HINGE TOOL SET-UP, ADJUSTMENT AND TROUBLESHOOTING GUIDE

HINGE TOOL SET-UP, ADJUSTMENT AND TROUBLESHOOTING GUIDE HINGE TOOL FORMING SET-UP High Level Process (For detailed information, reference Detailed Instructions): 1. Inspect and assemble tool (if required). Confirm detailed information. 2. Create sample set-up program to adjust tool and stroke length parameters. This program will be called Program 1 (Hit 1 and Hit 2) 3. Install tool 1 into punch press without material. Run Program 1 and adjust ram stroke length or tool length until upper and lower touch at the bottom of the programmed stroke for tool 1. 4. Insert proper material into punch press and run Program 1 (Hit1 and 2). Adjust tool length or ram stroke length to achieve desired or recommended results. 5. Using the same part geometry and hit locations from Program 1, create Program 2. Add hit 3 for tool 2 and call this Program 2. 6. Install tool 2 into the punch press without material. Run Program 2 and adjust ram stroke length or tool length until upper and lower touch at the bottom of the programmed stroke for tool 2. 7. Insert proper material into punch press and run Program 2 (includes Hit 1, Hit 2, and Hit 3) and adjust tool length or ram stroke length for tool 2 to achieve desired results. Additional adjustments may be required to fine tune final form. See Adjusting Hinge Tool Variables for additional tips. 8. Repeat Program 2 so that a complete hinge can be assembled.. 9. Create a part program and transfer settings and adjustments made for Program 2 to the actual part program. 10. See Adjusting Hinge Tool Variables or Hinge Tool Troubleshooting Guide for troubleshooting and additional adjustment tips. DETAILED INSTRUCTIONS 1. Inspect and assemble tool (if required). 1.1. Inspect tool and confirm tool is designed for correct material thickness, pin I.D. and form height. 1.2. Assemble tooling (if required). Note the key location and orientation for programming reference. 1.3. Confirm that the upper and lower assemblies are keyed with the same orientation to avoid tool damage. 1.4. Set tool length according to tool setup information provided by Mate. 1.5. Reference the Mate-supplied set-up drawings. 1.6. Like most forming tools, hinge tools are material thickness specific, and are designed to achieve a specific I.D. and formed height. The tool will not produce the same results in material other than their designed intent. Page 1 of 14

Using the same tools with thicker material may result in damage to the tools. 2. Create sample set-up program to adjust tool and stroke length parameters. This program will be called Program 1 (hit 1 and hit 2): 2.1. Create hinge tool 1 in the programming software. Tool 1 will be used for hits 1 and 2. 2.2. When creating the tool, the size and shape are not critical. The important feature is the tool center point, which is used to determine placement of the hit locations. The diagrams below are examples of tooling created for programming, and do not indicate the actual shape of the tools. Fig. 1 Above illustration shows example layouts for Tool 1 (left) and Tool 2 (right), with tool center points shown. Images have been colored for reference only. 2.3. Create a sample setup part using the Mate supplied drawings for tool 1 (hits 1 and 2). This will be called Program 1, and will be used to adjust tool length or ram stroke length for tool 1. Mate supplied drawings will have detailed information regarding recommended tab widths and lengths, in addition to hit locations for each tool. This part program can be created with as many tabs for forming as desired. A typical setup part may include up to 9 tabs. The number of tabs can be customized to suit the customer s setup needs. For example, a press that can adjust ram stroke length from one hit to the next might prefer a 9 tab setup part. A press without the ability to adjust stroke length from one hit to the next hit might be better suited with a 2 or 3 tab setup part. Fig. 2a. Setup program 1 showing hits for tool 1. Diagrams above show hit 1 (above left) and hit 2 (above right). Page 2 of 14

Fig. 2b - Note that hit 1 appears to be near the center of the flat tab and hit 2 appears to be placed beyond the notching of the tab. The hit locations are based on the center point of the tool, and not the actual forming point of the tool. Therefore, the actual forming takes place closer to the edge of the flat tab, as referenced above. 2.4. Programming the tooling sequence for the setup program. It is important to consider the location of all tooling required for producing a formed hinge part. Depending on the size of punch used on the straight edges, it is likely that the ends of a hinge part will need to be punched before the forming tools are used. Consider the size of the tool to be used here (specifically the size or diameter of the stripper) to prevent smashing forms during final parting/slitting sequence. There must be enough clearance between the stripper face and the formed hinges to prevent damage to the forms during the final punching sequence. If possible, place forming tools in a turret punch press as far away from punching tools as possible, and with a minimum of one station in between forming tools. The raised height of a forming tool die may cause blemishes or sheet distortion during punching operations. The minimum spacing will allow each forming tool to produce the form without interference from the other forming tool. Use all tooling required to punch the contour of the flat tabs. The diagrams above show the punching hits for notching the tabs (above left) and the punching hits for the ends of the flat tabs and clearance for forming tools (above right). Page 3 of 14

Punch the ends of the part free. Punching the ends free before using the forming tools will prevent damage to the formed hinges that could occur from the stripper of the tool used to punch the ends. Use tool 1 to punch hit 1 on all tabs of the setup part. Use tool 1 to punch hit 2 on all tabs of the setup part. Use the desired tool to punch the bottom edge of the part for part removal. It is important to make sure that all tools used after forming will raise high enough to clear formed hinges or that the tool travel path does not interfere with formed hinges. Failure to do so may result in damage to the formed hinges and possibly damage the tooling. In Trumpf machines, the last punching tool may require a urethane stripper or selfstripping punch. Trumpf machines do not allow a metal stripper to be used after forming tools in the same program. Page 4 of 14

2.5. Generate an NC program to create sample part called Program 1. 3. Install tool 1 into punch press without material. Run Program 1 and adjust ram stroke or tool length until upper and lower tools touch at the bottom of the programmed stroke for tool 1. 3.1. To increase the form height or angle, increase the ram stroke length or increase tool length (or both). 3.2. To reduce the form height or angle, shorten the ram stroke length or shorten tool length (or both) 3.3. Use this as a starting point for tool 1 tool length/ram stroke length adjustment. 4. Insert proper material into punch press and run Program 1 (Hit1 and 2). Adjust tool length or ram stroke length to achieve desired or recommended results. 4.1. Because the length from the edge of the flat tab to the bend in hit 1 is so short, it might be difficult to determine the adjustment necessary to achieve the proper angle of form for tool 1. 4.2. The safest procedure might require a minimal tool length/ram stroke length setting for hit 1 and continue with adjustments as required for hit 2. For example, from the starting point (point at which the upper and lower tools touch without material) increase tool length or ram stroke length until hit 1 creates a noticeable bend. Use this setting for hit 1 on all tabs. When hit 1 on all tabs has been completed, proceed to hit 2, adjusting tool length or ram stroke length until a recommended formed tab angle has been achieved (typically between 75 and 88. A higher angle is more likely to produce a better overall hinge form. Use precaution when making adjustments. Smaller increments in adjustments will help prevent tooling and or machine damage during the fine tuning process. 5. Using the same part geometry and hit locations from Program 1, create Program 2. Add hit 3 for tool 2 and call this Program 2. 5.1. The diagram below shows the part layout for setup Program 2 including all hits for hinge tools. Hits 1 and 2 (green) and hit 3 (light blue) are shown. The punching hits are not shown. 5.2. Repeat procedure 2.4 Programming the tooling sequence for setup program 5.3. Generate NC program to create sample part called Program 2. Page 5 of 14

6. Install tool 2 into the punch press without material. Run Program 2 and adjust ram stroke length or tool length until upper and lower tools touch at the bottom of the programmed stroke for tool 2. 6.1. Use this as a starting point for tool 2 tool length/ram stroke length adjustment. 7. Insert proper material into punch press and run Program 2 (includes hit 1, hit 2, and hit 3) and adjust tool length or ram stroke length for tool 2 to achieve desired results. Additional adjustments may be required to fine tune final form. See Adjusting Hinge Tool Variables for additional tips. 7.1. Using the starting point for tool 2 as a reference, adjust the tool length or ram stroke length down incrementally until the formed tab produces a closed hinge form or tool 2 has bottomed out (or reached the point at which the tools are only separated by the material between them and cannot travel any further) during the forming stroke. 7.2. Both hinge tool 1 and hinge tool 2 are designed to achieve a maximum form at standard die line. This means that once the upper tool reaches standard die line, the upper tool contacts the sheet, which is also in contact with the lower insert, and there is no more room for travel. Stroking the machine beyond this point can result in tool damage, and possibly machine damage. Signs that you ve bottomed out: The final form no longer changes as longer stroke or tool length adjustments are made Heavy witness marks appear around the formed hinge from the face of the upper insert The punch press yaws during forming process. This means that you can notice the frame of the machine flexing as the ram stroke reaches (or gets close to) bottom dead center 7.3. When all stroke adjustments have been made for tool 2, use these settings and punch out one complete setup part (Program 2) and insert a pin with the same diameter the hinge tools were designed for. 7.4. Observe the shape (roundness), inside diameter (I.D.), form height and formed hinge width. 7.5. Slight adjustments of hinge tool hit locations may be necessary to fine tune overall hinge form for I.D., height and roundness. Page 6 of 14

7.6. When the desired results have been achieved, measure the width of the formed knuckles and adjust tab width to assure the formed knuckles will fit between matching part. Formed hinges are typically wider than the original tab width due to material distortion (see photo below). 7.7. See the Adjusting Hinge Tool Variables section for tips and recommendations for further adjustments that might help improve formed hinge quality. 8. Repeat Program 2 so that a complete hinge can be assembled. 8.1. Using Program 2, with all settings and adjustments made to produce a quality hinge part, punch out two complete setup parts. 8.2. Assemble the parts together, inserting the proper diameter hinge pin to complete the assembly. 8.3. If further adjustments are necessary to improve the quality of the finished parts, repeat the adjustment procedure until satisfied with the results. 8.4. If no further adjustments are necessary, proceed to create a part program (step # 9). 9. Create a part program and transfer the settings and adjustments made for Program 2 to the actual part program. 9.1. Transfer all adjustments, tool settings and ram stroke length settings to the actual part layout, and create parts for production. If adjustments were made to hit 1, hit 2 or hit 3 to produce the best quality form, make those same adjustments to the part created for production. If adjustments were made to the ram stroke length to produce the best quality form, make the same adjustments to the part created for production. If adjustments were made to the flat tab width or length to produce the best quality form, make the same adjustments to the part created for production. When creating parts for production, whether they are in a nest, or a sheared to size part, consider the tooling and hit sequence that may be required to prevent damage to formed hinges during subsequent punching operations. 9.2. It is advised to reduce the speed of the ram and machine when using forming tools. Most forming tools require additional time to allow material springback and properly strip from the tools. An additional program dwell command may be necessary to allow the sheet to lay flat before advancing to the next forming location. 9.3. Sheet lubrication is also recommended (especially when forming stainless steel) to help the material slide freely through the upper opening of tool 2. Additional lubrication also helps reduce galling and premature tool wear. 10. See Adjusting Hinge Tool Variables or Hinge Tool Troubleshooting Guide for additional tips and information about using hinge tools. Page 7 of 14

ADJUSTING HINGE TOOL VARIABLES Minor adjustments to one or more variables may be required to achieve a successful hinge form. These variables may include: 1. Hit locations 2. Stroke lengths/tool lengths 3. Flat tab lengths or widths 4. Notching between flat tabs 5. Material type (Stainless steel, Aluminum, Mild Steel, others) 6. Grain direction 7. Other useful tips and recommendations 8. Additional troubleshooting information 1. Hit Locations 1.1. The formed hinge typically requires a total of three hits from two different tools. These are the variables most likely to command the most attention. There is a fine line between a successful hinge form and a less than perfect hinge form. Once the operator understands how these variables affect the final outcome, it is much easier to setup and achieve a successful hinge form. Hit # 1 This is the first of two hits with tool # 1. This is generally a small bend that will act as the leading edge of the hinge as tool #2 creates the final form. Hit # 1 First hit for tool # 1 creates the leading edge of the formed tab. This bend is small. Generally about 1mm 2mm (0.040 0.080 ) and is the same angle as hit # 2, which is also made with tool # 1 at the same ram stroke settings. The only adjustment usually required for hit # 1 is the ram stroke depth, which should be the same as hit # 2. In the event that the formed up tab sticks to the upper tool AFTER hit # 2, shorten the distance from the edge of the flat tab to the first hit location. 1.2. Hit # 2 This hit is also made with tool # 1, and bends the tab upright (between 75 and 88 degrees. The location of this hit may require modification. To allow more material for the form (increase the I.D. of the hinge) this hit should be moved further away from the flat tab edge. Hit # 2 Page 8 of 14

To allow less material for the form (decrease the I.D. of the hinge) move the hit towards the flat tab edge. When hit # 2 is modified, it usually requires a modification to hit # 3 also. 1.2. Hit # 3 The final form is completed with tool # 2. The location for this third and final hit may need to be modified, plus or minus, depending on the tab angle achieved with the second hit. An angle of 88 degrees may require the third hit to be moved slightly further from the flat tab edge, while an angle of 75 degrees may require the third hit to be modified slightly closer to the flat tab edge. These adjustments are made to ensure that the leading edge of the formed tab enter the opening of tool # 2 near the front (or lower edge) of the opening. Fig. 3 An ideal hinge form occurs when the formed tab enters the opening of tool 2 near the front (or lower edge) of the upper tool. 1.3. One of the keys to a successful hinge form is to have the leading edge of the formed up tab start contact near the front of the opening of tool # 2, thus allowing the material to slide around the inside diameter of the tool (see photos in Fig. 3 above). This will also decrease the chance for the tool to smash down the tab before sliding around the inside of the tool. When this happens, the result is usually a hinge form with flattened sides. Above: Sides are left flat (shown in red) and shape is distorted (shown in green). 2. Stroke Lengths / Tool Lengths 2.1. Hinge tools are designed for a specific material thickness and formed I.D. By design, the tools do not require excessive force to achieve the required results. Once the tools have bottomed out, no further ram stroke length or tool length is required. Longer ram strokes or tool lengths will only cause damage to the tools (and possibly the punch press). Stroke depth and tool length adjustments will generally have the same affect to the final hinge form (increasing the tool length with the same ram stroke length gives the same result as increasing the ram stroke length with the tool at the same length). A combination of the two variables are critical in achieving the angles necessary for the formed tab (tool # 1). The depth of the final stroke (tool # 2) is also a key element required to finish the hinge form. Page 9 of 14

2.2. If the stroke or tool length for tool # 1 is too short, the result will be a tab formed up to angles less than required. This could result in a formed tab that doesn t enter the interior of tool # 2, thus a smashed tab and scrapped part or sheet (see photo left). 2.3. A stroke or tool length that is too short can result in smashed tabs during final forming process. 2.4. If the stroke or tool length for tool # 1 is too long, the tab angle will form to its maximum design, but extra force on the tool could result in premature wear or permanent damage to the tool. 2.5. If the stroke or tool length for tool # 2 is too short, the formed tab will not slide completely around the inside diameter of the tool, resulting in a hinge form that is not closed, and possibly an I.D. larger than designed. 2.6. Stroke or tool length for tool # 2 is too short, resulting in an open form and larger than designed I.D. 2.7. If the stroke or tool length for tool # 2 is too long, the formed tab will slide around the inside diameter of the tool and possibly distort the final shape of the form. Most likely is premature wear and possible permanent damage to the tool. 3. Flat Tab Lengths and Widths 3.1. Flat tab lengths will determine how a formed hinge looks, and will affect the fit with a mating part. The notching required to create a flat tab may require modification depending on the forming results. For a typical, successful hinge form, the formed hinge is generally located just beyond the notched opening of the tab. A tab that is too long will leave an opening in the material when the hinge is installed with the mating part (see photo at right). A tab that is too short may result in distortion at the base of the form and the final form incorrectly located. Photo at right shows the distortion at the base of the form when hit 2 is too short, which results in an incorrect location of the final form. Poor location of final hinge form. Distortion at the base of the form. Page 10 of 14

4. Notching Between Flat Tabs 4.1. Flat tab widths and notching widths will determine how much play is present when hinges are installed with a mating part. The tab width and notch width between tabs may need modifications to assure a good fit. 4.2. A hinge tab, once formed, usually distorts slightly and results in a hinge slightly wider than the original tab width. After an initial setup has been completed, it is advised to measure the formed hinge, and make necessary adjustments to flat tab width and notching widths to allow proper fit after forming. Photo above shows typical measurement changes from a flat tab to a formed hinge. 5. Material Types 5.1. Different material types have different properties, including hardness and ductility, and will have an effect on the result of the final form. Adjustments to the prior mentioned variables may be required to achieve successful hinge forms. 5.2. Stainless Steel is a material with properties that cause it to be harder to form, especially in tight diameters. Reduced ram and machine speeds, additional lubrication and possibly programmed dwell commands will help produce quality hinge parts. 6. Grain Direction 6.1. Grain direction of the material being formed may have an effect on the final forming result as well. Forming with the grain may produce slightly different results than forming across or against the grain direction, and modifications may be necessary. Make adjustments as necessary. 7. Other Useful Tips and Recommendations 7.1. As with all forming tools, Mate recommends a reduced feed rate when using hinge tools. The slower feed rate allows the material more time to recover from the previous form, also assuring accuracy of the next form. 7.2. A programmable dwell command may be added to allow extra time for the material to form and strip properly from the tool (this can be especially helpful when using tool # 2) 7.3. Slower feed rates will help improve accuracy and location when producing hinge forms in a punch press, helping to reduce the number of scrapped parts due to improper forms, sheets pulling from clamps or other problems associated with forming parts in a press. Slower feed rates and programmed dwell commands also allow the sheet additional time to return to its flat state before advancing to the next forming location. 7.4. Mate recommends using lubrication when creating hinge forms in a punch press. Page 11 of 14

In addition to the machine s lubrication system, the use of additional lubrication directly on the formed tabs will help the tab to slide smoothly around the inside diameter of the knuckle tool (this is especially helpful with the production of stainless steel hinges created in a punch press). Above: Hinges formed in 18 ga. Stainless Steel without lubrication. Above: Hinges formed in 18 ga. Stainless Steel with lubrication using exact same machine settings. Lubrication helps the formed tab slide around the contour of tool 2 more easily, reduces wear on the tools, prevents galling and improves the overall quality of the form. 8. Additional troubleshooting information 8.1. For additional troubleshooting information, see Hinge Tool Troubleshooting Guide in the following section. Page 12 of 14

HINGE TOOL TROUBLESHOOTING GUIDE GOOD FORM. All hit locations and stroke depths create the perfect form Result: Leading edge of form doesn't quite curl around to create a nice round form. Distance from flat tab to hit # 1 is too short. Remedy: Increase distance from edge of flat tab to hit 1. Result: Leading edge of form is flat and doesn t curl around pin when inserted. Distance from flat tab to hit # 1 is too long. Remedy: Reduce distance from edge of flat tab to hit 1. Result: Bottom of hinge form doesn't sit flat and/or hinge form is not closed. Distance from flat tab to hit # 2 is too short. Remedy: Increase distance from edge of flat tab to hit # 2. Result: Slightly deformed shape with a slightly larger I.D. than designed for. Distance from flat tab to hit # 2 is too long. Remedy: Reduce distance from edge of flat tab to hit # 2. Result: Tabs are smashed by tool # 2. Angle of tab is too short, so the leading edge of the tab does not enter the opening of tool # 2. Remedy: Increase stroke or tool length to increase angle of formed tab to 77-88, allowing the leading edge of tab to enter opening of tool # 2. Page 13 of 14

Result: Tabs are smashed by tool #2. Distance from edge of flat tab to hit # 3 is too long or too short, as a result, the leading edge of the tab does not enter the opening of tool # 2. Remedy: Adjust distance from edge of flat tab to hit # 3 to allow leading edge of tab to enter opening of tool #2. Figure 1 Ideal location of formed tab to enter the opening of tool 2 Result: Form is not closed and I.D. is larger than designed. Distance from edge of flat tab to hit #3 is too short. Remedy: Increase distance from edge of flat tab to hit # 3 to allow leading edge of formed tab to enter opening of tool # 2 slightly closer to center of opening. Result: Form is not closed and I.D. is larger than designed. Stroke or tool length for tool # 2 is too short. Remedy: Increase stroke or tool length to allow tool #2 to close the form. Too high Result: Slightly deformed shape, form is too high and/or I.D. is too small. Tool #2 stroke or tool length is too long, resulting in a distorted form and premature wear and possible damage to tooling. Remedy: Reduce stroke or shorten tool length to achieve best form. Page 14 of 14