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Managing Horizontal Forces in Stamping Dies-Part 2 - MetalForming Magazine Article

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10.06.

2020 Managing Horizontal Forces in Stamping Dies—Part 2 | MetalForming Magazine Article

HOME ❯ ARTICLE ❯ TOOLING ❯ IN DIE PROCESSES

Managing Horizontal Forces in


Stamping Dies—Part 2
June 1, 2020
PETER ULINTZ
Technical Director

Last month’s column addressed the management of horizontal forces in


the dieset. This month: The prevention of die-component shifting due
to horizontal die forces.

Assuming a cutting thrust of 8000 lb.-force (lbf) exerted horizontally on the upper
trim section, and a friction coefficient of 0.15, how many socket head cap screws are
required to prevent the die section from shifting?

Dies experiencing significant side loads often have multiple causes,


including: poor alignment of die components during construction;
misalignment resulting from a bad hit or die crash; shifting of
components due to angular contact between angular form steels;
nonsymmetrical forms or draws where the punch and die are loaded
off-center at initial contact; and cutoff, trim, bending and flanging
operations where forces act on only one side of the die steel.

Shifting of Die Components

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10.06.2020 Managing Horizontal Forces in Stamping Dies—Part 2 | MetalForming Magazine Article

Maintaining alignment and designed clearances between die


components is paramount for long die life and consistent part quality.
When a die component shifts, alignment and clearances can alter
significantly enough to cause galling or shearing damage to the tooling.

Shifting of die steels is prevented through a combination of forces


applied normal (perpendicular) to the mounting surface and the friction
generated between the two surfaces. Friction occurs because the
surfaces in contact are not smooth. Small ridges on the mating surfaces
lock together, restricting movement. For movement to occur, these
ridges must be broken off (sheared) by a horizontal force of sufficient
magnitude. The force required to move two sliding surfaces over each
other, divided by the force holding them together, is known as the
friction coefficient (µ).

Intuitively, we know that higher frictional forces better prevent the


shifting of die components. Now let’s covert this intuitive
understanding into something more useful and easy to remember: 

Friction is fun, or F = µ N

Where F is the static frictional force, µ the friction coefficient and N the
normal force.

The friction coefficient for two pieces of steel in contact, clean and dry,
is approximately 0.75. With each surface lightly oiled, the friction
coefficient could approximate 0.15.

In general, cutting and forming forces act together with the mounting
screws to produce a normal force great enough to prevent shifting of

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10.06.2020 Managing Horizontal Forces in Stamping Dies—Part 2 | MetalForming Magazine Article

the die components. This is achieved through the selection of screw size
and quantity, and the torque applied to each screw.

Fastener Selection
In the accompanying illustration, assume a cutting thrust of 8000 lb.-
force (lbf) exerted horizontally on the upper trim section. Considering
that most die sections feature a light oil application to prevent rust and
the fact that we also want a safety margin, assume a friction coefficient
of 0.15. How many socket head cap screws are required to prevent it
from shifting?

Let X equal the total clamping force required

X = 7500 lbf divided by 0.15

X = 50,000 lbf total

1. Calculated pretension is approximately 75 percent of the screw’s yield strength 2.


Torque values based on K factors determined using DIN 946 (T=KDP) Source:
International Fastener Institute, Fastener Specifications for Hexagon Socket Head
Cap Screws

The accompanying table depicts the calculated pretension stress and


the tightening torque values for several 3-in.-long socket head cap
screws. Several viable options exist to meet the 50,000 lbf requirement:
Five 3⁄8-24 alloy-steel cap screws, torqued to 67 ft.-lbf; four 7⁄16-14
alloy-steel cap screws, torqued to 94 ft.-lbf; or three 1⁄2-13 alloy-steel
cap screws torqued to 144 ft.-lbf.
Be careful when selecting stainless steel cap screws, which feature

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10.06.2020 Managing Horizontal Forces in Stamping Dies—Part 2 | MetalForming Magazine Article

tensile-strength, pretension and torque values considerably less than


those of alloy steel. In the example, generating 50,000 lbf requires 12 of
the 3⁄8-24 stainless steel cap screws, torqued to 27 ft.-lbf.

Should stainless steel cap screws be required to help prevent in-die


magnetism, the quantity of screws could be reduced by increasing the
friction coefficient. Suppose that the mounting surface of the die
component is ground to a very high finish, lightly oiled and mounted on
a smooth, cold-rolled sub-plate. The friction coefficient can be increased
by leaving a rough ground surface on the bottom of the die section and
ensuring completely dry and oil-free mounting surfaces. Under these
conditions, let’s assume a friction coefficient of 0.75.

Let X equal the total clamping force required

X = 7500 lbf divided by 0.75

X = 10,000 lbf total

Now, four 3⁄8-16 stainless steel cap screws, torqued to 24-ft.-lbf would
suffice. However, it is imperative to assure that the friction conditions do
not change. Any decrease in friction requires an increase in the number
of screws or a change in the screw material in order to apply a higher
torque. 

Also, remember that torque requirements increase for dry, rough (or
damaged) tapped holes or when dirt or chips are present in the threads.
Be diligent in your maintenance practice.

Other difficulties may be encountered even when using the correct size
and quantity of screws. For example, the diemaker does not torque the
screws properly, if at all. My first-hand experience reveals that a torque
wrench seldom is found in a diemaker’s toolbox. Instead, very long
“cheater” pipes are slipped over the Allen wrench and pulled with as
much force as the die-maker can exert or thinks is needed.

Only when using a torque wrench will the full value for each screw be
obtained. When randomly tightened, only the tighter screws carry the
load. Screws tightened without a torque wrench may overstretch and

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10.06.2020 Managing Horizontal Forces in Stamping Dies—Part 2 | MetalForming Magazine Article

permanently yield. Many screws have broken from fatigue in die


operations due to overstressing.

Next month, this series on managing horizontal forces concludes by


addressing dowel pins, backup keys and methods to prevent
component tipping. MF

Industry-Related Terms: Bending, Die, Form, Forming, Shearing, Stainless Steel,


Surface, Torque
View Glossary of Metalforming Terms

Technologies: TOOLING

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