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%.