DIE BLOCKS

DIE BLOCKS

 Factors influence the design of a die block:-
• Piece part size
• Stock thickness
• Intricacy of the piece part contour
• Type of tool
• Machinery available for manufacturing the tool

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SOLID DIES
Made up of non shrinking tool steels Hardened & tempered to 58-62hrc

Considerations
• Critical nature of the Dimensions involved
• Extreme Pressures & Wear conditions while Shearing
• Sheet thickness
• Press force
• Strength & Life of the Die:
• Sufficient wall thickness at the weakest points
• Sufficient Die thickness according to the Severity of the specific operations.

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DIES THICKNESS

STOCK MATERIAL THICKNESS IN mm	FOR DIE BLOCK LENGTH
	upto125mm	125-200mm	200-400mm
upto 1	16	20	24
1  to  2	20	24	28
2  to  3	24	28	32
3  to  4	28	32	36
4  to  6	32	36	50
6  &  above	36	40	60

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DIE BUSHES

These are inserted in Mild Steel retainer plate.

Advantages:
Easily replaceable.
Reduces cost of the die manufacturing.
Applications:
In large piercing dies.

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SPLIT or SECTIONAL DIE BLOCKS

These are the dies having more than One Section.

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DECIDING FACTORS OF SOLID OR SPLIT DIES

SOLID DIE	SPLIT DIE
SIZE OF THE DIE BLOCK
Small	Bigger
	Reduces cost, Machining Time, Hardening Failures
SIZE OF THE DIE OPENING
Sufficient to perform internal working	Too small for Internal working
	Eases the machining process.
COMPLEXITY OF THE DIE OPENING
Simple contours	Intricate cotours, Sharp Corners in the component
	Eases machining
	Avoids Cracks at hardening.
PERISHABILITY
No possibility of Breakage	High Possibility of Breakage
	Simplify the manufacture of relatively perishable portions of the die block
PROFILE GROUND DIE OPENING
When internal grinding is possible	When internal grinding is impossible

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Locating & Clamping of Die Sections

Considerations
Tilting Due to Downward Thrust.
Lateral Displacement due to Lateral Thrust created by  the Punching Action.

Methods:
For Thin Stock materials, Dowels and Screws.
As the Stock material thickness increases, Need of Nesting arises.

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NESTING METHODS OF NESTING

Nesting in Die set pockets.
Nesting in Retainer Plate, which is of Mild steel.
Nesting in the above methods incorporating Liners.

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NESTING IN DIE SET with LINERS

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NEST BLOCKS

Advantages:
They do not weaken the die set.
Can be easily hardened for heavy work.
Can be easily ground, when Die needs to reground. As the Whole assembly of Die Sections are ground together.

Disadvantage 
Costly compared to pocket milled Die set type  nesting, as the separate nest block has to be machined & clamped to the die set.

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NESTING IN RETAINER PLATE
 

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LOCATING & KEYING OF CIRCULAR SECTIONS

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DIE INSERT

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CARBIDE DIES

Die Material: Tungsten Carbide.

Applications:
       Blanking, Piercing, Trimming, Forming, Drawing, and Swaging operation.
       Where production rates are high.
       Parts having Close tolerances.

DESIGN PRINCIPLE:
DRAW RADII or APPROACH ANGLES.
PUNCH & DIE CLEARANCE.
RELIEF

ALL Remains the same as that of the Steel Dies.

Supporting of Carbide Dies inserts:
         Inserts must be supported externally by pressing or shrinking them into a Hardened steel case.