DIE DESIGN AND CONSTRUCTION SPECIFICATIONS STAMPING - EUROPE GENERAL INFORMATION CAM DIES

Transcription

1 GENERAL INFORMATION 1. ANGLE OF CAM SLIDE AND DRIVERS ANGLE OF CAM SLIDE AND DRIVERS ARE TO BE DIMENSIONED ON THE DIE DESIGN. FOR DRIVER ANGLES SEE, PAGE 4-7. AVOID THE USE OF CAM ADAPTORS. IF THE CAM SLIDE IS ON AN ANGLE IN THE ELEVATION, CAST THE SHOE TO THE APPROPRIATE ANGLE TO SUPPORT THE CAM SLIDE EVEN IF THE SLIDE IS NOT PARALLEL TO A DIE CENTERLINE. (SEE W-DX7-40, PAGE 46). 2. CAM SLIDE TRAVEL TO LOAD AND UNLOAD THE PANEL THERE MUST BE A MINIMUM DISTANCE OF 30mm BETWEEN THE EDGE OF THE PANEL AND THE FRONT OF THE SLIDE IN THE RETURN POSITION. TO FACILITATE CAM SLIDE REMOVAL AND SOFTEN THE RETURN OF THE CAM SLIDE, ALLOW 2mm TO 5mm CLEARANCE BETWEEN THE CAM SLIDE STOP BLOCK AND CAM BUFFER IN THE RETURN POSITION. (SEE W-DX7-40M, PAGE 24). PIERCING PUNCHES MUST BE REPLACEABLE WITH SLIDE IN THE RETURN POSITION. TO FIX CAM SLIDE IN WORKING POSITION PROVIDE A LOCATION HOLE OF Ø20 H7 WITHIN THE SOLID ON A SUITABLE PLACE; SEE PAGE 12, 15 AND 41. CONSIDER BALANCE OF CAM SLIDE. 3. SLIDE GUIDES GIB PLATE SIZE AND THE AMOUNT OF SCREWS REQUIRED DEPENDS ON SLIDE WEIGHT. ADD INTERNAL GIB WHEN CASTING CAM SLIDE WEIGHT IS OVER 450 Kg OR WHEN WIDTH OF CAM SLIDE IS OVER 900mm. SEE W-DX7-40M PAGE 14. BUCKS OF FLANGE SLIDES ARE TO BE LOCKED TO PREVENT FLEXING. BUCKS OF TRIM SLIDES ARE TO BE LOCKED IF THE AREA OF SHEAR IS OVER 500mm ². SEE W-DX7-40M, PAGE 33. RETRACTABLE CAM SLIDES ARE TO BE PROVIDED WITH (2) Ø25 LOCATING HOLES FOR MACHINING AND SPOTTING THE SLIDES IN THE "HOME" POSITION.(SEE W-DX7-40M, PAGE 12). 4. DRIVERS HEELS AND/OR GUIDE POST MUST BE ENGAGED BEFORE DRIVER CONTACTS THE SLIDE. DRIVERS ARE NOT TO BE CAST INTEGRAL WITH THE DIE SHOE. WHEN DRIVERS ARE NOT HEELED, THEY ARE TO BE KEYED. FOR CAM SLIDES THAT BOTTOM OUT, THE DRIVERS ARE TO BE BACKED UP IN THE SHOE OR HEELED IN THE OPPOSITE SHOE (SEE W-DX7-40M, PAGE 40). WHEN SHOE IS NOT HEELED, DRIVERS ARE NOT TO BE HEELED IN THE OPPOSITE SHOE. DRIVERS ARE TO HAVE 50mm MINIMUM CONTACT WITH SLIDE AT START OF TRAVEL AND 2/3 MIN. ENGAGEMENT BEFORE WORK BEGINS. (SEE W-DX7-40M, PAGE 3). AREA CHANGED 1/3 THE WIDTH OF EACH DRIVER WEAR PLATE IS TO OVERLAP A WEAR PLATE UNDER THE CAM SLIDE. (SEE W-DX7-6M, PAGES 1 & 2). DRIVERS FOR RETRACTABLE CAM SLIDES ARE TO DWELL 40mm MINIMUM BEFORE WORK BEGINS. 5. SLIDE RETRACTION FORCE REQUIRED TO RETURN CAM SLIDES TO THE RETRACTED POSITION IS GIVEN IN THE TABLE ON W-DX7-40M, PAGE 2. RETRACTION OF CAM SLIDE WILL BE BY COIL SPRINGS, GAS SPRINGS OR AIR CYLINDERS. COIL SPRINGS WILL BE LIMITED TO TRAVEL UP TO 70mm. PROVIDE SHEET METAL GUARDS AT AREA OF EXTERNAL COMPRESSION SPRINGS TO AVOID PINCH POINTS AND HAZARD CAUSED BY SPRING BREAKAGE. 6. SLIDES IN UPPER DIE SHOE SLIDE TO BE RETRACTED SUFFICIENTLY TO GIVE 15mm MINIMUM CLEARANCE FOR REMOVAL OF UPPER PAD, (SEE W-DX7-40M, PAGE 6,). AFTER REMOVAL OF SLIDE STOP, THE SLIDE IS TO BE RETRACTABLE FOR 60mm TO 120mm, DEPENDENT ON PART SHAPE, FOR TRYOUT PURPOSES. CAM SLIDES FOR TRIMMING AND PIERCING MUST HAVE POSITIVE GUIDING BY "V" DRIVERS AND POSITIVE RETURN. CAM SLIDES FOR FLANGING DO NOT REQUIRE POSITIVE RETURN. 7. SLIDES IN UPPER PADS USE ONLY WITH PERMISSION OF FORD DIE DESIGN OFFICE. FOR APPLICATION SEE W-DX7-40M, PAGE 42. PAGE: 1

2 SLIDE RETRACTION FORCE THE RETRACTION FORCE MUST BE PROVIDED IN THE RETURNED POSITION. FORMULAS: FOR HORIZONTAL MOVING SLIDES: F = m ( g x µ + a ) FOR DOWNWARD MOVING SLIDES: F = m [ g ( cos α x µ + sin α ) + a ] F = RETRACTION FORCE IN N m = WEIGHT OF SLIDE IN kg g = GRAVITY ACCELERATION = 9.81 m/s² µ = COEFFICIENT OF FRICTION = 0.2 a = MAX. ACCELERATION OF PRESS = 2.0 m/s² FOR UPWARD MOVING SLIDES: F = m [ g ( cos α x µ + sin α ) + a ] RETRACTION FORCE OF AIR CYLINDERS, BASED ON A PRESSURE OF 3.5 BAR. AIR CYL.DIA FORCE IN NEWTON STROKE MASS RETRACTION FORCE RETRACTION FORCE MASS DOWNWARDS MOVING SLIDES UPWARD MOVING SLIDES SELECTION OF REQUIRED RETRACTION FORCE: ( IN NEWTON ) CAM ANGLE WEIGHT OF SLIDE IN KG PAGE: 2

3 CAM DRIVERS & WEAR PLATE APPLICATION FOR ALL CAMS b MIN.= h + 25 (NORMAL PRACTICE) h 1MAX. = 1/3 b (SPECIAL CASE) b b1 USE KEY FOR LIGHT BACK-UP REQUIREMENT. STANDARD KEY SEE W-DX30-60M PAGE 1 INITIAL CONTACT POSITION BEGIN OF WORK POSITION 50 MIN. 50 MIN. h CLOSED POSITION 2/3 X MIN. h1 WHEN (h) IS MORE THEN 250mm THE FLANGE WIDTH IS 50mm MIN. KEYS ARE NOT REQUIRED TO BACK-UP THE DRIVER WHEN THE DRIVER IS HEELED IN BOTH DIRECTIONS. CAM DWELL PLATES. SEE W-DX7-60M PAGE 9. USE STEEL OPPOSITE BRONZE. USE SINGLE WEAR PLATES FOR TRIMMING AND FOR THROUGH FLANGING MOUNTED AT CAM WORKING SLIDE. SEE W-DX13-70M PAGE MIN. CAM WORKING SLIDE RETRACTING SECTION FOR ALL CAM WORKING SLIDES THAT "BOTTOM OUT" USE DOUBLE WEAR PLATES: STEEL WEAR PLATES OPPOSITE BRONZE. PAGE: 3

4 SLIDE & DRIVER WORKING ANGLES 40 mm MINIMUM BEFORE CAM STARTS TRAVEL 25 MINIMUM 36 MAXIMUM 30 MINUS 1/2 OF SLIDE INCLINE 15 OR LESS HORIZONTAL SLIDE FOR LARGE CAM SLIDES SEE PAGE 5. UPWARD INCLINE DIRECT DRIVE USE ON APPROVAL ONLY TYPICAL PROVIDE LOOSE ADAPTOR UPWARD INCLINE USING INTERMEDIATE SLIDE-PUSH TYPE UPWARD INCLINE USING INTERMEDIATE SLIDE-PULL TYPE EQUAL 30 PLUS 1/2 OF SLIDE INCLINE EQUAL 30 OR LESS OVER 30 DOWNWARD INCLINE 30 OR LESS DOWNWARD INCLINE OVER 30 PAGE: 4

5 STARTER DRIVER FOR LARGE CAM SLIDES FOR NOISE ABATEMENT AND TO REDUCE CAM DRIVER IMPACT. WORKING ANGLE 25 MINIMUM 36 MAXIMUM STARTING ANGLE 10 MINIMUM 15 MAXIMUM INITIAL CONTACT POSITION CLOSED POSITION LARGE CAM SLIDES TO HAVE DOUBLE DRIVER. ONE DRIVER TO START CAM MOVING APPROXIMATELY 6 TO 10 mm BEFORE THE WORKING DRIVER CONTACTS. (IMPORTANT TO CHECK HEEL ENGAGEMENT, MUST BE ENGAGED 40mm MINIMUM BEFOR SLIDE DRIVER ENGAGES). PAGE: 5

6 TRAVEL MIN. A PARALLEL TRAVEL+ 60 TO 120 SPRINGS INSIDE SLIDE AS AN EXCEPTION ONLY B 36 MAX. PROVIDE SPRING ASSIST WHEN ADDITIONAL RETURN FORCE IS REQUIRED B A + 2 ASSEMBLY AND ADJUSTMENT PLATE A + 2 A + 4 SECTION B-B ENLARGED FOR FASTENING OF SLIDE SEE W-DX7-40M PAGE 7. PAGE: 6

7 AERIAL CAM WITH INCLINED DRIVER GASSPRING CAM SLIDE CAST INTEGRAL MIN. ALTERNATIVE AS BUCK CAM OUTFALL PROTECTION EN-JS 1030 POSITIVE RETURN EN-JS 1050 POSITIVE RETURN ALTERNATIVE α DRIVER STROKE SPRING STROKE CAM STROKE"A" β α β THE CAM STROKE "A" HAS TO BE LESS THAN THE DRIVER STROKE. (THIS RULE APPLIES ONLY FOR SELF DESIGNED CAMS,NOT FOR STANDARD CAMS!) PAGE: 7

8 NYLON HOLDBACK PIN FOR CAM SLIDES ALL SLIDES WORKING ON AN ANGLE OF 5 OR MORE ARE TO BE PROVIDED WITH ONE OR TWO NYLON HOLDBACK PINS DEPENDING ON SLIDE SIZE. PRIMARILY USED TO HOLD SLIDE IN THE BACK POSITION WHILE WORKING ON THE DIE, IN OR OUT OF PRESS. NYLON HOLDBACK PIN TO BE ATTACHED TO THE SLIDE (OR SHOE) WITH A CHAIN OR NYLON CORD. NYLON HOLDBACK PIN SEE W-DX7-60M PAGE 19 PIN IN STORAGE POSITION M10 SOC. HD. SCREW Ø32 H Ø36 TRAVEL BROKEN PINS MUST BE REPLACED PAGE: 8

9 SCREW REQUIREMENTS AND SAFETY SCREW FOR AERIAL CAM SLIDES SLIDE WEIGHT IN KGS. UP TO TO 500 TOTAL AMOUNT OF CAP SCREWS PER CAM SLIDE 6 MIN. 10 MIN. 500 TO MIN. MINIMUM OF 4 ADDITIONAL SCREWS REQUIRED FOR EACH ADDITIONAL 320 KGS. (700 LBS.) OF SLIDE WEIGHT. NOTES: SCREW THREAD TO BE ENGAGED IN CAST IRON AT LEAST 1.5 X SCREW DIA. AMOUNT AND POSITION OF SCREWS ARE TO BE SHOWN ON DIE DESIGN. SAFETY SCREW FOR UPPER CAMS USE MIN. 2 SCREWS EACH CAM MAXIMUM LOAD EACH SAFETY SCREW = 1t WEAR PLATES SEE W-DX13-70M PAGE 2. 35min SECURED WITH LOCTIDE ( GREEN; HIGHLY TIDE ) MIN 13+2 SPLIT PIN, 4 x 32 DIN 94-St DIN M16-8 HEXAGON SLOTTED AND CASTLE NUT ( M16 x H ) DIN 913; OR SIMILAR HEXAGON SOCKET SET SCREW WITH FLAT POINT M16 SCREW. BS 4168 OR DIN 912 MIN. STRENGTH GRADE 8.8. and HI-COLLAR LOCK WASHER SEE WDX30-4M PAGE 10. SELF LUBE GIB PLATES SEE W-DX7-70M PAGE 10. PAGE: 10

10 SUGGESTED SPACING OF WEAR PLATES FOR BASE MOUNTED & AERIAL CAM SLIDES ALWAYS PROVIDE RIBS IN LINE OR ACROSS V-DRIVERS AND WEAR PLATES FOR SUPPORT IN UPPER AND LOWER DIE TO INSURE POWER TRANSMISSION. 300 TO WEAR PLATES UNDER CAM SLIDE CAM SLIDES OVER 900 & UP TO 1500 WIDE DRIVER WEAR PLATES DOUBLE WEAR PLATES FOR ALL BOTTOMING CAMS. AREA CHANGED RIB IN AN AREA OPPOSITE CAM DRIVERS. CAM SLIDES WITH (2) OR MORE DRIVERS- MIN. OF 1/3 OF THE DRIVER WEAR PLATE IS TO OVERLAP A SLIDE WEAR PLATE 3 WEAR PLATES UNDER CAM SLIDE CAM SLIDES OVER 1500 & UP TO 2100 WIDE DRIVER WEAR PLATE 4 WEAR PLATES UNDER CAM SLIDE PAGE: 11

11 LOCATION HOLES FOR RETRACTING SECTIONS ALL RETRACTABLE SECTIONS ARE TO BE PROVIDED WITH (2) LOCATION HOLES Ø20 H7, TO BE USED FOR COORDINATING THE PANEL SHAPE WITHIN THE CAM SLIDE. EXCEPTIONS ONLY WITH APPROVAL OF FORD DIE DESIGN OFFICE. LOCATION HOLES MUST BE ACCESSIBLE. AREA CHANGED LOCATION HOLE A A Ø20 H7 1.6 AREA CHANGED SECTION A-A PAGE: 12

12 PLACEMENT OF WEAR PLATES & GIB PLATES FOR DOUBLE CAMS PAGE: 13

13 INTERNAL GIB FOR AERIAL CAM SLIDES ADD INTERNAL GIB WHEN CASTING CAM WEIGHT IS OVER 450 Kg. OR WHEN WIDTH OF CAM SLIDE IS OVER 900mm WIDE. MOUNT INTERNAL GIB AS CLOSE TO CENTERLINE OF CAM SLIDE AS POSSIBLE. FOR LARGE CAMS PROVIDE 2 OR 3 INTERNAL GIBS, EQUALLY SPACED, 900mm MAX. SEE SKETCH. WEAR PLATE WIDTH 50 SEE W-DX13-70M PAGES MAX EQUALLY SPACED ALWAYS PROVIDE RIBS IN LINE OR ACROSS V-DRIVERS AND WEAR PLATES IN UPPER AND LOWER DIE TO INSURE POWER TRANSMISSION. 900 MAX AREA CHANGED C L OF SLIDE WIDTH OF CAM SLIDE (NOTE ON DESIGN) CONSTRUCTION SOURCE TO STAMP TAG WITH INFORMATION AS SHOWN. WARNING INTERNAL GIB MUST BE REMOVED BEFORE REMOVING CAM SLIDE. SECTION A-A PAGE: 14

14 AERIAL CAM SLIDES C L OF SLIDE A - USE (1) 65mm WIDE "V" DRIVER FOR CAM SLIDES UP TO 300mm WIDE. - "V" DRIVERS ARE REQUIRED FOR AERIAL CAM SLIDES THAT TRIM OR PIERCE. - STANDARD WEAR PLATES ARE TO BE USED FOR DRIVERS OF AERIAL CAM SLIDES THAT FLANGE. (30 MIN.) (25 MIN.) SELF LUBE GIB PLATE SEE W-DX7-70M PAGE 10. A WIDTH OF CAM SLIDE PREFERRED POSITION FOR LOCATION HOLE TO FIX CAM SLIDE IN WORKING POSITION 1.6 ALWAYS PROVIDE RIBS IN LINE OR ACROSS V-DRIVERS AND WEAR PLATES IN UPPER AND LOWER DIE TO INSURE POWER TRANSMISSION. Ø20 H7 AS AN EXCEPTION CAM DRIVER BACK-UP FOR THRUST X Z AREA CHANGED SECTION A-A "V" DRIVER SEE W-DX7-70M PAGES 1-4. "V" DRIVERS TO BE BACKED-UP IN DIRECTION OF THRUST ONLY MIN. 15 MIN. TYP MIN. TYP. VIEW X ENLARGED VIEW Z PAGE: 15

15 AERIAL CAM SLIDES OVER 300mm WIDE, WITH TWO V-DRIVERS "V" DRIVERS ARE REQUIRED FOR AERIAL CAM SLIDES THAT TRIM OR PIERCE. USE "V" DRIVERS 65mm WIDE ONLY FOR CAMS UP TO 900mm WIDE. 125mm WIDE "V" DRIVERS CAN BE USED FOR ALL WIDTH. ADD WEAR PLATE DRIVER ON CENTER LINE OF CAM SLIDE WHEN WIDTH OF SLIDE IS OVER 900mm WIDE STANDARD WEAR PLATES ARE TO BE USED FOR DRIVERS OF AERIAL CAM SLIDES THAT FLANGE. FOR CAM SLIDES UNDER 1800mm WIDE DOUBLE CAM DRIVERS CAN BE MOUNTED TO A SINGLE CASTING. (OPTIONAL CAM DRIVER CAN BE CAST INDIVIDUALLY. FOR CAM SLIDES OVER 1800mm WIDE, CAST CAM DRIVERS INDIVIDUALLY. FOR INTERNAL GIB REQUIREMENT SEE PAGE 6. FOR COMPLETE INFORMATION SEE ALSO PAGE MIN. LC OF SLIDE WIDTH OF CAM SLIDE SELF LUBE GIB PLATE SEE W-DX7-70M PAGE 10. GIB PLATES WITHOUT SCREW HOLES SEE W-DX7-40M PAGE 10. DOWELS ARE TO MAINTAIN R. TO L. ALIGNMENT OF "V" DRIVER & DRIVER CASTING. "V" DRIVER SEE W-DX7-70M PAGES MIN. PLAN VIEW OF LOWER CAM DRIVERS PAGE: 16

16 APPLICATION FOR RETURNING CAM SLIDE USING GAS SPRINGS CAM SLIDE SHOWN IN OPEN POSITION WHEN CAM WORK TRAVEL OR SLIDE WEIGHT AND ANGLE BECOME TOO GREAT FOR DIE SPRINGS, USE AIR CYLINDERS OR SELF CONTAINED NITROGEN GAS SPRINGS MOUNTED TO THE GIB PLATE. RIB BACK-UP REQUIRED GIB PLATE TO BE BACKED-UP IN DIRECTION OF THRUST. BACK-UP REQUIRED FOR GAS SPRING. FIT SHEET METAL GUARD R 20 MINIMUM R 6 MINIMUM ENLARGED VIEW "Z" DO NOT BOTTOM GAS SPRING IN CLOSED POSITION. LEAVE 10% UNUSED STROKE IN GAS SPRING. * SEE NOTE ON W-DX7-40M PAGE 22 FOR LIMITATION OF SLIDE TRAVEL SEE PAGE 5 AREA CHANGED CAM SLIDE EAR MUST BE LARGE ENOUGH TO FULLY SUPPORT THE COLLAR. 15 SUPPORT COLLAR SEE WDX7-60M PAGE 13 ADD A 15mm SUPPORT COLLAR TO SUPPORT CYLINDER ROD WHEN CAM SLIDE TRAVEL IS 125mm OR LONGER. PAGE: 20

17 APPLICATION FOR RETURNING CAM SLIDE USING AIR CYLINDER SLIDES WITH STROKE OF 70mm OR MORE OR AN APPROACH ANGLE OF 30 OR MORE WHEN CAM WORK TRAVEL OR SLIDE WEIGHT AND ANGLE BECOME TOO GREAT FOR AIR CYLINDERS, USE SELF CONTAINED NITROGEN GAS SPRINGS MOUNTED TO THE GIB PLATE. RIB BACK-UP REQUIRED COUPLING PLATE SEE WDX7-60M PAGE 17 COUPLING NUT SEE WDX7-60M PAGE 18 LOCATE, DRILL & REAM DOWEL IN CYLINDER FEET AT ASSEMBLY (4) HOLES. AIR CYLINDER FULL STROKE FIT SHEET METAL GUARD 5 MIN. SLIDE STROKE 10 MIN. AIR CYLINDERS SEE WDX35-70M PAGES 1 THRU 7 THE FULL STROKE OF THE AIR CYLINDER MUST BE 15mm MIN. LARGER THAN THE STROKE OF THE SLIDE. AREA CHANGED * SEE NOTE ON PAGE 11 FOR CAM BUFFER SET-UP SEE PAGE 5 SLIDE STROKE SLIDE RETURN BY AIR CYLINDER MUST BE PROVIDED WITH AIR RESERVOIRS WITH A TOTAL CAPACITY OF TWICE THAT OF THE TOTAL CAPACITY OF THE RETRACTION CYLINDERS. USE AIR RESERVOIR WDX35-70M PAGE 8 PAGE: 21

18 APPLICATION FOR RETURNING CAM SLIDE USING COIL SPRINGS (FOR SLIDES THAT TRAVEL LESS THAN 70mm STROKE AND AN APPROACH ANGLE LESS THAN 30 ) WHEN CAM WORK TRAVEL OR SLIDE WEIGHT AND ANGLE BECOME TOO GREAT FOR DIE SPRINGS, USE AIR CYLINDERS OR SELF CONTAINED NITROGEN GAS SPRINGS MOUNTED TO THE GIB PLATE. FOR CAM RETURN BRACKET ASSEMBLY SEE: W-DX7-70M PAGES 5 THRU 9. FIT SHEET METAL GUARD STROKE INITIAL COMPRESSION WELD SPRING RETAINING PIN * SEE NOTE FOR CAM BUFFER SET-UP SEE W-DX7-40M PAGE 24 AREA CHANGED STROKE * NOTE: ORDER GIB PLATE WITHOUT SCREW HOLES WHEN DIE SPRINGS, AIR CYLINDER OR GAS SPRING IS MOUNTED TO GIB PLATE. CONSTRUCTION SOURCE TO DRILL APPROPRIATE AMOUNT OF SCREW HOLES AND COUNTERBORE WHERE NECESSARY. PAGE: 22

19 RETRACTION BY SPRINGS (USING SPRING RETAINERS & SPACER TUBES) FIT SHEET METAL GUARD STROKE OF SPRING SPRING RETAINER SEE W-DX14-70M PAGE 3. SPACER TUBE SEE W-DX14-70M PAGE 2. BRACKETS TO BE DESIGNED FOR THE APPLICATION AS REQUIRED. FOR CAM BUFFER SEE W-DX7-40M PAGE 24 AREA CHANGED STROKE OF SPRING NOTE: USE CAM RETURN BRACKET ASSEMBLY (W-DX7-40M PAGE 22) FOR SLIDES THAT TRAVEL LESS THAN 70 mm. PAGE: 23

20 LIMITATION OF SLIDE TRAVEL STOP MUST BE SHOULDERED AND SHOULD BE REMOVABLE WITH SLIDE IN RETURNED POSITION. FIT SHEET METAL GUARDS TO AVOID FINGER TRAPS WHERE NECESSARY. THE GAP BETWEEN GUARD AND SHOE MUST NOT EXCEED 4mm. THE METHOD SHOWN BELOW IS PREFERRED. CONSTRUCTION SOURCE MUST SHIP SLIDE SET-UP BLOCKS WITH THE DIE. SLIDE SLIDE SET-UP BLOCKS ARE TO BE ORDERED IN THE STOCK LIST. SEE W-DX7-60M PAGE REF. * DIMENSION MUST APPEAR ON DESIGN. 12 MIN MIN. REF. 30 TRAV REF TRAVEL 10 4 MAX. 30 MIN. "X" CAM STOP BLOCK SEE W-DX7-60M PAGE 16 CAM BUFFERS SEE W-DX7-60M PAGE 15 BUFFER SUPPORT BLOCK SEE W-DX7-60M PAGE 16 4 MAX. CLEARANCE ALL AROUND SHEET METAL GUARD VIEW "X" PAGE: 24

21 HOLDBACK SPRING FOR SLIDES ALL SLIDES RETURNED BY AIR CYLINDERS AND WORKING ON AN ANGLE OF 5 OR MORE ARE TO BE PROVIDED WITH HOLD BACK SPRINGS. STROKE AND FORCE OF HOLDBACK SPRINGS ARE TO BE CALCULATED TO OBTAIN A MINIMUM OF 50mm CLEARANCE BETWEEN WORK SURFACES WITH AIR SUPPLY DISCONNECTED AND CAM FALLING UNDER GRAVITY. EXAMPLE 1 50 MIN. 50 MIN. SPRING TRAVEL HOOK PANEL STRIPPER PAGE: 25

22 GUIDE POSTS & BUSHINGS FOR LARGE CAM SLIDE PADS SEE ALSO WDX07-40M PAGE 31 GUIDE POST SEE W-DX13-70M PAGE 8 GUIDE POST BUSHING SEE W-DX13-60M PAGE 8 CAM SLIDE PAD AREA CHANGED TOE CLAMP SEE W-DX13-60M PAGE 10 PREFERRED METHOD CAM SLIDE CAM SLIDE PAD ALTERNATE METHOD PAGE: 30

23 CAM STRIPPER PAD RETAINERS IF THERE IS THRUST ON PAD WORK ACCORDING METHOD SHOWN ON PAGE 19. FOR SPECIAL PAD RETAINER PINS USED WITH AERIAL CAM DESIGN SEE W-DX14-4OM PAGE 5 VERSION 1: USE PREFERED. USE IN COMBINATION WITH GUIDE POSTS ACCORDING WDX07-40M Page 30 TUBES TO BE ALL SAME LENGTH SLIDE H H U S H PAD AREA CHANGED DIE IN CLOSED POSITION VERSION 2: COMBINED RETAINER AND GUIDE ONLY TO USE IF NOT ENOUGH ROOM FOR GUIDE POSTS ACCORDING WDX07-40M Page 30 TRAVEL PAD THIS DIMENSION MUST BE GREATER THAN INITIAL COMPRESSION OF SPRING. H7 H7 Df6 10 SPRING SIZE GUIDE PIN DIAMETER D SLIDE CAST CUTTING SECTION HARDENED STEEL PAGE: 31

24 CAM PAD THRUST PLATES PAD SIDE THRUST PLATE HARDENED STEEL PLAN VIEW PAD TOP THRUST PLATE MILD STEEL TUBE HARDENED STEEL 15 MIN. TRAVEL +5 SPRING ASS'Y AS SHOWN ON PAGE 31. SLIDE M10 MIN. SOC. HD. SCR. AREA CHANGED PAGE: 32

25 LOCKING OF TRIM BUCK AND CLEARANCE FOR PAD A A ALTERNATE LOCATION PREFERRED LOCATION FOR ACCESSIBILITY CAM TRIM WITHOUT BALANCE BLOCKS x METAL THICKNESS CAM TRIM WITH BALANCE BLOCKS CLEARANCE mm BUCK UPPER PAD TRIM STEEL TRIM STEEL AREA CHANGED TRIM STEELS ARE TO BE KEYED FOR MATERIAL ABOVE LIMIT CURVE SECTION A-A RESULTING FORCE CAM WORKING DIRECTION USE SINGLE WEAR PLATES. LOCKING CLEAT TRIM BUCK TO BE LOCKED IF TRIM EXCEEDS 500 mm² (MATERIAL THICKNESS X LENGTH) IF DIRECTION OF CAM IS NOT HORIZONTAL USE RESULTING FORCE ONLY AND INCREASE THE TRIMMED AREA. ( THE FORCE IS DIRECTLY PROPORTIONAL TO THE TRIMMED AREA). PAGE: 33

26 BUCK LOCKING FOR FLANGING CAM SLIDES WITH CLEARANCE FOR UPPER PAD CAM FLANGE WITHOUT BALANCE BLOCKS x METAL THICKNESS UPPER PAD CAM FLANGE WITH BALANCE BLOCKS CLEARANCE mm UPPER PAD 30 min. BUCK SLIDE FLANGE STEEL LOCK BUCK WITH OVERLAP BY CAM SLIDE IF THE SLIDE IS DESIGNED WITHOUT A STRIPPER, SPRINGS WITH THE REQUIRED STRIPPING FORCE ARE TO BE FITTED BETWEEN THE NOSE OF SLIDE AND BUCK IN ADDITION TO THE SLIDE RETURN SPRINGS OR CYLINDERS. UPPER PAD α PAD ON SLIDE REQUIRED ONLY IF ANGLE " α " IS LESS THAN 30. FOR OUTER PANELS: CONTACT FORD DIE DESIGN OFFICE. PROVIDE CLEARANCE FOR UPPER PAD IN DIE CLOSE POSITION WITHOUT PANEL. AREA CHANGED UPPER PAD BUCK SLIDE FLANGE STEEL PAGE: 35

27 AERIAL CAM FLANGING CORNERS TRANSITION OF FLANGINGS WHERE VERTICAL AND CAM FLANGING IS COMBINED IN A DIE, THE METHOD SHOWN ON SKETCHES BELOW IS TO BE USED. EXAMPLE: AERIAL CAM FLANGING CORNERS THE FLANGE STEELS ON THE SLIDE COMMENCE FLANGING, FOLLOWED BY THE VERTICAL FLANGE STEELS. SIDE ELEVATION OF FLANGE STEELS SHOWN AT INITIAL CONTACT. MANDATORY: (SHOWN ON DESIGN). SIDE ELEVATION OF FLANGE STEELS SHOWN IN CLOSED POSITION. CAM STEEL UPPER PAD DIRECT STEEL RETRACTABLE SLIDE A B B RETRACTABLE SLIDE A SECTION A - A SECTION B - B TO AVOID SPRING- BACK THE CAM FLANGING STEELS SHOULD ENTER IN ADVANCE AT THE ENDS OF THE FLANGING LINE. (METHOD USED FOR OUTER SKIN PANELS) PAGE: 36

28 DOUBLE CAM OPERATED FROM TWO SIDES RETRACTABLE CAM DRIVER MUST DWELL A MINIMUN OF 40mm BEFORE FLANGING CAM CONTACTS PART. WEAR PLATES TO OFFSET THRUST FROM CAM PAD. CAM DWELL WEAR PLATE SEE W-DX7-60M PAGE 9. SOCKET HEAD CAP SCREWS. BS 4168 OR DIN 912 MIN. STRENGTH GRADE 8.8. PROVIDE DOWELS SEE W-DX30-4M PAGE 4. AIR CYLINDER COUPLING SEE W-DX7-60M PAGES 17 & 18. INTERLOCK TO PREVENT FLEXING. BLOCK FOR CYLINDER BACK-UP & SUPPORT. FOR ACCURATE PANEL LOCATION, AIR CYLINDER IS TO PUSH SLIDE INTO HOME POSITION BEFORE PANEL IS LOADED. PAGE: 40

29 DOUBLE CAM OPERATED FROM TWO SIDES PROVIDE BALANCE BLOCKS, W-DX13-70M Page 9, TO PREVENT THE CAM PAD FROM COCKING DUE TO OFF CENTER CONTACT OF THE PAD WITH THE PANEL. PROVIDE WEAR PLATES ON TOP OF CAM PAD WHEN THE PANEL SHAPE, SUCH AS FENDERS, TENDS TO FORCE THE PAD UPWARD. AREA CHANGED UPPER PAD PAD TRAVEL MIN. Ø20 H7 AREA CHANGED 1.6 ENGLARGED VIEW FROM PAGE 40 DIMENSION MUST APPEAR ON DESIGN SELF CONTAINED GAS SPRING LOCATION HOLE TO FIX CAM SLIDE IN WORKING POSITION PAGE: 41

30 AERIAL CAM WITH SLIDE MOUNTED IN UPPER PAD USE ONLY WITH PERMISSSION OF FORD DIE DESIGN OFFICE LOCATING CONE ASSEMBLY (4) REQUIRED. NOTE: USE GUIDE POST AND BUSHINGS TO GUIDE PAD. LOCATING CONES ARE REQUIRED FOR FINAL PAD ALIGNMENT WHEN CAM SLIDE IS MOUNTED IN UPPER PAD. DO NOT PROVIDE LOCK-OUT PROVISIONS (PINS) FOR UPPER PAD. CAM SLIDES MUST BE EQUIPPED WITH POSITIVE RETURN. PAGE: 42

31 PULLED CAMS FOR "V" DRIVER SETS SEE W-DX7-70M PAGES 1-4 PREFERRED POSITIV RETURN USE ONLY FOR SMALL PIERCING CAMS AREA CHANGED PAGE: 44

32 REVERSE AERIAL CAM SLIDE DO NOT PROVIDE LOCK-OUT PROVISIONS FOR UPPER PAD WHEN A REVERSE AERIAL CAM SLIDE IS USED. LOCK-OUT OF UPPER PAD WOULD RESULT IN A COLLISION WITH THE RETRACTING REVERSE CAM AND SEVERE DIE DAMAGE. RETURN DIRECTION OF REVERSE AERIAL CAM SLIDE IN RELATION TO PUNCH SHOE AND UPPER PAD. MUST BE PARALLEL REVERSE AERIAL CAM IN PUNCH SHOE DO NOT LOCK OUT UPPER PAD PROVIDE A SPECIAL ALUMINUM TAG AT FRONT & REAR OF PUNCH SHOE. PAGE: 45

33 AERIAL CAM WITH RETRACTABLE SECTION SOLID PANEL SUPPORT REQUIRED BELOW PAD AS SHOWN OR AT EACH END BEYOND THE RETRACTABLE SLIDE TO PREVENT PANEL FROM COLLAPSING. RETRACTABLE MUST BE REMOVABLE FROM THIS END. NOTE: (TO APPEAR ON DESIGN) THESE SURFACES TO BE PARALLEL. PAD SEE W-DX7-40M PAGE 7 BUCK OPEN 5 MIN..4 CLEAR NOTE ON DESIGN: TOOL & DIE TO FINAL CHECK NUMERICAL CONTROL ENGINEERING DATA FOR ALL WORKING ANGLES AND PROVIDE A WIPE CONDITION WITH AN ALLOWANCE FOR SPRING BACK PRIOR TO MACHINING DETAILS. REVIEW ANY DISCREPANCIES WITH METAL STAMPING ENGINEERING PERSONNEL. STANDARD WEAR PLATES ARE TO BE USED FOR DRIVERS OF AERIAL CAM SLIDES THAT FLANGE. TRAVEL OF SLIDE MUST CLEAR PAD FOR REMOVAL. SEE W-DX7-40M PAGE 6 CAM MOUNTING SURFACE IS PART OF THE DIE SHOE CASTING. PAGE: 46

34 DROP SLIDE DRIVEN & BACKED-UP WITH A SAW TOOTH SLIDE A BOTTOMING BLOCK SEE W-DX12-40M PAGE 13 DROP SLIDE ADAPTOR A SEE PAGE 49 PROVIDE KEYS OR CASTING BACK-UP FOR ADAPTOR. THIS TYPE OF CONSTRUCTION PROVIDES SOLID BACK-UP FOR DROP SLIDE. SECTION THRU C/L OF DIE RIGHT TO LEFT PAGE: 47

35 SAW TOOTH SLIDE FOR FILLING CAM SEE ALSO W-DX7-40M PAGE 49 PROVIDE SEPARATE AIR HEADER BLOCK FOR EACH AIR CYL. GAS SPRING GAS SPRING QUICK EXHAUST VALVE WITH SILENCER SEE WDX35-40M PAGE 17 FILLING CAM MATERIAL: EN-JS 1060 SAW TOOTH SLIDE STOP POSITION ON PLATE 4 STROKE THE CLOSED POSITION OF FILL CAM WILL BE CONTROLED BY SENSOR. WDX19-40M PAGE 5 STOP BLOCK 10 STROKE ADD GAS SPRING FOR ACCELERATION TO RETURN POSITION VIEW "Z" CAM DWELL WEAR PLATES SEE W-DX7-60M PAGE 9 ENLARGED DETAIL CYL. STROKE 80 min. 5 5 "Z" PROVIDE SUPPORT IF NECESSARY CYL. STROKE 80 min. 70 min STROKE SAW TOOTH SLIDE. AIR CYLINDER MUST HAVE 5mm UNUSED STROKE IN FORWARD AND RETURN POSITION. CAM BUFFER SEE W-DX7-60M PAGE 15 ONLY ON REQUEST OF FORD DIE DESIGN PAGE: 48

36 DROP SLIDE DRIVEN & BACKED-UP WITH A SAW TOOTH SLIDE ALSO SEE W-DX7-40M PAGE 21 THE CAM DRIVER INSURES THAT THE CAM SLIDES ARE IN PROPER POSITION. USE ALWAYS IF DIE DAMAGE IS POSSIBLE. IF NOT SEE W-DX7-40M Page 21. PROVIDE SUPPORT IF NECESSARY CAM DWELL WEAR PLATES SEE W-DX7-60MPAGE 9 RETAINER PLATE CYLINDER STROKE 80min DROP SLIDE (FILLING CAM) 5 5 SAW TOOTH SLIDE ADD GAS SPRING ACCELERATOR TO RETURN POSITION WITH WORKING STROKE 10mm. AIR CYLINDER IS TIMED TO BRING CAM SLIDES INTO "HOME" POSITION BEFORE PANEL IS LOADED. SECTION A-A PAGE: 49

37 DIE MOUNT CAM SLIDE UNIT APPLICATION CAM PIERCE DIE MOUNT CAM SLIDE UINTS SEE WDX7-62M SECTION SPACER PLATE SEE WDX7-62M PAGE 49. UNIT TO BE BACKED-UP IN DIRECTION OF THRUST ONLY. UPPER DRIVER DOES NOT REQUIRE BACK-UP AS LONG AS THE THRUST IS SELF-CONTAINED WITHIN THE UNIT. ALSO THE DRIVER MUST BE ENGAGED 20 TO 25mm PRIOR TO THE WORK BEING DONE. PAGE: 52

38 AERIAL CAM SLIDE UNIT APPLICATION KEYS ARE REQUIRED ON CENTERLINE OF STANDARD AERIAL CAM SLIDE UNIT. ALTERNATIV KEY TO BACK-UP IN DIRECTION OF THRUST. PLAN VIEW OF CAM SLIDE PREFERE BACK UP BEHIND CAM SPACER PLATE SEE WDX7-62M PAGE 49. AERIAL CAM SLIDE UNIT SEE WDX7-72M SECTION UNIT TO BE BACKED-UP IN DIRECTION OF THRUST. PAGE: 53

39 CALCULATION OF LOAD STROKE OF THE METRIC AERIAL CAM COMPONENTS. PAGE: 54