The architecture of the Salvagnini press is unlike any other NC punch press on
the market. It is an aggregate of independently programmable punch presses in ...
SALVAGNINI STYLE TOOLING • TYPE III TOOLING • TYPE 70 & 90 TOOLING • FULLY GUIDED ASSEMBLY • PU & PB FORMING ASSEMBLIES
• FORMING TOOLS
TOOLING OVERVIEW
1
SALVAGNINI PRODUCT LINE
CONTENTS… • TOOLING OVERVIEW SLUG FREE ® DIE OPERATION…………….2 SALVAGNINI TYPE III TOOLING SYSTEM..3-4
CARD GUIDE…………………………….15 COUNTERSINK…………………………..16 EMBOSSING…………………………17-18 EMBOSS - BEADING…………………19-20 EXTRUSION - PRE-PIERCE AND FORM..21-22 KNOCKOUT………………………….23-24 LANCE AND FORM…………………..25-26 LOUVER……………………………..27-28 SHEARBUTTON………………………….29 SHEETMARKER™……………………….30 THREAD FORM………………………31-32
• FEATURES • APPLICATIONS PUNCHES, STRIPPERS AND DIES DIE CLEARANCE AND HOLE QUALITY…..33 6 mm……………………………………5 CALCULATING PUNCHING FORCE……….34 10.5 mm………………………………..5 33 mm………………………………….6 60 mm AUTO INDEX…………………….7 60 mm BLANK HOLDER…………………7 70 x 90 mm TYPE 70 (3.1)……………..8 70 x 90 mm TYPE 90 (3.0)……………..8 90 x 90 mm TYPE 90 (3.0)……………..8 FULLY GUIDED PERFORATING ASSEMBLY…9 ASSEMBLY INSTRUCTIONS…………….10
• SPECIAL SHAPES SPECIAL SHAPES……………………….11 APPLICATIONS………………………….12
• SPECIAL ANGLE SETTINGS………….12 • CLUSTERS……………………….…13-14 • PUNCHING FORCE FORMULA……….14
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
aaaa SLUG FREE® DIE OPERATION
2
TOOLING OVERVIEW
aa Penetration begins and metal deforms into the entry taper
Material begins to fracture at stress points
Pressure point constricts slug
Punch stroke bottoms out as slug squeezes past pressure point
Punch retracts and slug is free to fall down and away through exit taper
Slug Free® Die Components
2
A
3
1
B
C
D
6
D
4
5
C
7
1. 2. 3. 4. 5. 6. 7.
Punch Stripper Material Slug Free® Die Slug Grind Life Entry – Constricting Taper 8. Pressure Point 9. Exit – Relief Taper
B
A
8
9
Hole/Slug Geometry A. B. C. D.
Rollover Burnish Fracture Burr
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
SALVAGNINI PRODUCT LINE
Slug fractures away from sheet
Material held securely by stripper before punch makes contact
3
aa
SALVAGNINI TYPE III TOOLING SYSTEM
TOOLING OVERVIEW
a
THE SALVAGNINI PUNCHING SYSTEM
SALVAGNINI PRODUCT LINE
SALVAGNINI POSITIONS P AND PR 12 TON
The architecture of the Salvagnini press is unlike any other NC punch press on the market. It is an aggregate of independently programmable punch presses in one punching head. This allows for the modular nature of the punching tools which can be unlocked hydraulically and changed quickly.
Punching operations can be programmed to occur simultaneously, performing like a cluster punch; or in sequence, so that punching and forming operations can occur within the same punching cycle. Some stations are capable of programmable rotation. With the addition of the right angle shear and external sheet rotator, Salvagnini becomes a very flexible and productive sheet metal fabricating system.
SALVAGNINI POSITIONS 1-20, 41-76 7 TON
PUNCHES
Salvagnini tool system punches are made of premium High Speed Steel which delivers incredibly long tool life under even the most extreme punching conditions. High abrasionresistance, high anti-galling properties, plus excellent hot and red hardness, means excellent punch life with little degeneration in punchedpart quality. Depending which station, punch size can be inscribed up to the dimensions of a 90mmsquare. A punch chuck is available for punch sizes 10.5mm and under. Punches can be resharpened up to .157(4.0) and dies to .060(1.5), yielding many additional spans of production. An infinite variety of special shape punches can be made to yourspecifications.
STRIPPER
The stripper is assembled into the upper cartridge.
SLUG FREE ® DIES
Are available as an option for all Type III stations.
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a
SALVAGNINI TYPE III TOOLING SYSTEM
EI EMBOSS STATIONS (OPTIONAL) Some positions can be fitted for low profile forming operations (max.height 6.5 mm) where no scrap is generated.
POSITIONS 30 - 35 BU EMBOSS OPTION Double action 8 + 7 ton presses that can be set up for forming operations. Maximum form height 16 mm where no scrap is generated. Forming tools - pages 15-32 PR OPTION Optional auto rotation 12 ton punching units that can be installed in punching positions 30-35. Punches, die and strippers to 60.0mm diameter/diagonal - page 7
Type III (H3 HEAD)
SALVAGNINI POSITIONS 21-24 26 TON
4
A wide variety of special shapes are available to a clearance of your choice, as well as standard shapes - rounds, rectangles, ovals and squares. Specify clearance as punch size PLUS clearance, NOT as clearance per side. Mate provides three options for punching corners in acute angles, reducing die wear and breakage, see special shapes page 11.
SPECIAL ASSEMBLIES
Mate special assemblies for Salvagnini complement and expand upon the capabilities of the Salvagnini punching system. Mate builds special assemblies for type III tooling featuring threadform, louver, beading, embossing, stamping, knockout and cluster punch assemblies. Special assemblies also perform slitting, shearing, multiple parts on sheet (shakeand-break) and tabbing functions.
From a drawing showing what you need to accomplish, Mate will manufacture a special assembly to your design. The forming tools pages in this catalog will help you specify your requirements. Mate will work with you in obtaining the results you want, achieving a balance between cost and effectiveness.
a
In addition to special assemblies, multiuse punch and die combinations are also available. Used in conjunction with the optional PR stations, the corner rounding, notching and quad radius tools are like several tools in one, providing greater value for your tooling dollar.
SALVAGNINI PRODUCT LINE
POSITIONS 21 - 24 Single action 26 ton presses with a maximum station size of 90 x 90mm: Punches, strippers, dies to 70 x 90mm - page 8 Punches, strippers, dies to 90 x 90mm - page 8 Punch supports for positions 21-24 - page 8 Special shapes - page 11 and 12 Cluster Punches - pages 13 and 14
DIES
TOOLING OVERVIEW
POSITIONS 1 - 20, 41 - 76 Single action 7 ton presses with a maximum tool diameter of 33mm: Punches, dies and strippers to 33.0mm diameter/diagonal - page 5 and 6 Special shapes - page 11 and 12
30
31
32
33
34
35
90 x 90
76
68
60
56
52
48
44
24
75
67
59
55
51
47
43
74
66
58
54
50
46
42
23
73
65
57
53
49
45
41
90 x 70
72
64
20
16
12
8
4
22
71
63
19
15
11
7
3
90 x 90
70
62
18
14
10
6
2
21
69
61
17
13
9
5
1
90 x 70
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
PUNCHES, STRIPPERS AND DIES
5
30
31
32
33
34
35
90 x 90
76
68
60
56
52
48
44
24
75
67
59
55
51
47
43
74
66
58
54
50
46
42
23
73
65
57
53
49
45
41
70 x 90
72
64
20
16
12
8
4
TOOLING OVERVIEW
70 x 90
22
71
63
19
15
11
7
3
90 x 90
70
62
18
14
10
6
2
21
69
61
17
13
9
5
1
Lock Screw
SALVAGNINI PRODUCT LINE
(included with Punch Chuck)
SALVAGNINI POSITIONS 1-20, 41-76 • Punches and dies are made of premium high speed steel for maximum production and minimum down time. • Punches can be resharpened up to .157(4.0) and dies up to .060(1.5), yielding many additional spans of production.
6 mm Size .030 -.236(0.8 - 6.0) ROUND ONLY
Lock Screw (included with Punch Chuck)
Insert Punch
Punch Chuck 3.189 (81.0)
VINPSO1O
.413(10.5)
Punch Chuck 3.189 (81.0)
Stripper .394(10.0)
.237-.413(6.0 -10.5) ROUND ONLY
PAPB0A* 2.362 (60.0)
.236(6.0)
10.5 mm Size Insert Punch
PAPA0A* 2.362 (60.0)
7 TON
VINPS020
Stripper .394(10.0)
S6PA0A
S6PB0A
Die .591(15.0)
Die .591(15.0)
DAPA00 Die Shim
DAPB00 Die Shim
MSP3
MSP3
Package 6 each: .004(0.1), .008(0.2), .012(0.3)
Package 6 each: .004(0.1), .008(0.2), .012(0.3)
*Add punch sizes as final digits of complete part number. 5th character represents shape.
Insert standard shape code for '_' in part number: 0 - Round 3 - Square 1 - Rectangle 4 - Single "D" 2 - Oval 5 - Double "D"
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
PUNCHES, STRIPPERS AND DIES 30
31
32
33
34
35
68
60
56
52
48
44
24
75
67
59
55
51
47
43
74
66
58
54
50
46
42
23
73
65
57
53
49
45
41
70 x 90
72
64
20
16
12
8
4
22
71
63
19
15
11
7
3
90 x 90
70
62
18
14
10
6
2
21
69
61
17
13
9
5
1
70 x 90
6
SALVAGNINI POSITIONS 1-20, 41-76 7 TON • Punches and dies are made of premium high speed steel for maximum production and minimum down time. • Punches can be resharpened up to .157(4.0) and dies up to .060(1.5), yielding many additional spans of production. • 33 mm punches and dies can be set at 0°‚ 90°, 180° and 270°.
TOOLING OVERVIEW
90 x 90
76
33 mm Size Punch 3.209 (81.5)
PAPC0A* PAPC_A
MATE 4-WAY TANG FOR 33 mm PUNCHES Punch tang is square with the same profile on all four faces. It can slide into the ram’s drive slot from any side permitting angle setting at 0°, 90°, 180° and 270°.
.394 (10.0)
Stripper
S6PC0A S6PC_A
Die .591 (15.0)
DAPC00 DAPC_0
Die Shim
MSP3 Package 6 each: .004(0.1), .008(0.2), .012(0.3)
*Add punch sizes as final digits of complete part number. 5th character represents shape.
Dimensions in inches (millimeters)
Insert standard shape code for '_' in part number: 0 - Round 3 - Square 1 - Rectangle 4 - Single "D" 2 - Oval 5 - Double "D"
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
SALVAGNINI PRODUCT LINE
UP TO 1.299(33.0) DIAMETER OR DIAGONAL
PUNCHES, STRIPPERS AND DIES
7
30
31
32
33
34
35
90 x 90
76
68
60
56
52
48
44
24
75
67
59
55
51
47
43
74
66
58
54
50
46
42
23
73
65
57
53
49
45
41
70 x 90
72
64
20
16
12
8
4
22
71
63
19
15
11
7
3
90 x 90
70
62
18
14
10
6
2
21
69
61
17
13
9
5
1
SALVAGNINI PRODUCT LINE
TOOLING OVERVIEW
70 x 90
SALVAGNINI POSITIONS 30-35 12 TON • Punches are made of premium high speed steel for maximum production and minimum down time. • Punches can be resharpened up to .157(4.0) and dies up to .060(1.5), yielding many additional spans of production.
60 mm Size
60 mm Size
Note:
AUTO INDEX
for use in Salvagnini Blank Holder style holders
angle setting required for ordering 60 mm size blank holder style
UP TO 2.362(60.0) DIAMETER OR DIAGONAL
UP TO 2.362(60.0) DIAMETER OR DIAGONAL
Punch 1.875 (47.6)
Punch 1.693 (43.0)
PAPD0A*
PAPX0A*
PAPD_A
.394 (10.0)
PAPX_A
Stripper
Stripper .276 (7.0)
S6PD0A
S6PX0A
S6PD_A
S6PX_A
.710 (18.0)
.710 (18.0)
Die
Die
D0PD00
D0PD00
D0PD_0
D0PD_0
Brush
Brush
MIS61188** (8 minimum)
MIS61188** (8 minimum)
*Add punch sizes as final digits of complete PUNCHING ORIENTATION part number. 5th character represents shape. Rectangles, ovals and any shape other **Items sold separately beyond minimum quantity. than round or
Insert standard shape code for '_' in part number: 0 - Round 3 - Square 1 - Rectangle 4 - Single "D" 2 - Oval 5 - Double "D"
square, specify orientation when ordering for positions 30 through 35.
X or 0° Y or 90°
FRONT OF PRESS
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a
PUNCHES, STRIPPERS AND DIES 30
31
32
76
68
60
24
75
67
59
70 x 90
74
66
58
23
73
65
57
70 x 90
72
64
20
22
71
63
19
70 x 90
70
62
18
21
69
61
17
34
35
52
48
44
55
51
47
43
54
50
46
42
53
49
45
41
16
12
8
4
15
11
7
3
14
10
6
2
13
9
5
1
30
SALVAGNINI POSITIONS 21-24 26 TON Type 70
Punches can be resharpened up to .157(4.0) and dies up to .060(1.5), yielding many additional spans of production
Type 90
33
34
35
68
60
56
52
48
44
24
75
67
59
55
51
47
43
74
66
58
54
50
46
42
23
73
65
57
53
49
45
41
70 x 90
72
64
20
16
12
8
4
22
71
63
19
15
11
7
3
90 x 90
70
62
18
14
10
6
2
21
69
61
17
13
9
5
1
Type 70 (3.1) 70x90 mm Size
Type 90 (3.0) 70x90 mm Size
Type 90 (3.0) 90x90 mm Size
2.755 x 3.543(70.0 x 90.0)
2.755 x 3.543(70.0 x 90.0)
3.543 x 3.543(90.0 x 90.0)
Punch Support
Punch Support
Punch
.432 (11.0)
32
76
8
70 x 90
VSPES
1.181 (30.0)
31
90 x 90
VSPES
Punch Support
VSPFS
Punch
Punch
PAPE0A*
PAPE0A*
PAPF0A*
PAPE_A
PAPE_A
PAPF_A
Stripper
Stripper
Stripper
a
SALVAGNINI PRODUCT LINE
1.775 (45.1)
33
56
TOOLING OVERVIEW
70 x 90
.669 (17.0)
Stripper and die come with brushes already installed. Order replacements separately.
S6QE0A
S6PE0A
S6PF0A
S6QE_A
S6PE_A
S6PF_A
Die
Die
D2QE00
D2PE00
D2PF00
D2QE_0
D2PE_0
D2PF_0
Brush
MIS61188**
(8 minimum)
PUNCHING ORIENTATION
Dimensions in inches (millimeters)
Die
Rectangles, ovals and any shape other than round or square, specify orientation when ordering X or 0° for positions 21 through 24. Y or 90° FRONT OF PRESS
Brush
MIS61188**
(8 minimum)
Brush
MIS61188**
(8 minimum)
*Add punch sizes as final digits of complete part number. 5th character represents shape. **Items sold separately beyond minimum quantity.
Insert standard shape code for '_' in part number: 0 - Round 3 - Square 1 - Rectangle 4 - Single "D" 2 - Oval 5 - Double "D"
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
9
a
FULLY GUIDED PERFORATING ASSEMBLY 30
31
32
34
33
35
90 x 90
76
68
60
56
52
48
44
24
75
67
59
55
51
47
43
74
66
58
54
50
46
42
SALVAGNINI POSITIONS 1-20, 41-76 7 TON 1.023(26.0) MAXIMUM
SALVAGNINI PRODUCT LINE
TOOLING OVERVIEW
aa
70 x 90
23
73
65
57
53
49
45
41
70 x 90
72
64
20
16
12
8
4
22
71
63
19
15
11
7
3
90 x 90
70
62
18
14
10
6
2
21
69
61
17
13
9
5
1
• • • •
Insert Punch
PAPS0A*
Punches and dies are premium high speed steel for maximum production and minimum down time.
Round punches can be resharpened up to .118(3.0), shape punches can be resharpened up to .079(2.0) and dies up to .060(1.5), yielding many additional spans of production. Perforating assembly and die can be set at 0°, 90°, 180° and 270°. Maximum recommended material thickness for perforating assembly is .134(3.4).
This fully guided perforating assembly improves piece part quality and tool life by utilizing ‘on the die stripping’. On the die stripping is a punching cycle process where:
PAPS_A
1) the assembly contacts the top of the material
2) the assembly exerts pressure to hold the material flat and in place, minimizing distortion
3) the punch pierces the material
4) the punch strips from the material as the ram retracts 5) the punch returns to the perforating assembly
Fully Guided Stripper
6) the perforating assembly returns to top rest position and is ready for another cycle.
This process assures hole accuracy, improves piece part quality and increases tool life.
S2PN0A
This tool is used in the 33 mm station but has a maximum punch size capability of 1.023(26.0) diameter/diagonal.
Perforating Assembly
ROUNDS
STANDARD SHAPES
S2PN_A
MATE 4-WAY TANG FOR 33 mm PUNCHES
Tang Assembly
Punch tang is square with the same profile VCPCS on all four faces. It can slide into the ram’s drive slot from any side permitting angle Tang assembly includes tang, spring, washer, draw bolt and retaining ring. setting at 0°, 90°, 180° and 270°. Does NOT include insert punch or spring loaded stripper.
Die
DAPC00 DAPC_0
Cartridge Stripper
Die Shim
MSP3
Package 6 each: .004(0.1), .008(0.2), .012(0.3)
*Add punch sizes as final digits of complete part number. 5th character represents shape.
Insert standard shape code for '_' in part number: 0 - Round 3 - Square 1 - Rectangle 4 - Single "D" 2 - Oval 5 - Double "D"
V0PC00US
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a a a a
FULLY GUIDED PERFORATING ASSEMBLY INSTRUCTIONS Assembly instructions:
1.
Stand punch on flat surface so that tapped hole and angle orientation slot are visible.
• Use Mobil grease C-MP or equivalent.
Insert assembly into the stripper so that the tang locating pin engages the vertical slot in the stripper.
7.
a
145 inch lbs (16 N • m) Tighten 6mm socket head cap
• Use Mobil grease C-MP or equivalent.
8.
3.
Place spring over punch shank on top of washer.
9.
4.
Place tang onto punch shank so that internal locating pin is visually in line with punch angle orientation slot.
screw to 145 inch lbs (16 N•m).
Place retaining ring over tang.
Place assembly into a vice or fixture so that it can be compressed axially approximately .040(1.0). The compression exposes the stripper body’s internal retaining ring groove. Groove must be completely visible. Note: the punch point opening must not be obstructed and the punch must be able to protrude through stripper face. Insert retaining ring by slowly coiling it into the retaining ring groove. Release tang and remove assembly from the vise or fixture. When properly assembled with a new punch, the stripper lead should be .030 (0.75).
Disassembly instructions:
5.
Insert 6mm socket head cap screw through tang and lightly tighten to the punch with a 5mm hex wrench - approximately 8 revolutions. Note: cap screw must not be over tightened at this step. Over tightening may result in misalignment during assembly.
1. Place assembly into a vice or fixture so that it can be compressed axially approximately .040(1.0). The compression relieves the spring pressure on the retaining ring. Note: the punch point opening must not be obstructed and the punch must be able to protrude through stripper face. 2. Remove retaining ring by slowly uncoiling it from the retaining ring groove. Clean retaining ring groove of dirt or obstructions prior to re-assembly. 3. Remove assembly from vice or fixture.
4. Loosen 6mm socket head cap screw with a 5mm hex wrench. Punch can now be sharpened or replaced.
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
SALVAGNINI PRODUCT LINE
aaaa a
Place spring washer over punch shank onto punch shoulder. Apply lubricant to punch shank.
10
TOOLING OVERVIEW
2.
Apply lubricant to outside surfaces of punch shoulder, spring, and tang flange.
6.
MATE SPECIAL SHAPES
11
Z
X
X
R R
45∞ Y
Y
A1
A2
Y
A3
Y
SINGLE D
A4
X
DOUBLE D
SQUARE WITH RADIUS CORNERS
B1
X
SQUARE WITH CHAMFERED CORNERS
45∞
Y
B2
X
RECTANGLE WITH RADIUS CORNERS
X
RECTANGLE WITH CHAMFERED CORNERS
30∞
R
Ø∞
45∞
X
Y 60∞
60∞ 45∞
X
B3
B4
X
SALVAGNINI PRODUCT LINE
SPECIAL SHAPES
X
B5
RECT/OVAL
HEXAGON
C1
OCTAGON
X
C2
X
EQUILATERAL TRIANGLE X
X
C3
X
45∞ RIGHT TRIANGLE
Y
TRIANGLE
R
X
Y R
Ø∞
X
X Z
Z
C4
C5
Y
C6
Y
RIGHT TRIANGLE
D1
Z
KEYWAY
KEYWAY
D2
Y
KEYHOLE
Z
D3
Y
KEYHOLE
Y
KEYHOLE
X R
.010 (0.3)
X
R
X
X Z
Z Y
D4
Y
D5
KEYHOLE
.015 (0.4)
Y
D6
DOUBLE KEYWAY Z
R
R
E1
SHAKE AND BREAK
Y
E2
X
4-WAY RADIUS
Y
E3
4-WAY RADIUS
4-WAY RADIUS X
X
Z
R-2
R R
R Y
Y
X∞
Y
X
E4
Z X∞
.030 (0.8)
E5
2-WAY RADIUS
10∞
E6
X
2-WAY RADIUS
R-2
R-1
E7
CABLE CONNECTOR
R
R-1
E8 ARC OVAL
E9 ARC OVAL
FOOTBALL Y
R-1
X (OPTIONAL)
R-1
X (OPTIONAL)
X
X
Z'
Z
Z
R-4 Y
Z R-2 R-3
E10 ELLIPSE
R-2
R
R R-3
E12 QUAD-RADIUS
E11 TRI-RADIUS
X
F1
F3
Y
X
DOUBLE KEYHOLE
DOUBLE KEYHOLE
Y
Y
Y
Y
F2
Y
X Z'
Z
Z
R Z'
Z'
Z' Z
Z
Z 10∞
F4
X
G1
Y
G2
X
X
G3
G4
X
DOUBLE RECTANGLE
*C2,C3,C4 ACUTE ANGLE OPTIONS
X dimension to theoretical sharp
X dimension tangent to radius
X dimension to centerpoint of radius
NOTE: Shape possibilities are not limited to those shown on this page; Mate can manufacture any shape you require. Just contact a Mate customer service representative. A detailed drawing of the shape (sent via fax or e-mail) will be required.
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
SPECIAL SHAPES 4-WAY CORNER ROUNDING D1
9-WAY CORNER ROUNDING
10.000(254.0)
R.4.0
R.5.0
D2 .100(2.5)
Radius
12
QUAD RADIUS Radius
R.3.0
1/2 parting width
R.2.5 R.6.0
D3
R.1.5
R25.4 R.8.0
8.000(203.2) R.12.0
Radius
4.000(101.6) Radius
R.10.0
6.000(152.4)
D4
Radius
INSIDE/OUTSIDE RADIUS
A single 9-way corner rounding tool provides nine popular radii in one tool. Auto indexing selects and rotates the desired radius to round off all corners of a piece part.
The quad radius tool nibbles large holes with smoother edges and fewer hits than using a round nibbling punch. In effect, smooth round holes not limited to station range.
3-WAY CORNER NOTCHING
SPECIAL SHAPE SOLUTIONS TO OTHER PUNCHING PROBLEMS…
30∞
45∞
Inside radius
Outside radius
90∞ 75∞
60∞
60∞
In addition to standard tooling, a few selected multi-purpose punches can fill out a very versatile tooling complement. Some very simple tools, along with auto index press capacity, can perform complex punching operations without resorting to other means to accomplish these tasks.
TWO POPULAR CONFIGURATIONS…
The 3-way notching tool can include angles from 150° to 15° - shown above are two popular arrangements. One tool can provide nine corner options - with auto index in two hits.
SALVAGNINI SPECIAL ANGLE SETTINGS TOP DIE VIEW CARTESIAN COORDINATE SYSTEM
TOP VIEW OF TURRET
PLEASE SKETCH IN SHAPE OF DIE OPENING AND THE ANGLE SETTING
90∞
90∞
60∞
X or 0° 180∞
0∞
180∞
0∞
Y or 90°
FRONT OF PRESS
270∞
270∞
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
SPECIAL SHAPES
This tool’s large radii results in blanks with smoother edges produced with fewer hits than with an ordinary radius punch. This tool can be programmed to punch holes with slugs or parts retained in the sheet, yet can be separated easily off the press.
SALVAGNINI PRODUCT LINE
The 4-way corner rounding tool can round all four corners of a piece part without rotating the tooling - use with standard parting tools for piece part separation.
13
CLUSTER PUNCH ASSEMBLY FULLY GUIDED PERFORATING CLUSTER PUNCH ASSEMBLY
FULLY GUIDED CLUSTER PUNCH ASSEMBLY • Better piece part quality and longer tool life from "on the die stripping" as provided by the fully guided stripper. • Cluster assembly and die can be set at 0°, 90° 180° and 270°. • Greater precision and better hole accuracy.
4-Way Tang
• Also available for auto index blank holder design. CL
ROUND CLUSTER
SPRING LOADED CLUSTER PUNCH ASSEMBLY
Retaining Ring
• A spring-loaded stripper with "on-the-die" performance is built into the punching assembly.
Stripper Spring
• Fully guided, spring loaded assembly with hardened and ground stripper guide posts are bolted into jig ground pockets in stripper and punch retainer for trouble free operation.
Washer Insert Cluster Punch
• Low cost replaceable inserts. • Optional one-piece punch construction available for greater economy. CLNON-SPRING LOADED CLUSTER PUNCH ASSEMBLY
Fully Guided Stripper Material Thickness
• Economical design includes replaceable inserts. • Optional one piece punch construction available for greater economy.
SALVAGNINI PRODUCT LINE
CLUSTER TOOLS
SHAPE CLUSTER
• Larger punching area not limited by stripper posts for more holes in fewer strokes.
SPRING LOADED/ FULLY GUIDED CLUSTER PUNCH ASSEMBLY
Cluster Die
NON-SPRING LOADED CLUSTER PUNCH ASSEMBLY Punch Retainer Stripper Spring
Guide Post
Cluster Inserts Stripper Plate Maximum Material Thickness Cluster Die
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a
CLUSTER PUNCH NOTES 1 HIT … 1 1 1FIRST 11 11 11 11
11 11
22 22
22 22
11 11
22 22
22 22
22 22
14
FOURTH HIT …
33 33
33 33
33 33
33 33
33 33
44 44
44 44
44 44
33 33
44 44
44 44
44 44
For greater hole uniformity and flatter sheets, spread the punches to avoid punching adjacent holes in the same hit. Complete the desired pattern with the technique known as bridge hitting.
CLUSTER TOOLS
a
DO NOT DOUBLE-HIT HOLES. Because of tolerances built into the punch press, using the cluster punch to finish missed holes in patterns will cause punches to shave sides of previously punched holes. The great lateral thrust from this shaving shortens punch life. Use a single-hole punch to complete the pattern.
SALVAGNINI PRODUCT LINE
THIRD HIT …
22 22
SECOND HIT …
11 11
PUNCHING FORCE FORMULA = linear length of cut x material thickness x shear strength = punching force in kilonewtons(kN). PUNCHING FORCE SHOULD NOT EXCEED 75% PRESS CAPACITY.
EXAMPLE: Grid of .250(6.35) diameter holes spaced on .157(4.0) centers. Area of punch covers 48 holes; punch every 4th hole (12 holes, 4 times). Mild steel .060(1.52) thick. (Linear length of cut = 3.14 x diameter x number of punches)
hole perimeter inches(mm) .785(19.94)
x
number punches in cluster
x
material thickness inches(mm)
x
12
x
.06(1.52)
shear strength tons/in2 2) (kN/mm x
=
punching force tons(kN)
x
=
14.1(125.5)
25(.345)
Spring pressure of the spring-loaded cluster assembly runs under a ton (9 kN) and can be ignored in calculations for machine capacity.
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a CARD GUIDE ASSEMBLY
15
aa
BU POSITON 30-35 12 TON
Retaining Screw
CL
Upper Holder
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Inverted Die
Forming height
Material movement
Material thickness (T)
Card guide width
Stripper
Retaining Ring
Lower Insert
Lower Holder Insert Holder
NOTE : USE DR1 FORMING CYCLE
Insert Retaining Screw
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a
COUNTERSINK ASSEMBLY CONTERSINK DOWN 1-20, 41-76 7 TON
16
COUNTERSINK UP 1-20, 41-76 7 TON
CL
Inverted Die
ROUND
Blank Upper Die
CL
SHAPE
FORMING TOOLS
Minor diameter
a
Major diameter
Material thickness (T) maximum .236(6.0)
SALVAGNINI PRODUCT LINE
Material thickness (T) maximum .236(6.0)
Minor diameter
Major diameter
Blank Die
Form Die
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
17
aa EMBOSSING ASSEMBLY
BU POSITION 30-35 12 TON
EI POSITION 1-20, 41-76 7 TON
1-20, 41-76 7 TON
NOTE : USE DR1 FORMING CYCLE FOR BU AND EI POSITIONS CL
aa Retaining Screw
Inverted Die
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Upper Holder
Inverted Die
Emboss Height
Emboss inside
Material thickness (T) .030-.138(0.8 -3.5)
Emboss Height .090(2.3) Maximum
Emboss Height .250(6.4) Maximum
Emboss inside
1.625(41.3) Forming limit diameter
Material thickness (T) .030-.060(0.8-1.5)
Stripper
Retaining Ring Lower Insert
Lower Holder Insert Holder
Retaining Ring Retaining Screw
Emboss inside
1.000(25.4) Forming limit diameter
Material thickness (T) .030-.060(0.8-1.5)
.687(17.4) Forming limit diameter
Lower Insert
Stripper
Retaining Ring Stripper Spring Lower Holder
Retaining Screw
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a EMBOSSING NOTES
WORK WITH THE METAL …
Gentle angle and generous radii perform best. When additional height and angle or less radius are required, the metal takes on added stress. A top area at least five times metal thickness helps to keep opposite sides of the emboss from stressing each other. A tall emboss may need a hole in the top for relief. A deep form may need polished metal and forming lubricant to slide over tools. A sharp angle may need to be made across the grain of the sheet to avoid cracking. If multiple embosses are required, space them at least .500(12.7) apart for tool clearance and stress distribution.
TE
(CROSS SECTION)
N S IO N
C
OM
N
ET AL
ST RE T
CH ES
METAL FLOWS
P R ES SION
IO
METAL THINS
M
COMP R E S S
METAL FLOWS
TENS
IO
N
EMBOSS DIMENSIONS …
A pre-pierced thru hole can increase emboss height …
≤ 45°
Maximum Height 3 x T to .185(4.7)
.03 R
Maximum Width 10 x T to .752(19.1)
CONDITIONS FOR GOOD EMBOSSES WITH MINIMAL DISTORTION …
Circle
Rectangle with Radius corners
PUNCHING FORCE …
Generally, formed embosses require less punching force than a hole of the same size. Lubricant will help the metal flow over the tool surface as the emboss is formed to reduce punching force and produce a better emboss.
Oval
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FORMING TOOLS
T = Material Thickness
Several dimensions are required to make a formed emboss. A normal circular emboss has diameter, height, angle of sidewall and radii of the sidewall bends. Diameter is the area inside the top plateau as measured between bend radii. For shapes other than round, specify length, width and any radii involved. Height is measured from the top surface of the sheet to the top of the plateau. With adequate sidewall angle and height, embossing forms can be any size or shape to maximum die forming limits.
SALVAGNINI PRODUCT LINE
aa
WHAT HAPPENS IN A FORMED EMBOSS …
18
19
aa BEADING ASSEMBLY
BU POSITION 30-35 12 TON
EI POSITION 1-20, 41-76 7 TON
1-20, 41-76 7 TON
NOTE : USE DR1 FORMING CYCLE FOR BU AND EI POSITIONS
aa Retaining Screw
Inverted Die
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Upper Holder
Inverted Die
Material thickness (T) .030-.138(0.8-3.5)
90∞ Minimum
Material thickness (T) .030-.060(0.8-1.5)
Emboss Height
90∞ Minimum
Bead Radius .125-.375(3.2-9.5)
Stripper
Retaining Ring Lower Insert
Lower Holder Insert Holder
Retaining Ring Retaining Screw
Emboss height .250(6.4) maximum in .060(1.5) material
Bead Radius .125-.375(3.2-9.5)
Material thickness (T) .030-.138(0.8-3.5)
90∞ Minimum
Emboss height .090(2.3) maximum in .060(1.5) material
Bead Radius .125-.375(3.2-9.5)
Lower Insert
Stripper
Retaining Ring Stripper Spring Lower Holder
Retaining Screw
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
aa BEAD FORMING NOTES
20
THE CONTINUOUS BEAD IS A FORMED EMBOSS … (CROSS SECTION)
EXAMPLE 2
➠
EXAMPLE 1
AUTO INDEX stations give 360° angular freedom to segmented beading tools from making curved beads to turning down the edge of a circle.
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FORMING TOOLS
For satisfactory continuous embossing, radius of the lower unit must be at least 2 times material thickness ( Example 1 ). A smaller radius tends to penetrate the material and hinder forming ( Example 2 ).
SALVAGNINI PRODUCT LINE
aa
.120(3.0) Flat is Standard
21
a EXTRUSION ASSEMBLY PRE-PIERCE AND FORM
BU POSITION 30-35 12 TON
EI POSITION 1-20, 41-76 7 TON
1-20, 41-76 7 TON
a a NOTE : USE DR1 FORMING CYCLE FOR BU AND EI POSITIONS CL
Retaining Screw
Retaining Screw
Stripper Spring
Upper Holder
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Stripper Spring
Upper Insert
Upper Insert
Inverted Die
Inverted Die
Extrusion ID .089-.375 (2.3-9.5)
2 – 2 1/2 T Maximum
Extrusion ID .089-.160 (2.3-4.1)
.250(6.4) Maximum
Material thickness (T) maximum .105(2.7)
Extrusion ID .089-.197 (2.3-5.0)
.090(2.3) Maximum
Material thickness (T) maximum .060(1.5)
Stripper
Retaining Ring Lower Insert
Lower Holder Insert Holder
Retaining Screw
Material thickness (T) maximum .060(1.5)
Lower Insert
Stripper
Retaining Ring Stripper Spring Set Screw
Lower Holder
Retaining Ring
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a EXTRUSION NOTES
EXTRUSION AND PRE-PIERCE DIAMETERS PRE-PIERCE DIAMETER
EXTRUSION I.D.
TAP OR SCREW SIZE
CUT THREAD
ROLLED THREAD
CUT THREAD
ROLLED THREAD
MAXIMUM MATERIAL THICKNESS
Prior to making an extrusion, the workpiece is pierced with a standard punch and die. This pre-pierced hole permits the metal to flow uniformly in the extrusion process. To develop a normal extrusion two-and-a-half times as high as material thickness, the diameter of the pre-pierced hole will be about 65% of the diameter of the finished extrusion.
22
ENGLISH SIZES
.089(2.3) .100(2.5) .107(2.7) .136(3.5) .150(3.8) .159(4.0) .173(4.4) .201(5.1) .218(5.5) .257(6.5) .272(6.9) .312(7.9) .332(8.4)
.100(2.5) .112(2.8) .120(3.0) .150(3.8) .167(4.2) .174(4.4) .194(4.9) .219(5.6) .235(6.0) .275(7.0) .288(7.3) .343(8.7) .343(8.7)
.050(1.3) .060(1.5) .070(1.8) .085(2.2) .090(2.3) .095(2.4) .104(2.6) .121(3.1) .131(3.3) .154(3.9) .163(4.1) .187(4.8) .199(5.1)
.048(1.2) .060(1.5) .075(1.9) .075(1.9) .090(2.3) .090(2.3) .090(2.3) .105(2.7) .105(2.7) .105(2.7) .105(2.7) .105(2.7) .105(2.7)
.065(1.6) .088(2.2) .110(2.8) .130(3.3) .176(4.5) .221(5.6)
.060(1.5) .075(1.9) .090(2.3) .105(2.7) .105(2.7) .105(2.7)
METRIC SIZES
M3 M4 M5 M6 M8 M10
.098(2.5) .130(3.3) .165(4.2) .197(5.0) .266(6.8) .334(8.5)
.108(2.7) .146(3.7) .183(4.6) .216(5.5) .293(7.4) .369(9.4)
.059(1.5) .078(2.0) .099(2.5) .118(3.0) .160(4.1) .200(5.1)
Screws in extruded holes develop nearly twice the holding power as in non-extruded holes. Maximum strength is obtained with thread rolling screws. Taps or thread cutting screws remove some of the extrusion wall, making it weaker. Extrusions in material thinner than 20% of screw diameter do not develop holding power in proportion to screw strength. Material thicker than screw diameter will develop enough holding power to break the screw even in holes that are not extruded.
Extrusions can become distorted if placed too close to edges, bends, or other extrusions. Minimum distance between the edge of an extrusion and the inside edge of a bend should be three times material thickness plus the inside radius of bend, but not less than .032(0.8) plus inside bend radius. Minimum distance between extrusions and metal edge should be at least three times material thickness. Minimum distance between extruded holes should not be less than six times material thickness.
6xT Minimum
3xT+R Minimum
a a
3xT Minimum
FORMING TOOLS
.060(1.5) .072(1.8) .076(1.9) .093(2.4) .100(2.5) .104(2.6) .116(2.9) .131(3.3) .141(3.6) .165(4.2) .172(4.4) .206(5.2) .206(5.2)
SALVAGNINI PRODUCT LINE
#4-40 #5-40 #6-32 #8-32 #10-24 #10-32 #12-24 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24
Radius (R)
Radius = 1/2 x T
Material Thickness (T)
MINIMUM POSITIONING DISTANCES FOR EXTRUSIONS
EXTRUSION I.D. [.375(9.5) MAX.]
RADIUS .015(0.4)
EXTRUSION HEIGHT
PRE-PIERCE DIAMETER
DIMENSIONS FOR EXTRUSIONS
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
23
a a KNOCKOUT ASSEMBLY
SINGLE KNOCKOUT* 1-20 41-76 7 TON
SINGLE KNOCKOUT BU POSITION 30-35 12 TON
SINGLE KNOCKOUT BU POSITION 30-35 12 TON 70 x 90
a a CL
Retaining Screw
Inverted Die
Upper Holder
Inverted Die
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Urethane Stripper
Maximum material thickness .079(2.0)
Urethane Stripper
Maximum material thickness .138(3.5)
Maximum material thickness .079(2.0)
Stripper
Lower Insert
Lower Insert
Stripper
Retaining Ring
Retaining Ring
Stripper Bolt
Stripper Springs
Lower Holder
Lower Holder
Step Die
Retaining Screw
NOTE : USE DR1 FORMING CYCLE
Insert Holder
Retaining Screw Stripper Spring
*ALSO AVAILABLE FOR EI POSITION(UPFORMING)
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a
KNOCKOUT FORMING NOTES
SPLITTING PUNCHING FORCE WITH TWO HITS …
a
PUNCHING FORCE CHART –
24
1.1 X MATERIAL THICKNESS
SINGLE KNOCKOUT, MILD STEEL
1st Hit
MATERIAL THICKNESS
REF Conduit Size in inches
2nd Hit
Actual 20 Ga. 18 Ga.. 16 Ga. .14 Ga. 12 Ga. 11 Ga. Diameter .035(0.9) .047(1.2) .060(1.5) .075(1.9) .105(2.7) .120(3.0)
DOUBLES … If punching force is over capacity, make first
hit single K.O. down, second hit single K.O. up with relief.
1.0 tons 8.9 kN
1.4 tons 12.3 kN
1.8 tons 15.7 kN
2.2 tons 19.7 kN
3.1 tons 27.5 kN
3.5 tons 3I.4 kN
.500 (12.7)
1.4 tons 12.3 kN
1.8 tons 16.4 kN
2.4 tons 21.0 kN
2.9 tons 26.2 kN
4.1 tons 36.7 kN
4.7 tons 41.9 kN
2nd Hit 1st Hit
2nd Hit
3/8
.687 (17.5)
1.9 tons 16.8 kN
2.5 tons 22.6 kN
3.2 tons 28.8 kN
4.0 tons 36.0 kN
5.7 tons 50.4 kN
6.5 tons 57.6 kN
TRIPLES …
Make first hit single K.O. up, second hit double K.O. up with relief.
.750 (19.0)
2.1 tons 18.3 kN
2.8 tons 24.6 kN
3.5 tons 31.4 kN
4.4 tons 39.3 kN
6.2 tons 55.0 kN
7.1 tons 62.9 kN
2nd Hit
1/2
.875 (22.2)
2.4 tons 21.4 kN
3.2 tons 28.7 kN
4.1 tons 36.7 kN
5.2 tons 45.9 kN
7.2 tons 64.2 kN
8.2 tons 73.4 kN
1st Hit
2nd Hit
QUADS …
2.7 tons 24.5 kN
3.7 tons 32.8 kN
4.7 tons 41.9 kN
5.9 tons 52.4 kN
8.2 tons 73.4 kN
1.125 (28.6)
3.1 tons 27.5 kN
4.2 tons 36.9 kN
5.3 tons 47.2 kN
6.6 tons 59.0 kN
9.3 tons 10.6 tons 82.5 kN 94.3 kN
1.250 (31.8)
3.4 tons 30.6 kN
4.6 tons 41.0 kN
5.9 tons 52.4 kN
7.4 tons 10.3 tons 11.8 tons 65.5 kN 91.7 kN 104.8 kN
9.4 tons 83.8 kN
Make first hit double K.O. up, second hit double K.O. up with relief.
Thickness Variation …
3/4
1
1.375 (34.9)
3.8 tons 33.6 kN
5.1 tons 45.2 kN
6.5 tons 57.6 kN
8.1 tons 11.3 tons 13.0 tons 72.1 kN 100.9 kN 115.3 kN
1.500 (38.1)
4.1 tons 36.7 kN
5.5 tons 49.3 kN
7.1 tons 62.9 kN
8.8 tons 12.4 tons 14.1 tons 78.6 kN 110.0 kN 125.8 kN
1.625 (41.3)
4.5 tons 39.7 kN
6.0 tons 53.4 kN
7.7 tons 68.1 kN
9.6 tons 13.4 tons 15.3 tons 85.2 kN 119.2 kN 136.2 kN
Dimensions in inches (millimeters)
A knockout tool assembly accommodates a ± .016(0.4) range in material thickness. Beyond ± .016(0.4), penetration is affected and knockout performance deteriorates.
Planishing …
The planishing punch pushes knockout back to 75% material thickness, leaving 25% still raised. Planishing the knockout further makes it difficult to remove and distorts the sheet. Satisfactory knockouts can be produced without planishing.
Custom Knockouts …
Custom knockouts are available to suit your application; rectangular knockouts for circuit boxes, oval knockouts for locking cylinders, small knockouts for screw holes or slots, etc.
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FORMING TOOLS
1.000 (25.4)
SALVAGNINI PRODUCT LINE
.375 (9.5)
a a LANCE AND FORM ASSEMBLY
25
BU POSITION 30-35 12 TON
1-20, 41-76 7 TON*
aa CL
Retaining Screw Upper Holder
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Inverted Die
Stripping Pin
Forming height Maximum .250(6.4)
Material thickness (T) Maximum .120(3.05)
.090(2.3) Maximum in .060(1.5) Material
Stripper
Lower Insert
Retaining Ring
Stripper
Lower Insert
Lower Holder Insert Holder
NOTE : USE DR1 FORMING CYCLE
Inverted Die
Material thickness (T) Maximum .090(2.3)
Retaining Ring Stripper Spring Lower Holder
Retaining Screw
Insert Retaining Screw
*ALSO AVAILABLE FOR EI POSITION(UPFORMING)
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a
LANCE AND FORM NOTES
R = .060(1.5) Minimum
Maximum Height .250(6.4)
85° Maximum
85° Maximum
OPEN END
DRAFT ANGLE 5° Minimum
TOP VIEW : WITH DRAFT ANGLE, SHOWING EFFECT AS FRONT EDGE OF TAB MOVES BACK IN DIE …
CLOSED SHAPE
For forms with sharp angles or curves, a ductile material such as aluminum or mild steel of medium thickness normally produces the best results. Lance and form assemblies can be any size and shape. Forming generally requires less press power than punching a hole of the same size.
When ordering a lance and form assembly, send drawings of the part showing all pertinent configurations and elevations.
For certain closed forms a draft angle is recommended. Also specify material type and thickness, and model of press the assembly is designed for.
➠
SIDE VIEW : FRONT EDGE OF TAB MOVES BACK IN DIE AS IT IS FORMED …
AUTO INDEX stations give 360° angular freedom to lance and form tools from forming all sides of a pocket with just one tool to angling a stop tab with another.
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FORMING TOOLS
a
45° Maximum
TOP VIEW : WITHOUT DRAFT ANGLE …
SALVAGNINI PRODUCT LINE
OPEN END
• Improves form quality • Improves piece part quality • Improves stripping
➠
Maximum Thickness .120(3.0)
26
DRAFT ANGLE
➠
SHEET METAL PARAMETERS
a LOUVER ASSEMBLY
27
aa
BU POSITON 30-35 12 TON
Retaining Screw
CL
Upper Holder
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Inverted Die
Reversible Blade
Forming height
Material movement
Material thickness (T) .120(3.0)
Louver width
Stripper
Retaining Ring
Lower Insert
Lower Holder Insert Holder
NOTE : USE DR1 FORMING CYCLE
Insert Retaining Screw
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
aa a LOUVER FORMING NOTES
28
CLOSED END LOUVERS • High strength configuration • No exposed corners • External placement
LOUVER SPACING
FLAT BETWEEN LOUVERS 3 x material thickness minimum
Because of their smooth edges and round enclosed corners, closed end louvers serve best on exposed surfaces of panels.
Front Air Gap ± .015(0.4)
Maximum Form Height .250(6.4)
SALVAGNINI PRODUCT LINE
OPEN END LOUVERS • Maximum air flow • Internal placement
Area of front gap includes the end angles for additional air flow. The exposed ends are best contained inside panels and enclosures.
FRONT SPACING
Draft Angle
10° standard, 5° minimum. During forming, the shorter front edge rises and the longer back edge bends to allow the sides to strip easily.
END SPACING
.315(8.0) minimum
SPECIFY LOUVER ANGLE OR WIDTH OF OPENING
CONTINUOUS LOUVERS • Prototypes • Short production runs • Extra long louvers
Continuous louvers are made by forming a closed end louver and then gradually advancing the tool along one axis to expand the opening.
Louver Angle
Width of Opening
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FORMING TOOLS
aa .500(12.7) radius recommended for stainless and cold rolled steel under .060(1.5 mm) to prevent corners from tearing.
29
a SHEARBUTTON ASSEMBLY
BU POSITION 30-35 12 TON
EI POSITION 1-20, 41-76 7 TON
1-20, 41-76 7 TON
aa NOTE : USE DR1 FORMING CYCLE FOR BU AND EI POSITIONS CL
Retaining Screw
Retaining Screw
Stripper Spring
Upper Holder
Upper Insert
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Stripper Spring Upper Insert
Inverted Die
Inverted Die
65% (T) maximum
Shear button diameter
65% (T) maximum
Material thickness (T)
Shear button diameter
65% (T) maximum
Material thickness (T)
Stripper
Retaining Ring Lower Insert
Lower Holder Insert Holder
Retaining Screw
Shear button diameter
Material thickness (T)
Lower Insert
Stripper
Retaining Ring Stripper Spring Set Screw
Lower Holder
Retaining Ring
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
a
SHEETMARKER™ ASSEMBLY 33 mm POSITION 1-20, 41-76 7 TON
30
a a Upper Tang
CL
Upper Insert Spring
Engraving Stylus Upper Insert
Set Screw
Set Screw
Die
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FORMING TOOLS
Sheetmarker™ Lower Insert
SALVAGNINI PRODUCT LINE
Dowel Pin
31
aa THREAD FORM ASSEMBLY
BU POSITION 30-35 12 TON
1-20, 41-76 7 TON*
aaa
CL
Retaining Screw
SALVAGNINI PRODUCT LINE
FORMING TOOLS
Upper Holder
Inverted Die
Inverted Die
Prepierce Required
Prepierce Required
Material Thickness See chart on page 32
Stripper
Retaining Ring Lower Insert
NOTE : USE DR1 FORMING CYCLE
Lower Insert
Stripper
Retaining Ring Stripper Spring
Lower Holder
Lower Holder
Insert Holder
Retaining Screw
Retaining Screw
*ALSO AVAILABLE FOR EI POSITION(UPFORMING)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
THREAD FORM NOTES A
Thread Size
Material Thickness
Pitch (Reference)
Maximum Minor Diameter of Screw
32 Minimum Form Diameter
TYPE “A” SCREWS - dimensions in inches
AB
B
6x18 8x15 10x12 12x11 14x10 20x90
.020-.030 .025-.040 .030-.045 .035-.054 .038-.060 .050-.060
.0556 .0667 .0833 .0909 .1000 .1111
.102 .123 .133 .162 .185 .234
.276 .306 .352 .406 .442 .556
TYPE “B” AND “AB” SCREWS - dimensions in inches .020-.030 .020-.030 .020-.030 .030-.040 .030-.040 .030-.040
.0500 .0566 .0625 .0714 .0714 .0833
.104 .122 .141 .164 .192 .244
.208 .296 .374 .400 .400 .552
TYPE “C” SCREWS (MACHINE SCREW) - dimensions in inches 6x32 8x32 10x24 10x32 1/4x20 5/16x12
.010-.020 .010-.020 .015-.025 .010-.020 .020-.030 .020-.030
.0313 .0313 .0417 .0313 .0500 .0556
.118 .144 .163 .170 .218 .276
.290 .324 .370 .348 .478 .490
METRIC SHEET METAL SCREWS - dimensions in millimeters .38-.63 .50-.70 .50-.80 .50-.80 .60-1.0 .75-1.0 .75-.1.0 .80-1.2
1.10 1.30 1.40 1.40 1.60 1.80 1.80 2.10
2.18 2.64 2.92 3.10 3.58 4.17 4.88 6.20
5.6 6.9 7.5 8.2 9.5 10.8 12.5 13.9
METRIC MACHINE SCREWS - dimensions in millimeters 3.5x0.6 4.0x0.7 5.0x0.8 6.0x1.0 8.0x1.25
.20-.38 .25-.45 .25-.50 .38-.63 .50-.75
0.60 0.70 0.80 1.00 1.25
3.09 3.52 4.46 5.32 7.16
7.0 8.0 10.0 12.0 16.0
MINIMUM FORM DIAMETER (REFERENCE)
APPROXIMATE 1.25 x PITCH PLUS METAL THICKNESS
PITCH (REFERENCE)
MATERIAL THICKNESS
PITCH MINOR DIAMETER OF SCREW (the pitch diameter of a type “C” screw)
Dimensions in inches (millimeters) REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FORMING TOOLS
2.9x1 3.5x1.3 3.9x1.4 4.2x1.4 4.8x1.6 5.5x1.8 6.3x1.8 8.0x2.1
SALVAGNINI PRODUCT LINE
C
6x20 8x18 10x16 12x14 1/4x14 5/16x12
33
aaa a DIE CLEARANCE AND HOLE QUALITY
WHAT IS DIE CLEARANCE ?
WHY USE PROPER DIE CLEARANCE ?
Die clearance is equal to the space between punch and die when the punch enters the die opening.
PUNCH
aa a a
DIE CLEARANCE
MATERIAL
PUNCH
DIE
DIE
DIE
SHEAR CRACK
SALVAGNINI PRODUCT LINE
FEATURES • APPLICATIONS
Die Clearance 1
Die Clearance 2
OPTIMUM CLEARANCE —
shear cracks join, balancing punching force, piece part quality and tool life.
PUNCH
SHEET METAL DIE
PUNCH
Total Die Clearance = Die clearance both sides of Punch
Total Die Clearance = Die Clearance 1 + Die Clearance 2
MATERIAL
DIE
RECOMMENDED DIE CLEARANCE
DIE
SHEAR CRACK
DIE CLEARANCE in terms of percent (%) of material thickness : Minimum Life Clearance 15% Optimum Clearance 20 - 25% Extended Life Clearance 30%
MATE always refers to TOTAL DIE CLEARANCE — NOT clearance per side. Aluminum Material Total Thickness Clearance
.040”(1.0mm) .060”(1.5mm) .080”(2.0mm) .100”(2.5mm) .120”(3.0mm) .137”(3.5mm)
.006”(0.15mm) .009”(0.23mm) .012”(0.30mm) .018”(0.45mm) .024”(0.60mm) .028”(0.70mm)
Mild Steel Material Total Thickness Clearance
.040”(1.0 mm) .060”(1.5 mm) .080”(2.0 mm) .100”(2.5mm) .120”(3.0 mm) .137”(3.5mm)
.008”(0.20mm) .012”(0.30mm) .016”(0.40mm) .020”(0.50mm) .030”(0.75mm) .034”(0.85mm)
Copper Material Total Thickness Clearance
.040”(1.0mm) .060”(1.5mm) .080”(2.0mm) .100”(2.5mm) .120”(3.0mm) .137”(3.5mm)
secondary shear cracks are created, raising punching force and shortening tool life.
ANATOMY OF A PUNCHED HOLE …
Total Clearance - (TC)
Rollover Depth - (RD)
Rollover Width - (RW)
.006”(0.15mm) .009”(0.23mm) .012”(0.30mm) .018”(0.45mm) .024”(0.60mm) .028”(0.70mm)
Stainless Steel Material Total Thickness Clearance
.040”(1.0 mm) .060”(1.5 mm) .080”(2.0 mm) .100”(2.5mm) .120”(3.0 mm) .137”(3.5mm)
CLEARANCE TOO SMALL —
.008”(0.20mm) .016”(0.40mm) .020”(0.50mm) .025”(0.64mm) .035”(0.90mm) .040”(1.00mm)
Material Thickness (%)
Burnish Land - (BL)
Burr Height - (BH)
EFFECT OF TOTAL CLEARANCE AS A PER CENT (%) OF MATERIAL THICKNESS TC 10% 15% 25% 35%
RD 10% 12% 16% 20%
RW 50% 40% 45% 50%
BH 15% 10% 6% 6%
BL 75% 55% 50% 45%
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
CALCULATING PUNCHING FORCE PUNCHES WITHOUT SHEAR FORMULA: • Punch perimeter in inches(mm) x • Material thickness in inches(mm) x • Material shear strength in lbs/in2(kN/mm2) = • Punching force in lbs(kN) To convert to Imperial Tons : divide lbs by 2000
To convert to Metric Tons : divide kN by 9.81
PUNCH PERIMETER —
FORMULA: • Punch perimeter in inches(mm) x • Material thickness in inches(mm) x • Material shear strength in lbs/in2(kN/mm2) x • SHEAR FACTOR = • Punching force in lbs(kN) To convert to Imperial Tons : divide lbs by 2000
To convert to Metric Tons : divide kN by 9.81
PUNCHES WITH SHEAR — CONSIDERATION: Punch shear tends to lessen punching force. The degree to which this happens is the SHEAR FACTOR. Shear factor does change as the punch becomes less sharp. Note that the factory does not recommend that you use shear to bring punching force within press capacity.
SHEAR FACTORS for material .050”(1.2 mm) to .250”(6.4 mm) for punches with shear For a cluster punch, the perimeter would be the sum of the linear distances of each of the punch components.
Material .050” Thickness 1.2 mm Shear Depth: .060”1.5mm
MATERIAL THICKNESS —
Material .135” Thickness 3.4 mm Shear Depth: .060”1.5mm
.78
.075” 1.9 mm
.105” 2.7 mm
.120” 3.0 mm
.50
.58
.72
.75
.165” 4.2 mm
.190” 4.8 mm
.250” 6.4 mm
.83
.86
.90
EXAMPLE: Formula for punching with shear (20.0 mm punch) — 80.0 mm x 3.0 mm x 0.3447 kN/mm2 x .75 = 62.0 kN NOTE: The factory does not recommend using shear to bring punching force within press capacity because dulling tool edges quickly raise punching force and press capacity may be exceeded.
PUNCHING FORCE CHANGES AS TOOLS BECOME DULL …
SHEAR STRENGTH- psi/in2(kN/mm2) : 25000(0.1724) 35000(0.2413) 50000(0.3447) 75000(0.5171)
HEAVY TOOL WEAR
May exceed punch press capacity
Punching Force
MATERIAL : Aluminum 5052 H32 Brass Mild Steel Stainless
Excessive
MATERIAL SHEAR STRENGTH — Material shear strength is a measure of maximum internal stress before a given material begins to shear. This property is determined by metallurgical science and expressed as a numerical factor. Popular materials like aluminum, brass, mild steel and stainless steel have approximate shear strengths of :
EXAMPLE PUNCHING FORCE PROBLEM —
punch perimeter is 80.0 mm, material thickness is 3.0 mm, material shear strength is 0.3447 kN/mm2.
80.0 mm x 3.0 mm x 0.3447 kN/mm2 = 82.7 kN
Optimal
Example: using 20.0 mm square punch into 3.0 mm mild steel:
Sharp
Dull
Tool Sharpness
Dimensions in inches (millimeters)
REV 10/01 • © 2001 Mate Precision Tooling • 1295 Lund Boulevard • Anoka, Minnesota 55303 USA • Phone 763-421-0230 • Fax 763-421-0285 • SALVAGNINI
FEATURES • APPLICATIONS
a
Material thickness is the width of the workpiece or sheet that the punch must penetrate in making a hole. Generally the thicker the material the more difficult it is to punch, but this isn’t Material Thickness the only factor.
.50
.060” 1.5 mm
SALVAGNINI PRODUCT LINE
Perimeter is simply the linear distance around a punch of any shape. For a round punch, this would be the circumference.
34
PUNCHES WITH SHEAR
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Printed in USA • © 2001 Mate Precision Tooling Inc. • 1000 • 1/05 • REV B • MP
LIT00041
