Thick Metal Punching

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The Process for Thick Metal Punching

Text of Thick Metal Punching

  • THE PROCESS

    FOR

    THICK METAL

    PUNCHING

  • CONVENTIONAL METHOD

    STEP ONE: Pierce the metal with a slightly smaller punch than

    final specifications.

    STEP TWO: Re-punch the hole with a shear punch to achieve

    design specifications for hole size and maximize wall shear.

    Metal piercing thicker metals with the

    current available punch tools requires two

    steps.

    2

  • METAL FLOW

    The punch tip makes contact with the metal stock

    The metal stock gives way under increased psi from the

    punch

    As the punch pierces the metal stock it shears the side

    walls of the hole.

    Metal around the hole becomes elastic and tries to close

    around the punch.

    3

  • THE CHALLENGE

  • As the punch tool wears, burrs (raised metal) are

    created. (CONDITIONS CREATE MAINTENANCE COSTS) 5

  • DOUBLE PIERCING CHALLENGES

    Misalignment of pieces

    Additional time in production cycles

    Insufficient shear reduces the quality of the hole

    6

  • STEP PUNCH

    Punch tool built with distinct tip diameters

    Challenge - Slivers in the die; Slug-ring ejection; Increased tool wear.

    Step punches in high volume applications requires increased die maintenance.

    7

  • THE SOLUTION

  • DUAL TIP TECHNOLOGY

    Dual Tip Technology (specifically, the Dual Tip Punch, or DTP) is capable of

    producing one thick-metal hole with one stroke.

    9

  • DTP WORKS WITH METAL FLOW

    During the pierce cycle, DTP moves through the metal stock. Metal flows into the annular groove and is cut off by the second cutting surface.

    10

  • THE RESULTS

    Excellent hole dimensions

    85+% shear

    Ability to re-insert the DTP into the hole

    11

  • THE BENEFITS

  • EXTEND TOOL LIFE

    During an extended production cycle, the first cutting surface becomes dull. It is at this point that the second cutting surface, which is still sharp, will correct any imperfections and maintain tolerances.

    13

  • OTHER BENEFITS

    Eliminates burrs

    Works to harness metal flow

    Reduces labor cost

    Eliminates alignment issues

    14

  • MEASURABLE

    RESULTS

  • SIX SIGMA CAPABLE

    A Six Sigma study of the DTP was conducted by one of our customers.

    This is a $7.2 Billion international company.

    24,000 employees around the globe

    409 Stainless Steel

    Thickness: 0.062 inch

    Hole diameter: 0.774 inch

  • SIX SIGMA CAPABLE

    Study results indicated outstanding performance during the entire life cycle

    The analysis indicated exceptional performance with sustaining hole

    diameter during the process and

    minimal burring

  • PROCESS CAPABILITY OF BURR

    HEIGHT / INCH

    0.00560.00480.00400.00320.00240.00160.0008-0.0000

    LB USL

    LB 0

    Target *

    USL 0.006

    Sample Mean 0.00145

    Sample N 30

    StDev (Within) 0.000276232

    StDev (O v erall) 0.000273861

    Process Data

    PPM < LB 0.00

    PPM > USL 0.00

    PPM Total 0.00

    O bserv ed Performance

    PPM < LB *

    PPM > USL 0.00

    PPM Total 0.00

    Exp. Within Performance

    M.O.M tools Process Capability of Burr Height / Inches

    18

  • PROCESS CAPABILITY OF HOLE

    DIAMETER / INCHES

    0.80600.80080.79560.79040.78520.78000.77480.7696

    LSL USL

    LSL 0.7677

    Target *

    USL 0.8071

    Sample Mean 0.7729

    Sample N 30

    StDev (Within) 0.000335057

    StDev (O v erall) 0.000332182

    Process Data

    PPM < LSL 0.00

    PPM > USL 0.00

    PPM Total 0.00

    O bserv ed Performance

    PPM < LSL 0.00

    PPM > USL 0.00

    PPM Total 0.00

    Exp. Within Performance

    M.O.M. Tools Process Capability of Hole Diameter / Inches

    19

  • RESULTS

    No parts fell outside the LSL or USL parameters.

    The DTP maintained tight tolerances during the entire cycle of the Six Sigma investigation.

    The DTP increased punch and button life by 536%

    $4,000 in annual hard savings per press

    20

  • TAKEAWAYS

  • 22

    The DTP will pierce and shave thicker metals

    in one stroke. The DTP will eliminate the

    alignment issue, reduce production time and

    create a shear that is greater than 85%.

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