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© RENAULT 2008 Origin: PEGI - Renault Page: 1 / 38
Press tooling. Tool for trimming, cutting out, punching. Basics on design
GE24-070R /C ________________________________________
Guide ________________________________________
Status Enforceable Importante Note : This document has been translated from the french. In the event of any dispute, only th french
version is referred to as the reference text and is binding on the parties. Object Define the recommendations for the design of trimming, cutting out, punching tools. Scope of application Renault group Issued by 65307 - Stamping Process Industrialisation Confidentiality Non confidential Approved by Function Signature Application date
D. COURATIN Head of department 65307 05/2008
GE24-070R /C
© RENAULT 2008 Origin: PEGI - Renault Page: 2 / 38
History of versions
Version Update Object of main modifications Author A 02/2004 Creation (1) B. Nouhant Dept
65307 C 05/2008 • Addition of precision which concerning « Floating scrap
cutter». • Put in coherence of the information with the standard
EM24.01.100, for scrap cutters. • Addition of the type of die with "pin"; • Addition of information for the scrap evacuation. • Addition of information for the the stake in operation. • Replacement of the standards CNOMO E01…., for the
metal materials, by Renault standards • Replaced standard EN 10025 by EN 10025-2 All modifications are marked by a solid line in the margin.
B. Nouhant Dept 65307
Supersedes GE24-070R of 01/2005 version B Availability Inside Renault, on the Intranet: http://gdxpegi.ava.tcr.renault.fr
Outside Renault, on the Internet: www.cnomo.com E.mail: [email protected]
Documents cited Regulations : International : ISO 3755, ISO 4957. European : EN 10025-2, EN 10083-1. French : CNOMO : Renault : EB01.14.220, EB01.31.212, EB01.33.211, EB01.41.050,
EB01.45.030, EM24.01.100, EM24.02.030, EM24.02.033, EM24.15.100, EM24.53.100, EM24.53.300, GE24-017R, GE24-040R, GE24-120R.
Other internal doc : Other external doc : Coding ICS: 25.120.10; 03.120.20 Class E24 Key words emboutissage, outillage de presse, outil de presse, dessin, fondamentaux, conception,
détourage, ajourage, poinçonnage, pressing, press tooling, press tool, design, basics, trimming, cutting out, piercing
Language English (1) Have participated in writing the document Site Dept Name Site Dept Name DIVD LHA 09610 Mme LEREVEREND
MM. BEAUFOUR / DELAFENESTRE / DELAHAYE / LECHEVALIER / LOISEL / MORVAN / TERRIER
TCE 65307 MM. BIANCIOTTO / MARMANDE / TRADOTTI
LHA 04734 MM.BAUBE / PASQUIER / ROULIER TCR 64140 M. GOURDET
GE24-070R /C
© RENAULT 2008 Origin: PEGI - Renault Page: 3 / 38
Contents
Page
1 General ........................................................................................................................................ 4 1.1 Tooling constituents ......................................................................................................................................4 1.2 Instructions for frames and foundry parts .....................................................................................................8 2 Cutting elements (Trimming)................................................................................................... 11 2.1 aterial tables ................................................................................................................................................11 2.2 Cast blades .................................................................................................................................................11 2.3 Welded or cast blades for thickness > 1,5 mm ...........................................................................................13 2.4 Moulded scrap cutter for panel thickness ≤ 1,5 mm ..................................................................................14 2.5 Scrap cutter for thickness > 1,5 mm............................................................................................................14 2.6 Scrap cutter by breakdown .........................................................................................................................15 2.7 Implantation instruction for scrap cutter ......................................................................................................15 2.8 Floating scrap cutter....................................................................................................................................20 3 Cutting elements....................................................................................................................... 21 3.1 Material tables .............................................................................................................................................21 3.2 Slotting.........................................................................................................................................................21 3.3 Punching......................................................................................................................................................24 4 Part centring and clamping ..................................................................................................... 26 4.1 Centring the part..........................................................................................................................................26 4.2 Punch range ................................................................................................................................................27 4.3 Pressers ......................................................................................................................................................28 5 General guidelines for scrap evacuation ............................................................................... 30 6 Start up ...................................................................................................................................... 35 7 Normative references for metallic materials cited in this document................................... 37 8 List of documents cited ........................................................................................................... 38
Foreword This guide is not:
A collection of "design rules". Exhaustive in propositions.
This guide is a reminder of a few basics and examples, and must be enriched with: The different user projects. All manufacturing sites by the intermediate of different DIVDs.
The reference documents related with the different materials cited in this guide are mentioned in the table included in chapter 7.
NOTE: All the information concerning the materials are indexed by an asterisk (*) : this means that the type of material is cited for information, and is defined by the EM24.01.100 standard and specific project standards.
GE24-070R /C
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1 General
1.1 Tooling constituents
For foundry thicknesses see paragraph 1.2.
1.1.1 Lower frame The frame includes or supports:
Column guiding and precentring stops. The storage spacers (elastic spacers, gas springs, fuse system). The adjustment spacers. The pneumatic fittings. The electric or electric-pneumatic fittings. The handling pins + handling with clamps. The safety jack ranges. The centrings and fasteners on production and backup press.
In addition, it ensures the functions specific to Trimming – Cutting out – Punching tools: Support and centre the punch. Support the gutters and scrap slopes. Allow evacuation of scrap. Material FGL 215HB *
Lower frame
Guiding gap
PIN AXIS
Offset punchP
ress
axis
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1.1.2 Punch The punch includes or supports: The lower cutting edges. The punching dies. The part centrers. The scrap cutters. The evacuation gutters. The detection probes. Material G50CrMo4 * T3+T7 local Offset grains (X153CrMoV12 * or 42CrMo4 *) Part centring with or without offset cover.
1.1.3 Lower frame / Single block punch. It groups the frame and punch functions
Material = FGL 215HB * + recharged edges (see EM24.15.100) Offset grains
This single block solution must be banned for: TGP tooling. Parts likely to be modified such as lateral door caissons, boot door caissons. THLE panel parts. Very narrow parts. For thickness, see table in paragraph 1.2.
Guiding gap
PIN AXIS
Pre
ssax
is
Lower frame single block without offset punch
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1.1.4 Presser The presser ensures the part clamping and stripping function. It is constructed with minimum vertical ribs to facilitate application of modifications. Material: FGL 215 * HB / FGS 600 3A * or, for complex shapes, to reduce fragility, for parts likely to be modified (e.g. door caisson), it is in cast steel 270-480W *. Presser guide
Guiding by cupro plate with inserts implanted on the presser. Plan on the frame the possibility to implanter a plate.
Plate guiding is preferential over column guiding, which must remain exceptional (Easier fitting/removing with plates), see paragraph 5. For aspect parts, cones or stands are implanted between presser and punch (or lower crane). Cones are mainly to be implanted for parts with "edge" lines. Note: if the presser is guided by columns, do not fit cones, only stands. Possibility to use "suspenders" (natural outlets) to implant cones or stands
Cones: seeEM24.52.100
Cones
Bea
rings
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1.1.5 Upper frame The upper frame includes or supports:
The bush guides and precentring. The storage spacer stands, jack ranges. The adjustment spacer stands. Handling pins + handling with clamps. Snap clamps + manual fitting Retainer pins of the presser or retaining/locking. Pressure elements (nitrogen equipment or spring). Punch holders and risers. Opening and trimming blades. Presser guides. Pneumatic fittings (or clearance) for new generation TGP/TTGP socket.
1.1.6 Reactions For "open" trimming lines exceeding 200 mm. For parts thickness ≥ 1.25 mm and HLE and THLE panels.
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1.2 Instructions for frames and foundry parts The sizes below are for indication only and must be adapted individually.
Type of press FOUNDRY ELEMENTS MATERIAL SIZES MP GP TGP Lower frame A 40 40 50 Upper frame
FGL 215HB * B 50 60 60 C 40 50 50 FGL215HB *or
FGS 600 3A * D 30 40 40 C 30 40 40
Presser 270-480W *
D 20 30 30 Cover 270-480W * E 30 30 30 Punch See paragraph 2 F 40 40 40
Note: For the design of the foundries, see Renault standard EM24.01.100 and Renault guide GE24-
040R.
Partial cross-sectionof entire tool
Partial cross-section : upper frame, presser, punch, cover
Cover
Punch
Presser
Poinçon
Upper frame
Presser
Lower frameExtend the blade bearings by 50 mm for key housingif required
Upper frame
Lower frame
4 or 6 contacts according to presser dimensions and shape
Pen
etra
tion
She
arin
g
Presser stroke + 10
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Position of the guides according to working parts. Position of general guides: general guides must be located on the same level as working parts. The 2D and 3D master drawings must hence be modified to meet these conditions.
Adjustment spacer located opposite ribs. If working reaction: Implant steel plates on insert cupro. "storage" position
50 m
in b
efor
e co
lum
n in
serti
on
Field of working parts
Tool
axi
s
Tool tip view Free tool position (HOL)
Tool
and
pre
ss a
xis
Eng
agin
g in
the
plat
es =
40
mm
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1.2.1 Calculations See GE24-040R paragraph 2
1.2.2 Aluminium parts The design is identical, except for materials specifications: refer to Renault guide GE24-120R.
1.2.3 Narrow parts, thick parts, HLE, THLE panels Narrow parts Fitting from top of presser Other presser design Blade holder design Other blade holder design
2 machining possibilities
Fitting from top of presser
Stro
ke
Ribs above blade parting lines
HA
ND
LIN
G
Blades
Compensation blocks
P
Blades
Blade holder270-480W
Holes Ø10H7 for reference
Tie-rod axis
Tie-rod axis
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2 Cutting elements (Trimming)
2.1 aterial tables Refer to standard EM24.01.100
2.2 Cast blades
Pour lames inférieures et coupe déchets
Vis
Trous M12 pour manutention et arrachage
Centrage par goupilles
Trous M12 pour manutention et arrachage
VisCentrage par goupilles
Rou
gh re
mov
al (m
axim
um w
eigh
tof
the
blad
e 20
Kg)
Zone treated(see EM24.15.100)
Machining overthickness
H =
60
min
Rib
Afte
r grin
ding
co
unte
rwei
ghts
Stripping possibleFor lower blades and scrap cutters
Centring by 2 pins GT 16 55
Fastening by CHc screws M16-50
2 M12 holes for pulling if required or handling for weight > 15Kg
Fastening device
Centring by pinScrews
M12 holes for handling and pulling
M12 holes for handling and pulling
Screws
Centring by pin
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Cast blades (cont’d) In the case of fragile zones or steep slope, include offset grains. The material of these grains varies according to the panel’s thickness To prevent rising of scraps or to evacuate them it is necessary to plan, in the blades, the implantation of separators. They must be implanted in flat scrap shapes.
Locking compoundor Loctite
Clearance possible according to push-rod stroke
Standard separator
See standard EM24.57.100
2 CHc screws M10-40
1 pin GT. 10-40
Offset grain
Blade profile
Sharpening face
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2.3 Welded or cast blades for thickness > 1,5 mm Solution with or without offset cover. Tabs and notches Its opening must be requested to facilitate scrap evacuation.
VIEW ALONG: F
Ver
tical
con
stan
t 20
mm
re
com
men
ded
VIEW ALONG: F
Ver
tical
con
stan
t 20
mm
re
com
men
ded
Stripping possible
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2.4 Moulded scrap cutter for panel thickness ≤ 1,5 mm
2.5 Scrap cutter for thickness > 1,5 mm
View along: FLower blade
Zone treated ≥ 54 HRC
About 30°
Pen
etra
tion
1-0.
5 m
in
She
arin
g About 10
1 M12 hole for pullingif required
Upper blade2 GT 16-55 pins 2 CHc screwsM16-35 Blade profile see page 7
Zone cleared to facilitate scrap evacuation
1 M12 hole for pulling
About 10
2 GT 10-40 pins2 CHc screws M10-40
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2.6 Scrap cutter by breakdown This solution is used for low width scraps, 5 to 8 mm max.
2.7 Implantation instruction for scrap cutter
IN NO EVENT CAN THE PART TO PRODUCE BE CENTRED ON THE SCRAP CUTTERS
This sticker is affixed on drawing No.1 of the INVENTORY. The scrap cutter profile must be below 5/10 in respect of the shape of the part covered on the centrer (Figure 1) The scrap cutters must not be implanted in part zones in counter blank (Figure 2)
Scrap cutters can be embedded in the punch to prevent spangle (skin parts).
5 to 8 max
View along « f »
Lower punch
Upper blade
Scrap
0.5 mm to specify in drawing0.5 mm to specify in drawing
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Positioning of scrap cutters.
REMOVE THE SCRAP CUTTERS FACE TO FACE AVOID BACK TO BACK SCRAP CUTTERS
. Scrap cutters must protrude from the theoretical blank by 10 mm min. Two consecutive scrap cutters must be open outwards by 5°. In no event should they form a closed angle, as the scrap remains keyed.
No centring on the part on the scrap cutters
Theoretical blank
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If "face to face" layout impossible
Include push-rods in the upper part and build the blank and cylindrical of the scrap cutters as follows:
Open the angle between the two scrap cutters at maximum.
If the scrap does not drop by gravity, fit the tool with tilting jacks. OTHER SOLUTION Scrap cutting in two steps. Use this process in all cases to maintain a sufficient loading and extraction tunnel, as well as a small slope with a drop exceeding 30°. Trimming of parts in 1 step with minimum scrap cutting, then, recutting large scrap. Framed scrap cutters are removed using the two step scrap cutter solution.
Stipping possible
High clearance at right angle
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Case of highly balanced parts. Ban protruding seating under scrap cutters.
The upper scrap cutters must not work on the trimming line angles.
10 mm to specify in drawing
Stripped
Che
ck b
y ca
lcul
atin
g th
e cr
oss-
sect
ion
10 mm to specify in drawing
Stripped
Che
ck b
y ca
lcul
atin
g th
e cr
oss-
sect
ion
AA CROSS-SECTION
Trimming scrap cutterScrap recuttingscrap cutter
Scrap end stopScrap 500 max. in diagonal(2nd cutting at next pressstroke)
Scrap cutter
1st scrapramp
1st ramp at 30° Cutting outline sketch
Straight cuttingtilted at 15° Punch
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Scraps must not form a U and include two angles of the trimmed part. The movement of the scraps must not meet other trimming lines. Scrap cutter(cont’d) These various scrap cutter layouts are applicable for scrap evacuation. However, consider relative
locations of scrap cutters in high locations Scrap cutters in counter-slope
Not OK OKNot OK OK
Notch Tab
If impossible
Avoid OK
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Sloping When the slope available is insufficient between two scrap cutters, exceptionally the latter can be increased by locating its top at 2/3 distance between scrap cutters.
2.8 Floating scrap cutter Necessarily used on toolings " aluminum parts ", it can be, nevertheless; used for the toolings of any other part
Attention : to obtain a push of the working forces in the axis of the RG, the floating t scrap cutter has to be in reach with the lower scrap cutter. Furthermore, when there is a force of lateral work, it is necessarily to implant reactions..
Initial slope
of
f1
f2
a a
f1 f2
section a
View f
DETAILS ON FLOATING SCRAP CUTTER
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3 Cutting elements
3.1 Material tables Refer to standard EM24.01.100
3.2 Slotting
3.2.1 The opening is not inside a 250mm-side square The lower frame has a single block punch acting as a die in the part to cut out (see § 3.1) The upper frame holds blades
3.2.2 The opening is not inside a ∅ 48 mm circle, but is contained in a square 250 mm side The lower frame has a single block punch or a blade holder acting as a die in the area to cut
out (see § 3.1) In the upper part, the cutting out punch is single block
Cyl
indr
ical
8 m
m
Blades
Single block punch
Pen
etra
tion
+ sh
earin
g
2 pins
Screws
Cyl
indr
ical
8 m
m
Single block punch
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3.2.3 Die
There are several types of dies: (according to Renault standard EM24.53.300). - die with pin - flanged dies - smooth die - flat die They are with or without orientation. Use preferably flanged dies for shape spans. They have a cylinder of 5 to 8 mm If the die is placed in a die holder, apply the implantation shown below. If punching must be performed at least at 15 mm from the trimmed edge, implant a grain used both as trimming blade and punching die.
3.2.4 Flanged punches Use preferably standardised punches defined in Renault standard EM24.53.100. Material X153CrMoV12 * T6 (56-58 HRC) If the punch is very fragile, use high speed steel HS6-5-2C * T6 (58-60 HRC). Reduce the cylindrical part to strict minimum. Dimensions and tolerances according to Renault standard EM24.53.100 Imperative height 80. Profile of punch made j6. The cutting gap is specified on the die. If punching is not contained in a circle ∅ 24: consider a single block punch for a basic shape or an offset pad on a riser for complex shapes. For punches ∅ ≤ 5.2, the working direction must be normal to the panel and for HLE, THLE panels, they will be lined. When lining the presser, the latter must be guided by columns.
Non through pins
Sleeved punch
Punch holder
Presser
Acc
ordi
ng to
pun
chØ
13
or 1
6
Dépouille cylindrique ou conique acceptées.
Accepted cylindrical or conical blank
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3.2.5 Housing for punch and die
Use preferably standardised punch holders defined in Renault standard EM24.53.100. For "non aspect" parts, punch holders can be used as die holder. Punch holder riser
Single block with upper frame: ensure stability of the stop with small ribs. Offset Specific punch holder.
Die
Standard punchholder
Plan large base for proper seating
Block
If possible STD punch holder
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3.3 Punching Dimension included in diameter 48.
3.3.1 Punching profile and tolerance An execution drawing should be sufficient for production without having to mention dimensions on an existing part or a reference. The execution drawing of a punch must show:
The punch profile Tolerances on punching profile
For non standardised dies and punches, refer to the "POKA-YOKE" drawings, available in Renault guide GE24-017R.
N° E 15 900 1019 die punch detail, N° E 15 900 1020 punch holder detail. Definition of the punch and die according to the type of punching.
PUNCHING
NON STANDARD STANDARD Panel th. / indifferent Panel th. ≤ 1 Panel th. > 1
Punch Die Punch Die Punch Die
POKA-YOKE POKA-YOKE Standard Standard Standard POKA-YOKE
In all non standard punching cases, punch dimensions are specified in the manufacturing sheet, in the folio on the appropriate operation.
Refer to table below for the number of items to include to nomenclature (spare included)
Number of identical
punches or dies
Number of spares
Total to include to nomenclature
1 2 3 2 2 4 3 2 5 4 2 6 5 2 7
n ≥ 6 n/2 3n/2
Clearances: The dimensions of the dies are deducted from the dimensions of the punch,
to which cutting clearances are added.
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3.3.2 Shock plate Delivered with punch holder
3.3.3 Penetration – Cutting gaps Punching: Penetrate by 1 to 2 mm beyond the die cylindrical. Trimming: Penetration 2 mm constant + shearing 3 mm. Cutting out: Penetrate by 1 to 2 mm beyond the die cylindrical and allow the scrap to loosen.
TRIMMING GAP: The constant gap measured between punch and die must be 4% panel thickness ± 0.01 mm.
PUNCHING GAP
MATERIAL THICKNESS e (in mm)
GAP BETWEEN PUNCH AND DIE: a
TOTAL GAP a x 2
0.5 0.03 0.06 0.6 to 1 0.05 0.1 1.25 0.08 0.16 1.5 0.1 0.2 2 0.15 0.3 2.5 0.2 0.4 3 0.25 0.5 3.5 0.3 0.6 4 0.4 0.8 5 0.5 1 6 0.6 1.2
Note: this table must be included in the tooling study drawings according to Renault standard EM24.02.030, paragraph 1.8.4.
a a
e
Pen
etra
tion
1 to
2 m
m
Separators
She
arin
g 3
mm
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4 Part centring and clamping
4.1 Centring the part The part is centred on its volume, on edges already trimmed or existing punches (Except for reference holes) which must not be used for driving the part. NOTE: any additions of precentring profile templates For parts centred exclusively on shape (Handle individually)
Centring on shape For parts with sufficient curves, centring is performed on the single block punch.
Fixed and mobile centrer If the part’s shape is insufficient to ensure proper centring, fit centrers on the punch outside the location of the scrap -cutters.
Centring upon cutting rework operation Use profile templates on lines trimmed definitely or pilots on punchings.
Flag centring If none of the solutions evoked above is appropriate, centring holes must be created by the OP for stamping.
Cross-section A
Centrers fitted « in flag »
Fixed centrer if blade between blade and centrer
Less
than
5 m
in
Mobile centrer(avoid)
Cross-section B
Centring
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4.2 Punch range The punch range for skin parts is ensured over a projected width of 100 mm. In the centre, support the part with a cross, plus strips to prevent collapse.
Support edge lines
Range for suction cupPunch range
Tool
axi
s
Tool axis
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4.3 Pressers Presser stroke
Add 10 mm to the stroke defined by scrap cutters to compensate for any spring load. Load on presser (tightening - stripping)
Plan a margin sufficient to cover the additional load resulting from subsequent modification. The choice of the type of pressure means is made according to the number of metal,
polyurethane or gas springs (RG) required. Check the balancing of clamping loads in respect of guiding and work loads.
Presser range for skin part The range width is 45 mm over the periphery and 95 mm beside the scrap cutters. Presser range for non visible part The range width is 30 mm over the periphery and 95 mm beside the scrap cutters.
In all cases, the cover range must protrude by 5 mm the presser range in order to prevent distortion.
For ALU parts, see Renault guide GE24-120R Note: The lower ribs are cleared by 10 mm.
For punchings, do not include an inspection door. For skin parts, the presser is balanced by cones or stands.
(See paragraph 1.1.4)
Fitting without elastic stripper and without inspection door
Punch range
Trimming line
Scrap cutter
Presser range
45 or 30
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PRESSER GUIDE - Guide / Plate Operating clearance Principle for very narrow parts
2 machining possibilities
Fitting from top of presser
Rib above bladeparting lines
HAN
DLI
NG
stro
cke
Examples : panel thickness 0.67 mmPlate guide min +0.1
max +0.37Column guiding min +0.1
max +0.57
Gap 0.5Punch/presser
Guiding clearance0.1 between frame/presser
Presser
Blade parting line
Gap ≤ 0.03 (between blades, flat)
Min: +0.1Max: panel th. -0.3
Column guiding
Min: +0.1Max: panel th. -0.1
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5 General guidelines for scrap evacuation Evacuation of trimming and punching scrap must be performed without manual intervention
and at each press stroke. This evacuation is performed at the front and back of the press. The minimum slope must be 30°. Avoid elbowing plane gutters. At the exit of the tool, the scrap is recentred in the pit by hoppers (EM24.02.033) The width of the scrap depends on the width of the evacuation flaps (EM24.02.033) Evacuation accessories have a perfectly smooth sliding surface, any welding spots are grinded
and smoothened to ensure no protrusion interferes with scrap evacuation. The lower scrap is evacuated on the natural slopes included in the study. Outline scraps are evacuated, in all possible cases, on natural slopes or ramps in drawn steel
∅ 10 mm. Include protection panels for the guides.
Scrap
Platform
Scrap
Machining if required
Separators
L = curved line length
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Evacuation of punching scraps
The scrap must arrive 1 by 1 at slope entrance. No scrap can be jammed in a slot or hole nor be blocked by protrusions. However, jamming can occur if several pieces of scrap get tangled in a bottleneck or if descent speed is insufficient. Therefore: Build an evacuation without strangling (grind the frame if required)
If several pieces of scrap must fall in the slope, avoid having them crossing at 90°.
Panel thickness 3 mm (scrap break)
Size D
XSize X + 2
YESNO
YESNO
90°θ ≥ 90°and differentdrawings
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Evacuation of scrap outside the lower frame Outside scrap For trimming scraps of sufficient dimensions and with an appropriate shape, use preferably deflectors in drawn steel ∅ 10. Implantation of ramps in drawn steel ∅ 10
These are laid out according to the configuration of the part during MAP for scrap evacuation.
When the scraps are too small or too complex-shaped or still when the evacuation path is not straight, use fairings or gutters in steel panel S185 * th. 3 mm with smooth surface and without welding. When using gutters, these must be easy to disassemble. They are protected by the tool sole which is extended to this effect close to the edge (even up to the edge) of the press platform, and chamfered. Gutter fasteners must not interfere with scrap evacuation. Use Fhc countersunk hex head screws. The sheets must be adjusted on the foundry.
Opening for scrapsPress platform
Tool and press axis
Tool
and
pre
ss a
xis
Handling zones must not be obstructed by scrap and recentred in respect of the opening outside platform
∅10
.5D
epth
1.6
Welding
∅ 6.5Fastening by chc screw M6X20
Adx panel gussetDepth : 3 to 4 mm
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Fhc screw recessed from sliding plane
Platform
Fhc screw recessed from sliding plane
Platform
Press frame
Not ok
OK
Protruding : 10 mm
The gutter joint must not protrude on the scrap path
M8 Countersunk head
If required gutter folding for storage (held by chain + hook)
No pipe or cable on scrap path
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To prevent "shelving" problems due to shrinkage of the frames during casting, for imprecise foundries or modifications, apply the following guidelines: In the case of rectangular scrap, include the passage under the foundry wall. BEWARE NOT TO WEAKEN THE TOOL By applying a constant angle, passage P is smaller than scrap X. Increase the passage by implementing two different slopes, slope 1 increases scrap inertia to compensate lack on slope 2. X < P < Q Ramp for evacuation of scraps in the tooling
If scrap evacuation is impossible, include other means of evacuation: conveyor belt, vibrating gutter, jack.
In very difficult cases (e.g. low height, flat scrap) use stainless chequered plate (X6CrNi18-10 T1, Company ALMET) provided the slope is 15°.
P
Q
P
Q
Platform
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6 Start up To start up punching:
Use clip-on punch holder sets according to standard EM24.53.100
To start up a cutting out/trimming operation: 2 Solutions:
• Double HOF (Validate this solution with production and backup sites) Beware the risks of interference between the different elements of the tool. This solution is
forbidden (due to impossible operation) for tools with strike function. • Start-up by means of pneumatic jack according to the principle of punch holders
mentioned above.
Punc
h w
ith
stan
dard
flat
Punch return strokeStroke
Jack
Flange punch
View along F (without shock plate)
Orientation pad
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Supply of pneumatic jacks
• Press type MP/GP/TGP Implement a pneumatic fitting between the lower and upper frame (helicoil) + the position handle, mention for each position the number of the product part.
4 Chc screws M 6 60
Note: to place at front of press,as low as possible
4 M6 holes
Legris pneumatic valve X234 391 801
Single blade tapered union G1/4X 155 061 104
Note: in the case of simultaneous RR L and lateral fitting, include circuit selectors for each pneumatic movement
Front of pressLower frame
Circuit selector
Connection of pneumatic and
electric-pneumatic plate
Connection of pneumatic and
electric-pneumatic plate
Circuit selector
Cross out inappropriate marks
Plastic tube P 14x2 SRX 215 141 901 For jack | A 63 or 80
Upper frame
Single tapped male unionX153 062 203
Connecting tip RBES male 3/8X 191 132 702
Double nip 3/8X 144 01 101
HC helicol-combi balancer HC 50-10STAUBLI X 217 146 301
Connecting block2X2 Chc screws M8X50
M 431 513 501
Lower frame
Plastic tube P14x2 SRX215 141 901(For connection to air inlet)
Plastic tube P 10x1.5 SRX 215 111 404 For jack | A 40 or 50
Plastic tube P10x1.5 SRX215 111 404 (To use the valve)
Single tapped male unionX153 062 203
2 holes |A9
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• New generation TGP press
Press fitted with pneumatic fitting blocks built into the ram (see drawing 454 82 in guide GE24-017R) No helicoil connection. (Beware the backup press) Management of positions is performed by the press program. Plan compatibility with the backup press.
7 Normative references for metallic materials cited in this document
Designation Reference document
270-480W * standard ISO 3755
42 CrMo4 * standard EN 10083-1
T4 pre-treated steel * standard EB01.14.220
FGL 215HB * standard EB01.41.050 FGL 240HB * standard EB01.41.050
FGS 600-3A * standard EB01.45.030
G 42Mn5 * standard EB01.31.212
G 50CrMo4 * standard EB01.33.211
HS6-5-2C* standard ISO 4957
S185 * standard EN 10025-2
X 153CrMoV12 * standard ISO 4957
FITTING WITH TOOL REMOVED
PRESS RAM
TOOLING
FITTING WITH TOOL CLOSED
4 Chc screws M12x80
4 washers DE 12
Foundry clearance
Semi rigid tube PN10 | 18x2Inserted and glued
PRESS RAM
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8 List of documents cited NOTE : For non dated documents, the latest version is applicable. ISO 3755 : Tempered steel. Section 1: Technical delivery conditions for special steel. ISO 4957 : Tool steel EN 10025-2 : Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-
alloy structural steels EN 10083-1 : Tempered steel. Section 1: Technical delivery conditions for special steel. EB01.14.220 : Bars in T4 pre-treated steel. Technical specifications. EB01.31.212 : Cast steel. G42Mn5. Technical specifications. EB01.33.211 : Moulded steel G50CrMo4. Technical specifications. EB01.41.050 : Lamellar graphite cast iron. FGL 175HB. FGL 215HB. FGL 240HB. Technical
specifications EB01.45.030 : Spheroid graphite cast iron FGS 400-18A and FGS 600-3A. Technical
specifications. EM24.01.100 : Presentation of the basic offer and free offer in press tooling design EM24.02.030 : Press tooling. Technical drawings. General presentation principles. EM24.02.033 : Press tooling. Evacuation of scrap and collection of "wire blanks". EM24.15.100 : Reloading press tooling. EM24.53.100 : Press tooling. Punch holder. Punches. Strippers. Shapes and dimensions. EM24.53.300 : Press tooling. Punching dies for round and shaped holes. GE24-017R : Press tooling. Miscellaneous master. GE24-040R : Press tooling. General design guidelines. GE24-120R : Design rules for press tooling for aluminium stamping.