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Press Tool Design (Simple Blank/Pierce/Cutting Operations.

MODULE TITLE PRESS TOOL DESIGN (SIMPLE


BLANK/PIERCE/CUTTING OPERATIONS.)

Nominal Duration Two Modules.

Module code EB 516

Module purpose The purpose of this module is for the participant to


develop the knowledge and skills to design simple single
operation press tools for blanking piercing
and cutting operations.

Relationship to This module will be modified in line


competency standards with the requirements of the National
Metals and Engineering Standards when
they become available.

The module contains the knowledge and


skills identified and agreed by all
states/territories. It has been developed on
the assumption that these will be reflected in the
Standards.

Prerequisites EA 504 Jig and Tool Drafting - Press Tools


(Introduction)

Summary of content 1. Press tool operations

- Blanking
- Piercing
- Cutting
Strip layouts
- basic blank shapes
- blank positioning
- multiple run layouts

- wide run, narrow run


positioning
- calculation of strip width
and component pitch
Cutting clearance
- component materials
- percentage thickness as
clearance
- calculation of punch and
die

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

Angular die clearance


- draft angles
- die shoe openings
Press loads
- Blanking force
- Stripping force
Die and punch shear
- application
- square and round dies
- punches

2. Punches, punch plates, die blocks

- Punches
- design considerations
- blanking punches
- piercing punches
- punch proportions
- punch materials & service
condition
- punch mounting methods
- composite punches and
punch sections

Standardised punches
- Punch plates
- design considerations
- punch plate proportions
- punch plate materials and
service condition
- punch mounting and location
methods

- punch plate location and


mounting methods
- standardised punch plates
- Die blocks
- design considerations
- die block proportion
- die block materials & service
condition
- die segments and sections
- die block location and
mounting and retention methods
- die block inserts
- standardised die blocks and
die sections

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

3. Strippers, stockguides, stops


and ejection systems

- Strippers
- design considerations
- types of stripper
- dimensions and proportions
- construction, materials &
service condition
- stripping mediums for spring
strippers
- rubber and urethane stripping
mediums
- stripper location, guiding and
retention methods
- punch openings in strippers
- punch guiding systems
- standardised stripper units
- Stops
- design considerations
- types of stops
- construction, materials and
service condition
- dimensions and proportions
- actuating mechanisms for
automatic stops

- Stock guides
- design considerations
- back gauge and front spacer
stock supports
- nest locators and gauging
- spring pushers
- stock gauge materials and
service condition

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

4. Design and draw Press tools


for Blanking, Piercing or Cutting
operations
- Design principles/conventions
- Design drawings of strip layout
component dimensions
- Calculation of blanking and
stripping forces
- Selection of press
- Report and calculation of work
design costs and quotation
estimates for tool construction
- Selection of die set
- Assembly drawing preparation
- three conventional views
- materials and parts list
- Detail drawings of press tool
components
- conventional views
- dimensioning techniques and
labels
- Australian standards

Delivery Participants should be encouraged to


adopt a project management approach
towards achieving the tooling design
solution for the product specification
assignment.

To achieve this, the product specification should be


presented as a project where participants must
undertake research and develop the tool
design solution.

Participants may work individually or


in teams and will be required to use
their background knowledge of the
metal stamping industry to recommend
the use of appropriate tool materials
and the type of equipment to achieve
the manufacturing target for the
product specification.

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

The key focus of the project is on


the tool design solution to achieve
the product specification. In
completing the project, participants
should estimate the costs for doing
the job, put in quotation estimates,
undertake the necessary research, do
all necessary calculations, identify
design solutions and complete any
assembly and detail drawing
requirements.

The design detail may be undertaken


using manual drafting techniques
and or a computer aided design
drafting facility.

Suggested on-job training for


maximum skill acquisition.

Work as a draftsperson/tool design


assistant in a tool design office.

These strategies may also involve:

- co-operative registered off-job


provider/employer delivery
sharing available resources;

- delivery by an employer who is


registered as an off-job provider,
with in-house qualified trainers
using unique resources to facilitate
on and off-job delivery;

- off-the-job objectives must


focus on the industry context while
on-the-job objectives will reflect
application within Enterprise
operations.

Assessment instruments will need to be


developed by the module provider which
will need to reflect consistency with
stated module learning outcomes and
related assessment criteria.

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

Alternative assessment procedures will


need to be considered and applied as
appropriate to participants needs.

This module is practical in nature and


theoretically integrated to complement
the acquisiton of practical design and
drawing skills which have relevance to
industrial applications.

It is suggested where possible, all


participants should observe and
investigate operational dies directly
in industrial settings.

It is recommended that all providers


have access to a range of completed
die/s for investigation and group
discussion.

Instruction and training should


support and consolidate the safety
requirements associated with the
handling of components and working
within a process manufacturing
environment.

The quality of the tool design


solution will conform to acceptable
industry standards.

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

Learning Outcomes On completion of this module the


learner will be able to:

Learning outcome 1 Observe and investigate the principles of operation for


blanking, piercing and cutting dies and determine the
relationship between component sizes to punch and
die sizes. Sketch and draw strip layouts. Calculate
press loads for press tools with and without shear in
blanking, piercing and
cutting operations.

Assessment criteria Given components or component drawings;

1.1 Identify and explain in the essential


features component size to punch and
die relationships.

1. Strip layout and strip width.


2. Cutting clearance between punch and
die.
3. Relationship of component sizes to
punch and die sizes.
4. Angular clearance applied as draft
angle to die apertures and die shoe
openings.

1.2 Calculate and determine:

1. Blanking force
2. Stripping force

1.3 Determine the relationship between


blanking force to shearing action
and allocate the correct percentage
(%) amount of shear to punches or
dies.

Conditions Access to suitable study environment.


Sample components and strip runs.
Sample drawings of components and press
tool designs.
Reference material and handout sheets for
each participant.
Access to operational dies or simulation
devices.
View any suitable video programmes.

Assessment method Short answer questions.


Practical application tasks.

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

Learning outcome 2 Select, design and draw punches,


punch plates and die blocks for blanking, piercing and
cutting dies.

Assessment criteria Given reference material, sample die


parts and sample die detail drawings.
2.1 Identify, explain and determine the
essential features of punches;
1. Select suitable punches for specific
tasks.
2. Proportions, materials, service
condition and construction methods.
3. Location methods.
4. Retaining methods.
5. Select suitable proprietary punches and punch systems
and apply to specific tasks.

2.2 Identify, explain and determine the


essential features of punch plates;
1. List and select suitable punch plates for specified tasks.
2. Proportions, materials, service
condition and construction methods
3. Punch guiding systems.
4. Location and retention methods.
5. Select suitable proprietary punch
plates units and systems and apply
to tasks.

2.3 Identify, explain and determine the


essential features of die blocks;
1. Select suitable die blocks and apply
2. Proportions, materials, service
condition and construction methods.
to specified tasks.
3. Support, location and retaining
methods.
4. Select suitable proprietary die block
sections and apply to specified tasks.
Conditions Access to a suitable study environment.
Proprietary catalogues of press tool
components.
Reference materials and handout sheets
for each participant.
Sample die parts.
Sample die detail drawings.
Assessment method Short answer questions.
Practical design exercises.

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

Learning outcome 3 Select, design and draw strippers, stock


guides, stops and blank ejection
systems for blanking, piercing and
cutting dies.
Assessment criteria Given reference material, sample die
parts and sample die detail drawings.

3.1 Identify, explain and determine the


essential features of strippers;

1. Select suitable strippers for


specified tasks.
2. Proportions, materials, service
condition and construction methods.
3. Guide plates and stock channel
dimensions.
4. Location, retention and punch
guiding systems.
5. Select stripper bolts and spring
mediums.
6. Knockout and shedder systems for
component ejection.
7. Select suitable proprietary stripper
units and systems and apply to
specified tasks.
3.2 List and select various types of die
stops and stock guides;
1. Select suitable die stops for
specified tasks.
2. Proportions, dimensions and materials.
3. Construction, materials and service
conditions.
4. Actuating mechanisms for automatic
operation.
5. Edge condition of guide plates and
stock guides for spring stripper
operation.
Conditions Access to a suitable study environment.
Proprietary catalogues of press tool
components.
Reference materials and handout sheets
for each participant.
Sample die parts.
Sample die detail drawings.
Assessment method Short answer questions.
Practical design exercises.

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

Learning outcome 4 Design and draw a press tool for


blanking, piercing and cutting
operations.

Assessment criteria Given sample component parts or


sample component drawings produce
assembly and detail drawings of blanking, piercing or
cutting dies and include:

1. Assembly drawing of the tool design


solution.
2. Component and strip layout.
3. Conventional views.
4. Materials and parts list.
5. Selection of suitable proprietary
die set or die set components.
6. Fully dimensioned detail drawings of
essential die components and non-
standard die parts.
7. Calculations and written report on
work design costs and quotation
estimates to produce the press tool.

Conditions Access to a suitable study environment.


Australian Standards AS1100.
Proprietary catalogues of die sets,
presses and ancillary equipment and
press tool components.
Reference material and handout sheets
for each participant.
Sample dies or die parts.
Sample die design drawings illustrating
sound design features

Assessment method Short answer questions.


Practical design exercise.

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Press Tool Design (Simple Blank/Pierce/Cutting Operations.)

Suggested learning - Suitable study environment.


Resources - Drafting boards (A1 or larger) on
stands.
- Drafting machines to suit boards.
- Access to computer aided design
drafting equipment. (if available)
- Examples of different types of
blanking, piercing and cutting
dies.
- Sample die design drawings and
components for blanking, piercing
and cutting dies.
- Manufacturers catalogues on die parts,
presses and ancillary equipment.
- Australian Standards.
- Component handout sheets.
- Worksheets.
- Suitable video programmes.

All references should be the latest


edition.

- Australian Standards:
1. AS1100 Part 101-1984
Australian Engineering Drawing
Handbook.
2. AS1100 Part 201-1984
Australian Engineering Drawing
Handbook.

3. AS1654-1987
Limits and Fits for Engineering.
- OSTERGAARD D.E. "Basic Diemaking"
McGraw-Hill Book Co. USA 1974.
- OSTERGAARD D.E. "Advanced Diemaking"
McGraw-Hill Book Co. USA 1974.

- TAFE "Fitting and Machining"


TAFE publications unit 1988.

- ASTME "Die Design Handbook"


McGraw-Hill USA 1975.

- PAQUIN JR "Die Design Fundamentals"


Industrial Press N.Y. 1970.

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