WORLDWIDE DIE DESIGN AND CONSTRUCTION SPECIFICATIONS EUROPE ONLY NUMERICAL INDEX DESIGN STANDARDS FOR ROLLFEED RF400 DAGENHAM

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1 NUMERICAL INDEX UNIT PAGE ITEM SUBJECT 8M 5 GENERAL INFORMATION 5. START OF DESIGN 5.2 CONSTRUCTION OF DIES 5.3 DIE FIXING 5. SHUT HEIGHT 5.5 MATERIAL. GUIDING UPPER-LOWER DIE. THRUST UPPER-LOWER DIE.8 BOLTING.9 SAFETY AREAS.0 STOP/BALANCE BLOCKS. GAS SPRINGS.2 CAMS.3 PART LOCATION. PART CONTROL.. PIERCE NUTS SKETCH 8 SKETCH 9 SKETCH 0 SKETCH 0.5 AIR CONNECTION 0. PRESS INFORMATION 2 TRIM AND PIERCE 2. TRIMMIMG 2.2 PIERCING 2.3 SCRAP OFFAL 3.0 SPECIAL HINTS 3. GENERAL INFORMATION MAI 2005 SECTION 08-8M PAGE

2 . GENERAL INFORMATION. WORLDWIDE DIE DESIGN AND. START OF DESIGN. DO PRESS FORCE CALCULATION FOR EACH PART. DO FEA FOR EACH PART. DO PART CONNECTION IN CENTER OF GRAVITY. IF COIL GUIDING IS NECESSARY, TAKE ROLLS SEE WDX8-0M PAGE. DO ALL DEPRESSIONS IN THE FIRST FORM OPERATION TO AVOID DEFORMING THE RIM STRIP. DO LOCATION HOLES AS FLANGE HOLE IF POSSIBLE. WEIGHT FOR UPPER AND LOWER DIE MAX. 3 TONS; TOGETHER MAX. 5 TONS! PART EXIT IN FLOW DIRECTION. NO ELECTRIC BELT CONVEYOR. FULL TRAVEL OF PRESS IS USABLE FOR WORKING TRAVEL..2 CONSTRUCTION OF DIES. THE CONSTRUCTION OF ALL DIES IS: M (METRIC). SEPERATE THE DRAW STATION IN ANY CASE. IF ALL OTHER OPERATIONS SEGMENTED, DECIDED IN THE SIMULTANEOUS ENGINEERING..3 DIE FIXING. BOLTING AREA: 50mm THICK, AREA 00 X 00mm. QUICK-CLAMPING IN UPPER DIE IS MOVABLE IN EACH SLOT. IN LOWER DIE LET MIN. 50mm CLEARANCE ABOVE THE QUICK-CLAMPING AREA. LOCATION ACC. 5-0M, PAGE 33 (2 SLIDING BOLSTER). POSITION SEE PRESS SHEET.. SHUT HEIGHT. STANDARD SHUT HEIGHT IS 0mm + / -3 STANDARD COIL HEIGHT IS 380mm..5 MATERIAL. UPPER AND LOWER DIES ARE TO BE MADE FROM EN-JS030. IF BOTTOMING OUT MAKE THEM EN-JS050. AFTER CONSULTING THE DIE DESIGN GROUP, THE DIE CAN BE DONE IN STEEL: SEE ATT., WHICH SHOWS SECTION AA AND ALTERNATIVE RF-250. SHUT HEIGHT RF-00 TO RF-250 DAGENHAM ATT. TO RF-00 DAGENHAM DESIGN STANDARDS RF WITH ADJUSTMENT RF MAI 2005 SECTION 08-8M PAGE 5

3 . GUIDING UPPER AND LOWER DIE. DIES WILL BE GUIDED BY POSTS 3-0M, PAGE. GUIDE POSTS TO BE FITTED IN THE UPPER DIE. ALL GUIDE BUSHES TO 3-0M, PAGE 8.. THRUST UPPER-LOWER DIE. ALL THRUSTS ARE TO BE HEELED..8 BOLTING. ALL BOLTS WITHIN DIE ARE TO BE SECURED WITH SPRING WASHERS..9 SAFETY AREAS. PROVIDE SAFETY AREAS TO 2-0M, PAGE 22. ADD ALUMINUM PLATE WITH PITCH AND SHUT HEIGHT INFORMATION..0 STOP/BALANCE BLOCKS. STOP/BALANCE BLOCKS 3-0M, PAGE 5 AND ARE TO BE ATTACHED TO THE UPPER DIE. FOR DRAW DIES USE BLOCK FOR ALL OTHER DIES 3-0-0, THESE BLOCKS HAVE TO BE MOUNTED IN THE LOWER DIE.. GAS SPRINGS..2 CAMS. GAS SPRINGS ALLOWED. COIL LIFTER ONLY WITH GAS SPRINGS. IN DRAW DIE TAKE GAS SPRINGS AS NEAR AS POSSIBLE TO THE DRAW PUNCH. CAM PIERCING ALLOWED, BUT NOT WITH SPRING RETURN, ONLY WITH GAS SPRING BECAUSE OF SPEED..3 PART LOCATION. COIL LIFTER HAS TO BE OVAL AND CHAMFERED AT FRONT. COIL LIFTER HAS TO BE PLACED OUT OF TRAPPING POINTS AND NOT IN CUTOUT AREAS. ALL COIL LIFTERS HAVE TO BE PUSHED DOWN BY THE PAD. TO PREVENT THE PAD FROM TILTING, SUPPORT THE PAD WITH A PIN AGAINST THE LOWER DIE (8-0M, PAGE 5). PILOT PINS REALIZE PART LOCATION. PILOT PIN FOR COIL: LENGTH,5 PLUS 8mm CONUS; DIAMETER: 0-0,, CHANGEABLE IN THE PRESS. LOWER DIE MUST BE CLEARED IN THIS AREA (8-0M, PAGE 9). FIRST PILOT PIN BE ONE PITCH AFTER FIRST PIERCING AND THEN IN EACH OF THE FOLLOWING STATIONS ALWAYS IN THE SAME HOLE. ADD SPRING PLUNGER AT SIDE (MIN 2XS). MAKE HOLE FOR PILOT PIN AS A FLANGE HOLE FOR THIN MATERIAL IF POSSIBLE. IF THERE ARE 2 OPPOSITE HOLES, ONE FLANGE HOLE IS ENOUGH.. PART CONTROL. MAKE PITCH CONTROL AS A SWING BLOCK (SEE PICTURE PAGE ), INSTALLED ONLY IN FRONT OF INCOMING COIL. PITCH CONTROL HAS TO BE VISIBLE FOR THE WORKER. IF NECESSARY USE CONTROL-DIODE AS SHOWN IN THE ELECTRIC SKETCH. PITCH CONTROL HAS TO BE 20mm HIGHER THAN COIL. PITCH WILL NOT BE CONTROLLED BY THE PRESS. ELECTRIC SHEET SEE SKETCH ON PAGES 8, 9, AND 0. ALSO 9-0M, PAGE. ELECTRIC CONNECTION BOX RIGHT REAR. ADDITIONAL TO THE PITCH CONTROL USE INDUCTIVE SENSOR AS A REAR PART CONTROL. SEE 9-0M, PAGE 2/3. UNLOAD CONTROL SEE SKETCH ON PAGE 8... PIERCE NUTS. WORLDWIDE DIE DESIGN AND IF PIERCING NUTS ARE USED: USE ADDITIONAL PITCH CONTROL ONE STOP BEFORE DOING THE NUTS. SEE SKETCHES ON PAGE 9 AND 0. (WINDOW OF GUARD HAS TO BE MODIFIED). ATTENTION: IN THE BEGINNING OF THE DIE CONSTRUCTION, CONTACT THE MANUFACTURER OF THE PIERCE NUT AUTOMATION AND THE DIE DESIGN GROUP. MAY 2005 SECTION 08-8M PAGE

4 SKETCH : PITCH CONTROL AS A SWING BLOCK. SPRING CALPIER WITH INDUCTIVE SQUARE SENSOR SEE PAGE 8. FOR THE CONSTRUCTION AND DETAILS OF THE SWING BLOCK, PLEASE CONTACT DIE DESIGN GROUP. MAY 2005 SECTION 8-8M PAGE

5 ELECTRIC CIRCUIT 09-ZNE-EA-0003 GENERAL LOWER DIE SKETCH 2: A 2 3 HAN 5 8 FRONT A PITCH CONTROL BEGINNING COIL. TRANSPORT CONTROL END OF COIL. UNLOADING CONTROL RIGHT/LEFT FOR FLAT PARTS. OR FOR EXTREME FORMED PARTS. ELECTRICAL BOX WITH POL HARTING HAN m CONNECTION CABLE WITH ANGLE PLUG, PLUG CONNECTOR PITCH CONTROL BEGINNING COIL: SENSOR AND HOLDER SPRING-CALIPER 2mm TRAVEL MAY 2005 SECTION 8-8M PAGE 8

6 LOWER DIE WHEN PIERCE NUTS USED SKETCH 3: 2 3 A FRONT 2 3 / A PITCH CONTROL BEGINNING COIL. PART CONTROL ONE STEP BEFORE DOING PIERCE NUTS. PART CONTROL ONE STEP BEFORE DOING PIERCE NUTS. TRANSPORT CONTROL END OF COIL. UNLOADING CONTROL RIGHT/LEFT FOR FLAT PARTS. OR FOR EXTREME FORMED PARTS. ELECTRICAL BOX WITH POL. HARTING HAN. 5m CONNECTION CABLE WITH ANGLE PLUG, PLUG CONNECTOR PITCH CONTROL: SENSOR AND HOLDER SPRING-CALIPER 2mm TRAVEL MAY 2005 SECTION 08-8M PAGE 9

7 SKETCH : WORLDWIDE DIE DESIGN AND UPPER DIE WHEN PIERCE NUTS USED TO PROXIMITY SENSOR IN PIERCE HEAD ( RELEASE SIGNAL WHEN A FASTENER IS PLACED IN THE PIERCE HEAD ). PERMANENT COMPRESSED AIR ELECTROMAGNETIC VALVE PLUG FOR HAN PROXIMITY SENSOR PROXIMITY SENSOR PIERCE HEAD Changed Area PIERCE HEAD PIERCE HEAD LOCKING DECEMBER 200 FRONT OF PRESS PLUG CONFIGURATION IN UPPER DIE IN LOWER DIE = +2V DC = +2V DC 2= 0V DC 2= 0V DC 3= NUT 3= START OF STRIP = NUT 2 = END OF STRIP 5= NUT 3 5= STRIP BEFORE STEP = NUT = STRIP BEFORE STEP 2 = = 8= PLUG CONTROL 8= 9= VALVE LOCK 9= 0= VALVE RELEASE 0= PLUG CONTROL = VALVE LOCK 2 = 2= VALVE RELEASE 2 2= 3= 3= CODING 8 = = CODING 5= 5= CODING 2 = = CODING ENQUIRIES TO ELECTRICAL ENGINEERING. NY/FF-.5 AIR CONNECTIONS. CONTROLLED AIR OUTLETS AT RIGHT REARS, AIR RIGHT REAR.. PRESS INFORMATION. THE PRESS INFORMATION SHEET FOR THE ROLLFEED RF 00 IS SHEET NO. 3. THE DIRECTION OF SCRAP SHEDDING HAS TO BE INDICATED BY AN ARROW. SECTION 8-8M PAGE 0

8 Changed Area 2. TRIM AND PIERCE. 2. TRIMMING. CUTTING AND FORMING NOT INTEGRATED IN ONE STEEL. ADD SPRING PLUNGER IN ALL LARGER CUTTING/FORMING STEELS. REQUEST FOR IGES DATA FOR ALL CUTTING/FORM STEELS DEMANDED BY DIE DELIVERING. MULTIPLE SECTION MATRIX PREFERRED, WITH ONLY ONE HOLE PER STEEL IF POSSIBLE. 2.2 PIERCING. PUNCH LENGTH 00mm. USE STANDARD PUNCH RETAINER AND BUSHES INSTEAD OF STEEL PLATES AND INSERTS (SEE 5-0M). PIERCE SPC HOLES AFTER DOING THE LAST FORMIMG. 2.3 SCRAP OFFAL. MAKE MATRIXES FREE UNTIL THE SCRAP WILL DEFINETELY FALL. SCRAP TO FALL AWAY IN TABLE OPENINGS. LENGTH OF SCRAP MAX. 20mm, IF PART IS FLAT: 500mm. 3.0 SPECIAL HINTS. 3. GENERAL INFORMATION. DO CAST OPENINGS FOR THE FORK LIFT IN THE BOTTOM OF THE LOWER DIE. FOR OLD DIES: ONE RISER FOR PUNCH 00mm THICK. TWO RISERS FOR BED 5mm THICK. DECEMBER 200 SECTION 8-8M PAGE END