Forming dies are typically made by tool and die makers and put into production after mounting into a press. The die is a metal block that is used for forming materials like sheet metal and plastic.
For the vacuum forming of plastic sheet only a single form is used, typically to form transparent plastic containers (called blister packs) for merchandise. Vacuum forming is considered a simple molding thermoforming process but uses the same principles as die forming. For the forming of sheet metal, such as automobile body parts, two parts may be used, one, called the punch, performs the stretching, bending, and/or blanking operation, while another part, called the die block, securely clamps the workpiece and provides similar, stretching, bending, and/or blanking operation. The workpiece may pass through several stages using different tools or operations to obtain the final form. In the case of an automotive component there will usually be a shearing operation after the main forming is done and then additional crimping or rolling operations to ensure that all sharp edges are hidden and to add rigidity to the panel.
Die components / Die block / Punch plate / Blank punch / Pierce punch / Stripper plate / Pilot / Dowel Pin / Back gage / Finger stop
Forming operations work by deforming materials like sheet metal or plastic using force (compression, tension, or both) and rely on the material’s mechanical properties. Forming dies are typically made by tool and die makers and put into production after mounting into a press.
For the vacuum forming of plastic sheet only a single form is used, typically to form transparent plastic containers (called blister packs) for merchandise. Vacuum forming is considered a simple molding thermoforming process but uses the same principles as die forming.
For the forming of sheet metal, such as automobile body parts, two parts may be used: one, called the punch, performs the stretching, bending, and/or blanking operation, while another part that is called the die block securely clamps the workpiece and provides a similar stretching, bending, and/or blanking operation. The workpiece may pass through several stages using different tools or operations to obtain the final form. In the case of an automotive component, there will usually be a shearing operation after the main forming is done. Additional crimping or rolling operations may be performed to ensure that all sharp edges are hidden and/or to add rigidity to the panel.
The main components of a die set (including press mounting) are as follows. Because nomenclature varies between sources, alternate names are in parentheses:
Die shoes (holders) – the set of flat, parallel plates that serve as the foundation for mounting die components.
Guide pins (pillars) – together with guide bushings, the pins align the die shoes precisely during each press stroke.
Die set (plates). Placement can be inverted depending on the operation, such as use of a knock-out:
Die block – the lower (bottom) half of the die set. Machined to conform to the desired shape of the workpiece being formed or cut.
Punch plate – the upper (top) half of the die set. Holds and supports the different punches in place.
Punch – male portion of the die which punches through the sheet metal and into the corresponding (female) section of the die block. More specifically:
Blanking punch – performs a dual-purpose operation where either a profiled slug, called the blank, is cut out and used for further working, or where a finished piece is cut free from the sheet metal.
Pierce punch – cuts a desired shape (circular, polygonal, etc.) out of the workpiece. The slug is discarded.
Stripper plate (pad) – spring-loaded plate that separates (i.e., strips) the workpiece from the withdrawing punch after each press stroke.
Pilot – This will help to place the sheet accurately for the next stage of operation.
Stock guide – ensures that the material being worked on always goes in the same position, within the die, as the last one.
Setting (stop) block – This part is used to control the depth that the punch goes into the die.
Shank – installs the punch plate to the press. It should be aligned and situated at the center of gravity of the plate
Metal stamping is a cold metal processing that applies pressure to the stamping die through a punch press machine to shape the iron material into the product parts.
Therefore, stamping processing requires stamping molds, which are indispensable equipment in production. The quality of stamping molds is positively related to processing, production efficiency and finished products.
The quality of the stamping die is crucial, it will highly affects in terms of production efficiency, lower maintenance rate and the quality of the product. With the low quality of the stamping die, will potentially occurs the risk of cracking or even collapse due to the high pressure.
Metal stamping is a cold metal processing that applies pressure to the stamping die through a punch press machine to shape the iron material into the product parts.
Therefore, stamping processing requires stamping molds, which are indispensable equipment in production. The quality of stamping molds is positively related to processing, production efficiency and finished products.
The quality of the stamping die is crucial, it will highly affects in terms of production efficiency, lower maintenance rate and the quality of the product. With the low quality of the stamping die, will potentially occurs the risk of cracking or even collapse due to the high pressure.
Die forming is a widespread sheet metal forming manufacturing process. The workpiece, usually a metal sheet, is permanently reshaped around a die through plastic deformation by forming and drawing processes.
Simulations can be carried out in order to avoid cracks, tears, wrinkles, too much thinning, and stretching. They are also useful to estimate and overcome the springback phenomenon: once the forming process is done and the forming tools are removed, the workpiece attempts to partially recover its initial shape through relaxation of the elastic stresses.
The springback can cause the formed blank to get an unexpected state of warping. To cope with this effect, it is possible to overbend the sheet. The die, the punch, and the blank holder must be manufactured to incorporate this effect. In this model, a flat metal sheet is pressed onto a curved die by a similarly shaped punch. Both the forming and the springback phenomena are modeled.
From a simulation point of view, the problem is severely nonlinear due to contact, geometric nonlinearity, and large plastic strains.
These dies differs from the Drawing dies as in forming dies the shape of die and punch is given to the blank sheet but applying force with Press Ram.
It can be anything like a simple profile complicated profile or a contour profile, but the method will be same . just to keep the blank sheet and to deformed with help of punch and die with same profile as per component.