Die (manufacturing)

Die Stamping Operations
– Progressive die with scrap strip and stampings
– Blanking and piercing are die cutting operations
– Bending is an example of a die forming operation
– Die forming works by deforming materials using force
– Forming dies are made by tool and die makers
– Blanking produces a flat piece of material
– Die blanking offers accuracy, appearance, and flatness benefits
– Broaching removes material using multiple cutting teeth
– Bulging expands the closed end of a tube using fluid or rubber dies
– Coining forms different features on either face of the blank
– Compound dies perform multiple operations on the part
– Curling rolls the material into a curved shape
– Cut off dies remove excess material or cut a predetermined length
– Drawing undergoes severe plastic deformation with material extending around the sides
– Extruding deforms blanks into finished parts using high pressure

Die Components
– Die shoes serve as the foundation for mounting die components
– Guide pins align the die shoes precisely
– Die set consists of plates, with the die block as the lower half
– Punch plate holds and supports the punches
– Punches include blanking and pierce punches

Types of Manufacturing Dies
– Pancake die: Performs blanking and/or piercing with manual removal of finished product.
– Piercing: Used to create holes in stampings.
– Transfer die: Provides different stations for operations to be performed.
– Progressive die: Feeds sheet metal as a coil strip and performs different operations at each station.
– Shaving: Removes a small amount of material from the edges of the part.
– Steel-rule Die: Also known as cookie cutter dies. Used for cutting sheet metal and softer materials. Cutting surface is made of hardened steel strips. Rubber strips are used as a stripper plate. Low cost to make, but not as robust as solid dies.
– Rotary Die: Cylindrical shaped die used to process soft materials like paper or cardboard. Uses cutting and creasing rules. Faster than flat dies. Also used in the roll forming process.
– Wire Pulling: Wire-making dies have a hole through the middle. Wire is lubricated and reduced in size. Lubrication is added to prevent metal to metal contact. Multiple dies are used for progressive reduction of diameter. Standard wire gauges refer to the number of dies used.

Differences between Materials
– Vacuum forming is used for plastic sheet forming
– Sheet metal forming uses a punch and die block
– Automotive components may require shearing and additional operations
– Crimping or rolling operations can hide sharp edges and add rigidity
– Stock guide ensures consistent positioning within the die

References
– Hedrick, Art. ‘Die Basics 101: Intro to Stamping.’
– Finn, Jay. ‘The case for laser blanking in automotive stamping.’
– Delfini, Ron. ‘Parts of a Die.’
– Misumi Corporation. ‘Press Dies Tutorial § 028, Basics of Die Structure (3).’
– Johnson, Carl-Johan. ‘DESIGN KNOWLEDGE REUSE IN DESIGN OF PROGRESSIVE STAMPING TOOLS: A QUALITATIVE STUDY.’ Source:  https://en.wikipedia.org/wiki/Die_(manufacturing)