesign by doubling the number of arms. The steps used in producing the flange spacer from stainless-steel strip are (I) pretrimming to permit flow of material in subsequent operations: (2) cupping for the center hub; (3) finish drawing the center hub: (4) finish trimming the six arms and piercing for the center hole; (5) finish sizing and squaring at the hub; (6) cutoff and finish forming. Elimination of welding on the grids and flange spacer avoided possible loss of accuracy. Perforated Bulkhead. The original design of a bulkhead (Fig. 2-3A) used conventional geometric layout of holes to provide air flow. Holes had to be kept small in size to minimize distortion is subsequent forming as shown in view C. In this design, the

4 ---- Trim loose 3rd 2nd 2nd 1st & finish form draw pre-trim draw draw 1 st pre-trim Fig Six-station progressive die strip development for producing electron-gun flange spacer from 114 hard fine-grain stainless-steel strip (0.010 X in X mm). (John Volkert Metal Stampings. Itlc.) shearing load of the many small perforating punches was heavy. and the limited capacity of available presses required the perforating and the circumferential blanking to be done in separate operations. When the die had to be rebuilt. the number of holes was reduced to approximately one-half and made larger to provide equivalent flow area (Fig. 2-3B). and the hole layout was so arranged as to avoid the ribs and highly stressed areas involved in subsequent drawing. Fig Redesign of perforated bulkhead: (A) old design (B) new debign: (C) subsequent forming. ' The larger hole size reduced the total perimeter of holes by 33%. The reduced shear load enabled piercing and blanking to be combined in a single two-station die, with the piercing and blanking punches so stepped that the cutting loads at the two stations were not in full action at the same instant. In the new design. die life was increased 400%. Die cost was reduced approximately 50%. Where it is known that the production of a stamped part or assembly will be limited, it is highly advisable to consider the possible redesign of the part. so as to achieve minimum tool cost. In Fig part A (of unimportant overall detail) is a hinged key. The hinge is of conventional curved design, and the hinge would require two or more operations. In redesigned part B, the only significant change was to move the hinge pin-hole as far as possible from the bent section at u. Part B was produced in two operations at about half the tooling cost for part A. Also shown in Fig. 2-4 is part C, a simple clevis in five design variations. Part C, is acasting, heavy and rather high in machining cost. C, is milled from bar stock and welded to a stamping; design is better, but the drilling and welding operations increase the cost.

5 Part C Fig Examples of piece part redesign.' C, is a good design of two symmetrical stampings welded together. C, is a one-piece stamping involving simple operations and assuring uniform hole alignment. C, is probably the ultimate in simplicity of design and economy in tooling and production. DESIGN FOR EFFICIENT STOCK UTILIZATION Use of Standard Mill Stock. The size, shape, appearance, and intended use of a stamped product will generally dictate the stampings-materials specifications. However, applied knowledge of the grades, qualities, gages, sizes, physical forms, and finishes available in standard mill stamping stock will frequently assist in securing the best die design and stamping efficiency. Maximum Volume for Given Area of Material. The calcular principle of maxima and minima can be used to determine the least amount of sheet metal required to form an open-top square-bottomed box of given volumetric capacity. For the box shown in Fig formed from a blank of width a and length a, the volume would be (x)(a - 21-)', and

6 would be a maximum when The four corners of s2 area each, whether cut out or folded in, would be minimum waste under such conditions. I Fig Relnt~on of flat blank to formed box of maximum volumetric capacity. By the same principles. the minimum amount of metal in a plain cylindrical can of given volumetric capacity, closed at one end, and making allowance for waste in blanking the circular end. but none for crimping the end to the shell. is determined by the formula Diam. Height H = - 2 Utilizing Grain Structure. In designing parts to have formed sections, such as lugs or ears. plan if at all possible to form such sections at right angles to the direction of grain in the metal (Fig. 2-6C); otherwise they may crack in forming. Generally, it is preferred practice to design formed sections parallel to each other, as at A and C, or at an angle to each other not exceeding 45'. Where sections must be formed at right angles to one another, blanking them d&onally in the strip, as in view B, will provide somecontinuous grain running through such sections. Where the face of a right-angled lug or ear must receive a large thrust load, the part should be so designed that the thrust will he in the direction that induces shear (lug tends to bend in same direction as formed. upper lug, Fig. 2-6C). rather than in the direction that would bend the lug back into the original flat (lower lug, Fig. 2-6C), with danger of cracking. The shear strength of a formed lug is greatest along its narrow edge (view A). Product Design for Minimt~m Scrap. Stock layout is one of the most important phases of die engineering. and one of the first steps to be taken. However, cases frequently occur where a slight to moderate change in product design, while in no way impeding the functioning of the part. will save appreciable materials and tooling expense. The simple hook-ended flat blank in Fig. 2-7A in conventional layout utilized only 62% of the strip; no other nesting was more efficient. Consultation between the product designer and die designers revealed that the only mandatory dimensions in the piece were A, B, and C. When the piece was redesigned. a new strip layout was possible which

7 Lugs at angle no greater Lug perpendicular to grain; recommended Lugs parallel to grain; may crack in forming; not recommended Greatest shear strength C- Grain of metal - Fig Shear strength of lugs with reference to grain direction: heavy arrows indicate direction of applied force. utilized nearly 100% of the material. In the case of the part shown in Fig. 2-7B. a 14% material saving was made just in changing strip layout from single in-line to an alternating double-row arrangement. Further investigation showed that about one-third of each piece could be cut from the piece ahead without changing the utility of the part, and resulting in a 32% saving in material, compared with the original layout. It is good practice to examine the product design for any corners or flanges projecting New Original Blank layout-original Original vs. Blank layout-new stamping design. Stock utilization only 62% new design stamping design. Stock utilization (A) nearly 100% L Wasteful layout-4 BIC square inches per blar lk f BIC 4 Best layout; enabled by slight redesign -only 23/4 square inches per blank Better layout-3%a square inches per blank L Fig Stock layout for minimum scrap.' (B) 2-6

8 Stock saving size Fig Unnecessary corners cut off to permit use of narrower >trip stock.' at the top, bottom, or sides which can be cut off without detriment to strength or necessary welding surface. This practice. as shown in Fig. 2-8, permitted a considerably narrower strip to be used. Study of some product designs may show that the part can be made in two pieces to reduce scrap. Aside from the width and length savings in materials, referred to above, savings through use of a thinner stock can commonly be realized through judicious use of beads, ribs, embosses. and flanges. DESIGN TO INCREASE STRENGTH OF STAMPINGS Beads, ribs. and flanges may often be used to impart rigidity to stampings which might otherwise be too flexible and weak. Their judicious use may reduce required material thickness by as much as one-half. Beads and Ribs. The ribs specified in Fig. 2-9' and Table 2-1 have been so designed that the angle of the sides will normally allow their use not only on flat surfaces but also on curved and angular surfaces without producing back draft. In a right-angle bent sheet, the bend is usually a weak point. By the use of stiffening ribs (Fig. 3- lo'). overall rigidity is increased by 100 to 200%'. If a hole in the flange of a part is functional (not just a lightening hole), a rib as shown in Fig may be formed between the hole circumference and the edge of the part. Since the blank contour is made first, the holes second, and the ribbing last. the ribbing should be as far away from the hole as possible, to minimize distortion of the finished part and to avoid trimming. A limitation to bead depths may arise from inability to form stretched recesses, such as beads. to the desired depth, since the maximum obtainable depth is a function of the minimum bottom depth R. 2 TS R = - for circular recesses P TS R = p for elongated recesses where R = bottom radius, in. (mm) T = stock thickness, in. (mm) S = tensile strength. psi (Pa) P = forming pressure, psi (Pa) (2A)

9 TABLE 2-1 Bead-Design ~ata''~ Low-carbon Steel, Aluminum, Magnesium Titanium * Maximum thickness for rubbel-pad-formed beads on hydraulic press. i. Maximum thickness for beads formed by punch and die on mechanical press. 2 Use when edge of bead to edge of qheet does not exceed dimension shown. 7 Maximum distance between edge of bead and edge of sheet. See Fig T(0.016 in. min) Fig Bead design." 2-8

10 Size L Design Data Spacing between beads Type 1 -. Section A-A Section B-B Section C-C i Fig Corner head designs.5 The proportions of locked-in beads (those terminating short of the edge of the sheet are shown in Table 2-1. If these proportions are maintained, all aluminum alloys (with th~ heat-treatable alloys in soft condition). all magnesium alloys (condition "0"), low carbon steels, and annealed corrosion-resistant steels can be formed by the processe listed in the footnotes. The minimum stock thickness is in. (0.41 mm), with thc maximum as listed in the table. The beads in the proportions shown may be formed in titanium alloy RE-T-41 an( titanium-pure AMS 4901, hot or cold, and in RE-T-32. cold only. The radius R, shoulc be in. (7.92 mm) for in. (1.60-mm) thick RE-T-32 alloy. Bead ends are blended into the flat sheet surfaces by generous radii to preven distortion and warping. Figure 2-12 shows sundry other general design suggestions for thl use of strengthening ribs and beads. Internal Beads. This type of bead is produced when the metal is formed into a reces in a form block. In rubber forming of internal beads, the platen contacts the whole we1 simultaneously, and as pressure builds up. it tends to clamp the sheet in place. As pressurl

11 Section A-A A Fig Reinforcing ribs around holes in stampings continues to increase, the metal stretches into the bead depression. while the metal around the depression is more tightly locked. Most of the deformation is therefore confined within the bead itself. and distortion of adjacent metal is minimized. When a mechanical press is used, matched male and female dies are used to form the bead. The male die first contacts the blank and begins to form the bead before a holding contact is established. This so stretches and distorts adjacent material that it is objectionable for some parts. An improvement results from using a double-action die and a spring-loaded pressure pad to keep the metal from wrinkling as the bead is formed in the sheet. The maximum possible internal bead depth u depends primarily on the bead width A, standard beads commonly having a ratio AIN between 4 and 6. Beads are spaced as closely together as possible to give a maximum strength and to avoid wide flat areas, which are inherently weak. Between parallel beads the minimum spacing is about 8u to allow full bead formation without fracturing the metal. Between a bead and flange at right angles to the bead, allow 20; between beads at right angles to each other, allow 34; and between a bead and a flange parallel to the bead, allow 50. External Beads. In rubber-formed external beads. the highest point of stamping pressure is on the crown of the forming strip. Metal is locked at thih point, with increasing pressure, and the area between bead strips is stretched until it bottoms on the form block. Deformation being thus spread progressively over a large area, an external bead can be formed considerably deeper than an internal bead of the same curvature. Somewhat offsetting this advantage. a rather large edge radius is required. Because of the sharper resulting contours, external beads are more efficient stiffeners than internal beads. Die-formed external beads are formed by metal movement very similar to that for rubber forming of internal beads. However, a very deep external bead designed for rubber forming cannot be produced in a single die operation. Figure 2-13A gives the minimum recommended center-line distances of external beads parallel to the edge of the sheet and the minimum recommended distance for the end of the bead to the edge of the sheet, using an Alu range between four and six. Dimensions A and C refer to parts with flanges, while B and D refer to parts without flanges. Figure 2-13B shows the ratio of width A to depth a for beads which can be formed using the usual rubber pressure of between 1,100 and psi (7.6 and 9.6 MPa). Buttons or Bosses. These are flat-bottomed circular depressions or elevations in this sheet (Fig C). used to increase buckling resistance of unstiffened area, and where drawing of the material must be held to a minimum. Distance from center of button to a flanged edge should exceed 60% to 80% of the button diameter, and 70% to 100% to a free edge. Flanges. A flange as formed on a sheet-metal part is the result of a simple bending operation. or combinations of bending and compression (shrink flanges). or combinations of bending and elongation (stretch flanges). In Fig. 1-14, these are respectively designated as types A, B, and C. Type D flange is a combination of types A. B. and C.

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