Thick Metal Punching
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Transcript 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%.