NORTH AMERICA ONLY GUIDELINES FOR DIES WITH PIERCING OPERATIONS

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1 GUIDELINES FOR DIES WITH PIERCING OPERATIONS 1.0 APPLICATION OF THE STANDARD THE FOLLOWING GUIDELINES APPLY TO ALL DIES WITH PIERCING OPERATIONS, E.G. BLANK, TRIM, PIERCE AND CAM DIES. 2.0 GENERAL INFORMATION ON PANELS SYMMETRICAL ABOUT THE CENTERLINE, OR RIGHT AND LEFT HAND PANELS, TRY TO COMMUNIZE PUNCH REQUIREMENTS BY ELIMINATING OPPOSITES. AVOID BALL SEAT LOCATIONS THAT WOULD REQUIRE OPPOSITE DETAILS. FOR PREFERRED LOCATIONS OF BALL SEAT, SEE W-DX5-62M. PUNCHES, BUTTONS AND RETAINERS ARE SHOWN IN THE STANDARD, ITEMS 2.1, 2.2, AND 2.3. SPECIAL TYPES WHICH ARE NOT INCLUDED IN THE ABOVE STANDARDS, MUST BE DISCUSSED WITH THE FORD ENGINEERING GROUP AND COMPLETELY SOILD MODEL. SEE PAGES 7 AND 8 FOR ORDERING INFORMATION. CLASSIFIED SHAPE PUNCHES AND DIE BUTTONS ARE PREFERRED OVER SPECIAL. ORDER THESE BY DESCRIPTION: PUNCHES W-DX5-62M PAGES 20 AND 21 AND DIE BUTTONS W-DX5-80M PAGES 20 AND 21 OR FROM MANUFACTURER'S CATALOGS. WHEN USING A MANUFACTURER'S CATALOG ORDERING NUMBER, USE THE LETTER (F) IN PARENTHESES BEFORE THE ORDERING NUMBER TO SPECIFY THAT THE MANUFACTURED PUNCH OR DIE BUTTON MUST BE MADE TO FORD W-DX5 SPECIFICATIONS. RADIUS ON PUNCH POINT TO BE 0.5 ±0.01 WHEN NOT SPECIFIED. 2.1 PIERCING PUNCHES TO STANDARD PUNCHES WITH HEAVY DUTY BALL LOCK RETAINER ARE LISTED UNDER W-DX5-62M, PAGES 1 THRU 21. SEE W-DX5-52M PAGE 6 FOR BALL LOCK PUNCH LOGICAL NUMBERING SYSTEM. FOR SPECIAL PUNCHES SEE W-DX5-52M PAGE DIE BUTTONS TO STANDARD DIE BUTTONS WITH DOWEL SLOT LOCKING DEVICE, SEE W-DX5-80M PAGES 12 THRU 21. FOR DIE BUTTON LOGICAL NUMBERING SYSTEM SEE W-DX5-52M PAGE 7. FOR SPECIAL DIE BUTTONS SEE W-DX5-52M PAGE 8. 2

2 GUIDELINES FOR DIES WITH PIERCING OPERATIONS 2.3 PUNCH RETAINER TO STANDARD PUNCH RETAINER FOR BALL LOCK PUNCHES ARE LISTED UNDER W-DX5-60M PAGES 19 AND 21. SPECIAL PUNCH RETAINERS ARE TO BE USED WHEN HOLES ARE TOO CROWDED TO USE STANDARD RETAINERS. FOR MULTI PUNCH RETAINER SETS, SEE W-DX5-52M PAGE SELECTING THE PIERCING PUNCHES 3.1 DETERMINING THE PUNCH SIZE FROM THE PART DRAWING MC-HOLES: +0.1 MANUFACTURING TOLERANCE -0.0 PUNCH SIZE = PART DATA DIMS EXCEPTION: PROGRAM WORK ACCORDING TO ES-YF AA MANUFACTURING TOLERANCE ±0.05 PUNCH SIZE = PART DATA DIMS USE BUTTON BLOCKS WITH ALL MASTER CONTROL HOLES. 3

3 GUIDELINES FOR DIES WITH PIERCING OPERATIONS SPECIFY PUNCH POINT IN INCREMENTS OF 0.5mm WHEN PART DATA HOLE CALL OUT IS A ONE-PLACE DECIMAL DIMENSION. SEE EXAMPLES (A), (B), (C), AND (D). USE STANDARD PROCEDURE FOR ROUNDING OFF PART DATA HOLE CALLOUT. EXAMPLES: 10.2 ROUND OFF DOWN TO 10.0, 10.3 ROUND OFF UP TO 10.5, 10.7 ROUND OFF DOWN TO 10.5, ETC. * SPECIFY PUNCH POINT IN INCREMENTS OF O.1mm WHENEVER PART DATA HOLE CALL OUT IS A TWO-PLACE DECIMAL DIMENSION. SEE EXAMPLES (E), (F), (G), AND (H). USE STANDARD PROCEDURE FOR ROUNDING OFF PART DATA HOLE CALLOUTS. EXAMPLES: ROUND OFF DOWN TO 10.2, ROUND OFF UP TO 10.3, ROUND OFF UP TO 10.3, ETC. WHEN A RANGE IS GIVEN, OR A TOLERANCE SPECIFIED, ROUND OFF UP TO THE HIGHEST 0.1mm INCREMENT THAT IS WITHIN THE RANGE OR TOLERANCE. SEE EXAMPLES (J) AND (K). AGAIN, PUNCH POINT SIZES ENDING IN.0 OR.5 ARE PREFERRED AND TAKE PRIORITY. SEE EXAMPLE (L). NOTE: NORMAL PART DATA HOLE SIZE TOLERANCE IS ±0.4mm AS PER GENERAL ENGINEERING SPECIFICATION. * EXAMPLE A B C D E F G H J K L HOLE SIZE CALL OUT PUNCH POINT SIZE * NOTE: TENTATIVELY SPECIFY PUNCH POINTS AS PER EXAMPLES. POSSIBILITY OF ROUNDING OFF TO.0 OR.5 IN THE FUTURE. 3.2 SELECTING THE PIERCING PUNCH TYPE ALL DIES USE HEAVY DUTY BALL LOCK PUNCHES SEE W-DX5-52M PAGE SELECTING THE DIE BUTTONS DIE BUTTONS WITH DOWEL SLOT LOCKING DEVICE. IF THE HOLES ARE TOO CLOSE TOGETHER OR NEAR A TRIM LINE OR FLANGE BREAK, THEN AN INSERT MUST BE USED (SEE W-DX5-54M PAGE 9. 4

4 HEAVY DUTY BALL LOCK PUNCH LOGICAL NUMBERING SYSTEM R CODE=S STD. BALL SEAT LOC. CODE=C 90 CODE=A CODE=B P W "L" (16 CHARACTERS) PUNCH ORDERING EXAMPLE: F P E 5 S X FORD STANDARD P = PUNCH V = INVERTED PUNCH E = EJECTOR PUNCH PUNCH POINT STD. C = CONE POINT E = RECTANGULAR N = NAIL POINT O = OBLONG P = PILOT R = ROUND S = SQUARE B = BLANK CLASSIFIED SHAPE D = DEE F = KEY FLAT G = RAD. TRIANGLE H = HEXAGON K = KEY HOLE L = FLAT DUO LOBE M = MONO LOBE T = TAB U = FLATTED ROUND Y = KEYO Z = TRAPEZOID RADIUS ON PUNCH POINT IS 0.5mm WHEN NOT SPECIFIED IN ORDERING NUMBER. SHANK DIA. 1 = 10 DIA. 2 = 13 DIA 3 = 16 DIA. 4 = 20 DIA. 5 = 25 DIA. 6 = 32 DIA. 7 = 40 DIA. BALL SEAT LOCATION A = 0 B = 45 C = 135 S = 90 OVERALL LENGTH (L) X = 80 Y = 100 POINT SIZE P =20.10 FOR NORTH AMERICA PUNCHES USE ONLY 90 AND 0 BALL SEAT LOCATION. IF STANDARD PUNCH RETAINER CAN NOT BE ROTATED, BECAUSE OF ROOM RESTRICTION THEN USE A SPECIAL PUNCH RETAINER. OTHER BALL SEAT LOCATIONS USE ON APPROVAL ONLY E = 180 F = 225 G = 270 H = 315 FOR HEAVY DUTY BALL LOCK PUNCHES SEE W-DX5-62M PAGES 1 THRU 21. POINT SIZE W =10.10 RADIUS R =1.5 ADDITIONAL LENGTH FOR PILOT PUNCH S = 90 T = 110 U = 125 V = 140 W = 150 NOTE: PUNCH POINT (P) MUST BE LARGER THAN (W). 6

5 DIE BUTTON LOGICAL NUMBERING SYSTEM FOR DIE BUTTONS SEE W-DX5-80M PAGES 12 THRU STANDARD DOWEL SLOT LOCATION (CODE "S") P 0 BODY DIA. R W (17 CHARACTERS) BUTTON ORDERING EXAMPLE: 28 F B E 5 S S FORD STANDARD B = DIE BUTTON STD. SHAPE E = RECTANGULAR O = OBLONG P = PILOT R = ROUND S = SQUARE B = BLANK BODY DIA. 2 = 13 DIA 4 = 20 DIA. 5 = 25 DIA. 6 = 32 DIA. 7 = 40 DIA. 8 = 50 DIA. 9 = 63 DIA. A = 76 DIA. B = 85 DIA. C = 90 DIA. D = 100 DIA. DOWEL SLOT LOCATION S = 0 A = 90 LAND LENGTH ("B") S = STANDARD A = ALTERNATE N = NO RELIEF HOLE SIZE P =10.10 HOLE SIZE W = RADIUS R = 1.5 SEE CHART ON PAGE 3 FOR DIMENSIONS CLASSIFIED SHAPE D = DEE F = KEY FLAT G = RAD. TRIANGLE H = HEXAGON K = KEY HOLE L = FLAT DUO LOBE M = MONO LOBE T = TAB U = FLATTED ROUND Y = KEYO Z = TRAPEZOID 7

6 GUIDELINES FOR DIES WITH PIERCING OPERATIONS 5.0 SPECIAL PUNCH/PILOT AND DIE BUTTON ORDERING INFORMATION (1) SPECIAL PUNCH, PILOT AND DIE BUTTON MUST BE COMPLETELY SOLID MODEL TO FORD SPECIFICATIONS. DESIGN MODEL MUST MATCH PRODUCT GEOMETRY AND INCLUDE BREAKAGE WHEN REQUIRED, (2) GROUP MATING PUNCH AND DIE BUTTON ON ESP REPORT. (3) ASSIGN AN FP NUMBER TO PUNCH/PILOT AND FB NUMBER TO DIE BUTTON BASED ON THE DIE NUMBER AND THE DETAIL NUMBER. ORDERING EXAMPLE: FP XAW4FA FB XAW4FA DETAIL NUMBER DIE TYPE DIE NUMBER EXCLUDING DRAWING CLASSIFICATION AND ACTIVITY CODE. FORD SPECIAL PUNCH/PILOT DETAIL NUMBER DIE TYPE DIE NUMBER EXCLUDING DRAWING CLASSIFICATION AND ACTIVITY CODE. FORD SPECIAL DIE BUTTON (4) SPECIAL PUNCH/PILOT AND DIE BUTTON NUMBER MUST APPEAR UNDER STANDARD ITEMS AVAILABLE COMMERCIALLY. 300 SERIES ON STOCK LIST OF ESP REPORT. (5) FOR PILOT PIN SPECIFICATIONS SEE W-DX16-50M PAGE 5. (6) PUNCH SHANK AND DIE BUTTON DIMENSIONS TO FORD WDX5 SPECIFICATIONS AND TOLERANCES. (7) MANUFACTURING TOLERANCES TO BE CONSIDERED WHEN DETERMINING THE PUNCH AND DIE BUTTON PROFILE. (8) MANUFACTURER MUST ETCH FORD NUMBER AND MANUFACTURER'S NAME ON ALL PUNCHES/PILOTS AND BUTTONS. 8

7 MULTI PUNCH RETAINER SET GUIDE LINES 90 Ø E Ø6 Ø9 Ø8 DOWEL Ø BACKING PLATE 15 B BALL DIA H 41 Ø Ø9 ORDERING EXAMPLE SPECIAL PUNCH RETAINER AISI-D2 HARDNESS HRC FR XAW4FA R.H. (1) REQUIRED DIE TYPE FORD SPECIAL RETAINER DETAIL NUMBER FOR M5 FLAT HD.SCR. (2) REQUIRED DIE NUMBER EXCLUDING DRAWING CLASSIFICATION AND ACTIVITY CODE. RETAINER BALL MUST CONFORM TO AISI STANDARD B D E G SPECIAL PUNCH RETAINER MUST BE MODEL WITH THE FOLLOWING REQUIREMENTS H ALL SCREW, DOWEL, AND JACK OUT SCREWS EXTRACTION MUST BE SHOWN IN THE SOLID MODEL (SEE WDX30-50M PAGE 4). ERROR PROOF ALL PUNCH RETAINER DO NOT USE SYMMETRICAL SCREW OR DOWEL HOLE PATTERN. ERROR PROOF PUNCH SHANK DIAMETERS. THE BALL SEAT REPRESENTATION MUST BE SHOWN IN THE SOLID MODEL. USE PARAMETERS IN THE ABOVE CHART AND 15 DEGREES TO CREATE THE REPRESENTATION OF THE BALL SEAT IN THE SPECIAL PUNCH RETAINER SOLID MODEL. PROVIDE THE CORRECT ORIENTATION OF THE BALL SET IN THE SOILED MODEL. THE ACTUAL MANUFACTURING OF THE BALL SEAT WILL BE DONE TO THE CURRENT PUNCH/ RETAINER MANUFACTURING STANDARDS. EACH SPECIAL PUNCH RETAINER MUST BE PERMANENTLY MARK WITH FORD PART NUMBER AND MANUFACTURER'S BRAND. ØD G B BALL DIA. IT IS THE DESIGN SOURCE RESPONSIBILITY TO SPECIFY BACKING PLATE DETAIL NUMBER IS PART OF THE PUNCH RETAINER IN THE REMARKS COLUMN OF THE ESP REPORT. 9

8 QUICK CHANGE RETAINER PIPING REQUIREMENTS THIS SCHEMATIC IS ONLY AN EXAMPLE QUICK CHANGE RETAINER SEE WDX5-60M PAGE 24 (2) STRAIGHT FITTINGS (1/8 NPT) INCLUDED WITH CHANGE RETAINER NOTE: IF ELBOWS OR TEES ARE REQUIRED IN DESIGN, THESE ITEMS MUST BE ORDER SEPARATELY MANUAL CONTROL AIR VALVE SEE WDX5-60M PAGE 23 (3) STRAIGHT FITTINGS (1/4 NPT) INCLUDED WITH CONTROL VALVE STRAIGHT FITTING 1/8 NPT X 6mm I.D. LINE NUMBER BA6-1/8-S OR EQUIVALENT PIPE REDUCER (1/2 TO 3/8 NPT) PARKER NUMBER 209P-8-6 OR EQUIVALENT NYLON AIR HOSE Ø6mm O.D. LINE NUMBER BA20-6 OR EQUIVALENT AIR COUPLING BLOCK SEE W-DX35-60M PAGE 1 10 END