103

7 Advantages of Wire
EDM for Die Making
Tool and Die Making
Wire EDM has revolutionized tool and die making. To understand the extent
of the wire EDM revolution for stamping dies (Figure 7:1), let Carl share some
history.

Courtesy Agie
Figure 7:1
Tool and Die Stampings

Old-Fashioned Tool and Die Making—Carl Sommer

In 1950, I started to work in a machine shop; one year later, I became an
apprentice tool and die maker in a large handbag frame plant in Brooklyn. The
plant produced a large variety of handbag frames which required many kinds of
fixtures and dies.
From 01 tool steel, we milled, ground, or filed the form punch. The punch was
then hardened in a gas-fired oven that had no temperature gauge. In those days, one
learned early the necessary cherry red color to indicate that the punch was ready to
be quenched in oil. After quenching, we used a gas torch to temper the punch to a
light straw color.
Using the hardened punch as a template, we traced the pattern on a piece of tool
steel colored with Dykem blue. We used a band saw to cut as close to the line as
possible. We placed the hardened punch on top of the soft die section and placed
both of them under a power press. The power press was bounced by hand until we
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made an indentation into the soft die section.

Then we used a filing machine and hand files to remove the excess material. We
brushed Dykem blue into the cavity, and the punch and die were again placed in
the press to make a further indentation. Then the workpiece went back to the filing
machine. We repeated this process over and over until a proper fit was made. Then
we set the filing machine on an angle to produce the proper taper. The die was then
hardened with hopes that the 01 tool steel would not distort when quenched in oil.
Then I took another position in a precision die shop in Long Island City, Queens,
NY. This shop was a new world of die making. Here we ground the die sections to
exact specifications—some within .0001" (.0025 mm).
To make these dies, we had no comparator or optical equipment. One worker
used a large magnifier to check his die work for the proper clearance; but this made
his eyes bloodshot from constantly looking through the magnifier. When my turn
came to make these dies, I decided to grind the punch and die sections to precise
dimensions. Instead of constantly relying on sight, I used a tenth indicator and
gauge blocks to obtain the proper dimensions. See Figure 7:2.

Figure 7:2
Author's handwritten shop sketch for grinding floral pick punches and dies.
These dies ran continuously. The floral picks went into automatic dispensers, so no burrs were tolerated.
The called-for clearance was between .0005" (.013 mm) to .001" (.025 mm).
 Advantage of Wire EDM for Die Making 105

To produce these floral pick dies, the clearance between the punch and die was
between .0005 to .001" (.0127 to .0254 mm). There could not be any, "Opps."
These floral picks came in stacks and were placed in automatic machines. There
could not be any burrs on them.
This is one of the notes I wrote making this precision floral pick die: “Grind flat
with .016 radius (.40 mm). Move cross feed .001 (.025 mm) at a time. Leave .0003
(.0076 mm) over for finish grinding. Then touch front and back off .0002 (.005
mm), then grind flat. Use dresser three times." See Figure 7:3.

Figure 7:3
Old-Fashioned Precision Die Making
Note the tight tolerances the author wrote for grinding the tip of the floral pick
die section: “Grind flat with .016 (.40 mm) radius. Move crossfeed .001 (.025
mm) at a time. Leave .0003 (.0076 mm) over for finish grinding. Then touch front
& back off .0002 (.005 mm), then grind flat. Use dresser three times."
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The Revolution
To produce these precision dies, it required highly skilled tool and die makers.
Then came wire EDM. Now, by simply making a computer program of the shape,
the production of a much better and more accurate tool was possible.
Tool and die makers are still needed to assemble tooling, but wire EDM has
eliminated the need for those skilled die makers to make the many elaborate punch
and die sections. Today, wire EDM performs that costly and laborious job. As a
result, it has greatly reduced tooling costs, and at the same time produced superior
quality dies. See Figure 7:4.

Courtesy Makino
Figure 7:4
Precision Tool and Die Machining

Advantages of Wire EDM Dies

1. One-Piece Die Sections
Previously complicated dies were sectionalized—this allowed the die
sections to move. See Figure 7:5. Now with wire EDM, the die can be made
from a solid block of tool steel producing a much more rigid die, as in Figure
7:6. In addition, sectionalized dies require much more mounting time than a
one-piece die section.

Figure 7:5 Figure 7:6

Sectionalized Die Sections Solid Die Section
Wire EDM eliminates costly sectionalized dies and
produces superior and less costly solid dies.
 Advantage of Wire EDM for Die Making 107

2. Exact Spare Parts

To keep up production, spare sections can be on hand in case of wear or
breakage. Since computer programs can be stored, spare sections can be precisely
duplicated without having the previous part.
3. Dowel Holes EDMed
When die sections or punches need to be changed due to wear or design change,
dowel holes can also be EDMed. This produces exactly duplicated replacement die
or punch sections.
4. Better Tool Steels
With wire EDM, dies and punches can be made with tougher tool steels, even
tungsten carbide. These tougher tool steels produce much longer tool life.
5. Accuracy
Many wire EDM machines move in increments of at least 40 millionths of
an inch (.00004"—.001 mm); therefore, they can maintain accurate forms and
clearances.
6. Die Repairs
Broken dies can be saved by replacing the damaged section with a wire EDMed
insert, or the damaged area can be hard welded and then wire EDMed, see Figures
7:7 and 7:8

Insert

Figure 7:7
Damaged Die Section Repaired with an Insert
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Weld

Figure 7:8
Damaged Die Section Repaired with Welding and EDMing

7. Fine Textured Finish

The fine textured surface produced from wire EDM produces longer tool life
because of improved surface retention of lubricant.
8. Eliminates Distortion
Punch and dies can be wire EDMed after heat-treatment. This eliminates the
distortions that are created in heat-treating.
9. Inserts for High Wear Areas
If certain areas in the die have a larger wear ratio, inserts can be designed for
these wear areas. Then, instead of sharpening the entire die, inserts can be installed
even with the die in the press.
10. Smaller Dies
Wire EDM allows the building of smaller progressive dies, thereby reducing
costs.
11. Longer Lasting
A die lasts only as long as its weakest link. Dies last longer because wire
EDM produces exact die clearance which allows the dies to last longer between
sharpening and allows dies to be sharpened much deeper.
 Advantage of Wire EDM for Die Making 109

12. Punches and Dies from One Piece of Tool Steel

A punch and die can be produced from one piece of tool steel, as illustrated in
Figure 7:9.

Punch Die Section

Figure 7:9
Punch and Die Made from One Piece of Tool Steel

13. Cutting Stripper and Die Section Together

Often the stripper may be mounted on the bottom of the die section and cut
simultaneously with the die section, as shown in Figure 7:10. This significantly
reduces the cost when strippers are required.

Die Section

Stripper

Figure 7:10
Cutting the Stripper and Die Section Together
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Wire EDMing Punch and Die Sections

Punches
A. Large Punches
When mounting large punches to a die set, as shown in Figure 7:11, they can
be held onto the die set by putting dowels and screws directly into the body of the
punch.
Caution: Use large enough dowels, and particularly large enough screws to
prevent the punch from moving, in case of misfeeds on the power press. Also,
leave enough metal around the die section to avoid the die from cracking. This is
especially important when stamping thick materials.

Figure 7:11 Large Punches

Bolt large punches directly to punch holder.
 Advantage of Wire EDM for Die Making 111

B. Holding Small Punches

Let's take a small punch where one is unable to mount dowels and screws into it,
as illustrated in Figure 7:12. There are various methods of holding small punches
like these. The following illustrations will demonstrate how to hold such small
punches.

Figure 7:12 Small Punches

1. Footed (Figure 7:13)

Milled or Ground
Surface

Figure 7:13 Footed Punch

2. Shoulder (Figure 7:14)

Surface Can be Either

Ground or Wire EDMed.

Figure 7:14 Shoulder Punch

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3. Keyed In—Toe Clamps (Figure 7:15, 16)

Grind or EDM Recess

Exposed Toe Clamp

Can insert hardened backup plate

Figure 7:15 Keyed In-Toe Clamp

Recessed Toe Clamp

Figure 7:16 Recessed Toe Clamp

4. Keyed In—Keyway (Figure 7:17)

Milled Pocket Keyway

Figure 7:17 Recessed Keyway

 Advantage of Wire EDM for Die Making 113

5. Press Fit (Figure 7:18)

Press Fit

Figure 7:18 Press Fit

Not recommended for heavy stripping pressures.

6. Peened Edge (Figure 7:19)

Peened Area
Peened Edges

Figure 7:19 Peened Edge

Not recommended for heavy stripping pressures.

7. Dowel Pin Reamed (Figure 7:20)

Punch is EDMed Soft

Dowel Pin

Figure 7:20 Dowel Pin

Punch is EDMed Before Heat-Treating.
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8. Dowel Pin EDMed (Figure 7:21)

Should the pressed fit or the peened fit ever come loose, a dowel hole can be
EDMed.

Starter Hole Dowel Hole is EDMed

Figure 7:21 Dowel Pin EDMed

9. Set Screws (Figure 7:22)

Should the pressed fit or the peened fit ever come loose, a slot can be ground and
set screws used.

Double Set Screws Area is tapered so set screw

forces punch against the die set.

Figure 7:22 Set Screws

Not recommended for heavy stripping pressures.

10. Socket Head Cap Screw (Figure 7:23)

Figure 7:23 Socket Head Cap Screw

Edm Punch Holder and Hold Punch with a Socket Head Cap Screw
 Advantage of Wire EDM for Die Making 115

11. Ball Bearings (Figures 7:24-25)

To mount small punches with ball bearings, use a carbide ball end mill to put
a radius indentation in the punch. Use the small end mill to the same depth as the
punch to mill out the sides of the punch retainer. Put in hardened steel bearings to
hold punch.

A A

Figure 7:24 Ball Bearings

Mill Pocket with Ball End Mill without Punch

Ball Bearings

Use Carbide End Mill to Put a

Radius Indentation in Punch

View A A

Figure 7:25 Ball Bearing Construction

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C. Skim Cutting
On close tolerance dies, skim cuts are made depending on the accuracy of the
punch and die sections. The die sections cause no difficulty in skim cutting, since
the cavity is open. However, in skim cutting the punch, the punch has to be held
with a tab. The tab is made in a straight section, and then cut off in the final cut and
ground to size. See Figure 7:26.

Tab for Skim Cutting. Tab Is

Later Removed by Grinding

Figure 7:26 Skim Cutting Punches for Precision Dies

Die Sections
A. Heavy Blanking Dies
Always use a sufficiently large die block to avoid splitting when thick steel is
being cut. The nominal cost is well worth not having to remake the die.
B. Avoid Sharp Corners
Sharp corners are the weakest area of a die section. When possible, avoid them.
C. Heat-Treating
Cut die sections in the heat-treated condition. This avoids heat treat distortions.
D. Large Die Sections
Large sections should be double and even triple tempered in order to remove
 Advantage of Wire EDM for Die Making 117

all the stresses, particularly in close tolerance dies. Even then, some stresses may
remain. To ensure minimum stresses on precision dies, cut out the mid-section on a
band saw, leaving at least a ¼ inch of wall, or put in relieving slots. For illustrations,
see Chapter 5: “Understanding the Wire EDM Process."
E. Tapers

1. Taper and Land

Due to the accuracy of wire EDM, there is no need for large tapers. Dies can be
made with a taper and land; however, most die sections can be tapered right up to
the top of the die section. See Figure 7:27. With a ¼ degree taper, the die will only
become .001 larger per side when .250 is removed.

Taper

Land

Taper

Figure 7:27 Taper and Land

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2. Straight Cut and Taper

Wire EDM can go from taper to straight, as shown in the cut off punch and die
in Figure 7:28. In areas where the punch can be supported in the die, stipulate a
straight land to support the heel of the punch. This adds significant strength to the
punch in case of a misfeed of the die.

Die Clearance

Slip Fit for Heel

Die Clearance

Slip Fit for Heel

Figure 7:28 Straight Cut and Taper

Wire EDM has provided the tool and die designer with many options in build-
ing dies. In the next chapter, we will demonstrate one of the fastest and most cost
effective ways to produce stamping dies.
 Advantage of Wire EDM for Die Making 119

Free Training Videos

(ReliableEDM.com)
Introduction to Tool and Die Making: Part 1 (5:18)

Introduction to Tool and Die Making: Part 2 (6:04)

Old Fashioned to Modern Tool and Die Making: Part 1 (7:51)

Old Fashioned to Modern Tool and Die Making: Part 2 (8:52)