MATERIAL USED FOR DIE MAKING

In the die making practice a large variety of materials are available for use. These include many different kinds of steels, castings of both ferrous and non-ferrous metals, and even non metallic materials.

Carbon Die Steel-This steel may contain 0.90-1.15 Carbon, 0.20-0.45 Manganese, 0.16 Silicon, 0.025 Phosphorus, and 0.025 Sulphur.

Carbon Die Block Steel- 0.55-0.65 carbon, 0.50-0.70 manganese, 1.25-1.75 nickel, 0.60-1.10 chromium.

Tungsten Oil Hardening Steel- This steel contains about 1.20 carbon, 1.75 tungsten, and 0.25 manganese.

High –Alloy Oil-Hardening Steel- This class of non deforming steel contains about 2.15 carbons, 12.00 chromium, and manganese content of about 0.35.Vanadium, tungsten, and nickel are other elements which may be added to this class of steel.

Manganese Air Hardening Steel- A typical composition contains 0.90 carbon, 2.5 manganese, 1.5 chromium, 1.00 molybdenum, and 0.30 silicon.

Chromium Air Hardening Steel- This steel usually contains about 1.00 carbon, 5.00 chromium, 1.00 molybdenum, 0.50 manganese, 0.25 silicon, and in some cases 0.50 vanadium is added.

High Alloy Air-Hardening Steels- These steels like the high alloy oil-hardening type, have about 12.00 chromium. The carbon content varies from 1.00 to 2.15, manganese 0.35, silicon 0.35, molybdenum 0.80, and in some cases 0.50 vanadium.

Material for producing low cost dies.

In the manufacture of air craft and various other products their have been important developments in making die other than steel or cast steel, which meet practice requirements and yet make it possible to greatly reduce the die cost. This is particularly true where sheets, such as aluminium and magnesium, must be formed or drawn but in quantities that are not large enough to require as durable and expensive a material as steel, for example. These low cost die may be made of non-ferrous alloys such as Kirksite and Cerrobend and non-metallic material may also be used such as Masonite, plastics, Bakelite, dancified wood, and rubber. These die are utilized for drawing or forming in the usual manner and also in conjunction with stretch-forming process. The low cost dies referred to are extensively used for medium

MATERIAL USED FOR DIE MAKING

In the die making practice a large variety of materials are available for use. These include many different kinds of steels, castings of both ferrous and non-ferrous metals, and even non metallic materials.

Carbon Die Steel-This steel may contain 0.90-1.15 Carbon, 0.20-0.45 Manganese, 0.16 Silicon, 0.025 Phosphorus, and 0.025 Sulphur.

Carbon Die Block Steel- 0.55-0.65 carbon, 0.50-0.70 manganese, 1.25-1.75 nickel, 0.60-1.10 chromium.

Tungsten Oil Hardening Steel- This steel contains about 1.20 carbon, 1.75 tungsten, and 0.25 manganese.

High –Alloy Oil-Hardening Steel- This class of non deforming steel contains about 2.15 carbons, 12.00 chromium, and manganese content of about 0.35.Vanadium, tungsten, and nickel are other elements which may be added to this class of steel.

Manganese Air Hardening Steel- A typical composition contains 0.90 carbon, 2.5 manganese, 1.5 chromium, 1.00 molybdenum, and 0.30 silicon.

Chromium Air Hardening Steel- This steel usually contains about 1.00 carbon, 5.00 chromium, 1.00 molybdenum, 0.50 manganese, 0.25 silicon, and in some cases 0.50 vanadium is added.

High Alloy Air-Hardening Steels- These steels like the high alloy oil-hardening type, have about 12.00 chromium. The carbon content varies from 1.00 to 2.15, manganese 0.35, silicon 0.35, molybdenum 0.80, and in some cases 0.50 vanadium.

Material for producing low cost dies.

In the manufacture of air craft and various other products their have been important developments in making die other than steel or cast steel, which meet practice requirements and yet make it possible to greatly reduce the die cost. This is particularly true where sheets, such as aluminium and magnesium, must be formed or drawn but in quantities that are not large enough to require as durable and expensive a material as steel, for example. These low cost die may be made of non-ferrous alloys such as Kirksite and Cerrobend and non-metallic material may also be used such as Masonite, plastics, Bakelite, dancified wood, and rubber. These die are utilized for drawing or forming in the usual manner and also in conjunction with stretch-forming process. The low cost dies referred to are extensively used for medium

TOOL STEELS

Tool steel is specified for numerous die components and it may be well to discuss briefly the most commonly used types. they are:

1. Water hardening tool steel.

2. Oil hardening tool steel.

3. Air hardening tool steel.

4. High carbon high chromium tool steel.

5. High speed steel.

6. Shock resisting tool steel.

7. Hot work die steel.

1. Water hardening tool steel

As its name indicates water hardening tool steel is hardened by quenching it in water after it has first been heated to proper hardening temperature. it is employed for parts which can be ground after hardening. water hardening tool steel is subject to distortion in hardening process and it should not be specified for parts with internal contours that must remain accurate and which cannot be ground after hardening.

2. Oil hardening tool steel.

oil hardening tool steel contains chromium and it is quenched in oil in the hardening process.warpage or distortion is much less than for corresponding grades of water hardening steels. when accurate surfaces cannot be ground after hardening, and anticipated production rates are average, oil hardening tool steel should be specified. the abbreviation is O.H.T.S.

3. Air hardening tool steel.

air hardening tool steel need not be quenched in either oil or water for hardening to occur. after heating beyond the critical range, it is simply exposed in air until cool. air hardening tool steels have minimum warpage and this is combined with greater toughness and wear resistance than corresponding grades of oil or water hardening tool steels.

4. High carbon high chromium tool steel.

high carbon high chromium tool steel, have about the same properties as air hardening steels except that they posses a greater degree of resistance to wear. high carbon high chromium tool steel should be specified for die parts when long production runs are anticipated.

5. High speed steel.

The outstanding quality of high speed steel is its toughness, combined with a high degree of wear resistance. it should be specified for weak die parts such as frail inserts, small diameter punches, and the like another excellent application is in dies for cold working, coining and upsetting of metal.

6. Shock resisting tool steel.

shock resisting tool steel contain a smaller amount of carbon and therefore it is tougher than other types. it is employed for heavy cutting and forming operations where steels with higher carbon content would be subject to breakage.

7. Hot work die steel.

These steels are employed in dies designed for forming hot materials because they posses high resistance to softening under heat.

TYPE OF STEEL	Non deforming properties	Safety in hardening	Toughness	Wear resistance	machinability	Resistance to softening under heat
water hardening tool steel	POOR	FAIR	GOOD	FAIR	BEST	POOR
oil hardening tool steel	GOOD	GOOD	FAIR	FAIR	GOOD	POOR
air hardening tool steel	BEST	BEST	FAIR	GOOD	FAIR	FAIR
high carbon high chromium tool steel	BEST	BEST	POOR	GOOD	POOR	FAIR
high speed steel	GOOD	BEST	BEST	GOOD	FAIR	GOOD
shock resisting tool steel	FAIR	GOOD	BEST	FAIR	FAIR	FAIR
hot work die steel	BEST	BEST	BEST	FAIR	FAIR	GOOD

TOOL STEELS

Tool steel is specified for numerous die components and it may be well to discuss briefly the most commonly used types. they are:

1. Water hardening tool steel.

2. Oil hardening tool steel.

3. Air hardening tool steel.

4. High carbon high chromium tool steel.

5. High speed steel.

6. Shock resisting tool steel.

7. Hot work die steel.

1. Water hardening tool steel

As its name indicates water hardening tool steel is hardened by quenching it in water after it has first been heated to proper hardening temperature. it is employed for parts which can be ground after hardening. water hardening tool steel is subject to distortion in hardening process and it should not be specified for parts with internal contours that must remain accurate and which cannot be ground after hardening.

2. Oil hardening tool steel.

oil hardening tool steel contains chromium and it is quenched in oil in the hardening process.warpage or distortion is much less than for corresponding grades of water hardening steels. when accurate surfaces cannot be ground after hardening, and anticipated production rates are average, oil hardening tool steel should be specified. the abbreviation is O.H.T.S.

3. Air hardening tool steel.

air hardening tool steel need not be quenched in either oil or water for hardening to occur. after heating beyond the critical range, it is simply exposed in air until cool. air hardening tool steels have minimum warpage and this is combined with greater toughness and wear resistance than corresponding grades of oil or water hardening tool steels.

4. High carbon high chromium tool steel.

high carbon high chromium tool steel, have about the same properties as air hardening steels except that they posses a greater degree of resistance to wear. high carbon high chromium tool steel should be specified for die parts when long production runs are anticipated.

5. High speed steel.

The outstanding quality of high speed steel is its toughness, combined with a high degree of wear resistance. it should be specified for weak die parts such as frail inserts, small diameter punches, and the like another excellent application is in dies for cold working, coining and upsetting of metal.

6. Shock resisting tool steel.

shock resisting tool steel contain a smaller amount of carbon and therefore it is tougher than other types. it is employed for heavy cutting and forming operations where steels with higher carbon content would be subject to breakage.

7. Hot work die steel.

These steels are employed in dies designed for forming hot materials because they posses high resistance to softening under heat.

TYPE OF STEEL	Non deforming properties	Safety in hardening	Toughness	Wear resistance	machinability	Resistance to softening under heat
water hardening tool steel	POOR	FAIR	GOOD	FAIR	BEST	POOR
oil hardening tool steel	GOOD	GOOD	FAIR	FAIR	GOOD	POOR
air hardening tool steel	BEST	BEST	FAIR	GOOD	FAIR	FAIR
high carbon high chromium tool steel	BEST	BEST	POOR	GOOD	POOR	FAIR
high speed steel	GOOD	BEST	BEST	GOOD	FAIR	GOOD
shock resisting tool steel	FAIR	GOOD	BEST	FAIR	FAIR	FAIR
hot work die steel	BEST	BEST	BEST	FAIR	FAIR	GOOD

GLOSSARY OF PRESS TOOL TERMS

GLOSSARY OF PRESS TOOL TERMS

ANNEALING:
A process involving the heating and cooling of a metal, commonly used to induce softening.
The term refers to treatments intended to alter mechanical or physical properties or to produce a definite microstructure.
BEAD:
A narrow ridge in a sheet-metal work piece or part, commonly formed for reinforcement draw:
(a) A bead used for controlling metal flow.
(b) Rib like projections on draw ring or hold-down surfaces for controlling metal flow.
BED, PRESS:

The stationary and usually horizontal part of a press that serves as a table to which a bolster plate or lower die assembly is mounted.

BEND ANGLE:
The angle through which a bending operation is performed.

BENDING:
The straining of material usually flat sheet or strip metal, by moving it around a straight axis which lies in the neutral plane.

BEND RADIUS:
(a) The inside radius at the bend in the work
(b) The corresponding radius on the punch or on the die.

BLANK:
A precut metal shape, ready for a subsequent press operation.

BLANK DEVELOPMENT:
(a) The technique of determining the size and shape of a blank.
(b) The resultant flat pattern.

BLANK HOLDER:
The part of a drawing or forming dies which holds the work piece against the draw ring to control metal flow.
BLANKING.
The operation of cutting or shearing a piece out of stock to a predetermined contour.


BOLSTER PLATE:
A plate secured to the press bed for locating and supporting the die assembly.

BUCKLING:
A bulge, bend, kink, or other wavy condition of the work piece caused by compressive stresses.


BULGING:
The process of expanding the walls of a cup, shell or tube with an internally expanding
segmental punch or a punch composed of air, liquids, or semi liquids, such as waxes or Rubber and other elastomers.
BURNISHING:
The process of smoothening or plastically smear¬ing a metal surface to improve its finish.
BURR SIDE:
The side of a punched blank that presents a rough edge around its periphery or around a hole or opening in it.

CAM ACTION:
A motion at an angle to the direction of an applied force, achieved by a wedge or cam.

DIE HEIGHT (SHUT HEIGHT):
The distance from the finished top face of the upper shoe to the finished bottom face of the lower shoe, immediately after the die operation and with the work in the die.

DIE HOLDER:
A plate or block upon which the die block is mounted.

DIE RADIUS:
The radius at the edge of a female die over which metal is formed or drawn into the die.

DRAWABILITY:
(a) A measure of the feasible deformation of a blank during a drawing process;
(b) Percentage of reduction in diameter of a blank when it is drawn to a shell of maximum practical depth.

DRAWING:
A process in which a punch causes flat metal to flow into a die cavity to assume the shape of a seamless hollow vessel.

EMBOSSING:
A process that produces relatively shallow indentations or raised designs with theoretically no change in metal thickness.
EXTRUSION:
The plastic flow of a metal through a die orifice.

IRONING:
An operation in which the thickness of the shell wall is reduced and its surface smoothened.

KNOCKOUT:.
A mechanism for ejecting blanks or other work from a die. Commonly located on the side, but may be located under the bolster.

NOTCHING:
The cutting out of various shapes from the edge of a strip, blank, or part.

PARTING:
An operation usually performed to produce two or more parts from one common stamping.

PIERCING:
The process of die-cutting holes in sheet or plate material. Pilot pin or projection provided for locating work in. subsequent operations from a previously punched or drilled hole.
PRESS:
A machine having a stationary bed or anvil, and a slide (ram or hammer) which has a controlled reciprocating motion toward and away from the bed surface and at right angles to it. The slide being guided in the frame of the machine to give a definite path of motion.

PUNCH:
(a) The male tool part, usually the upper member and mounted on the slide;
(b) To die-cut a hole in sheet or plate material;
(c) A general term for the press operation of producing holes of various sizes in sheets, plates, or rolled shapes.

PUNCH HOLDER:
The plate or part of the die which holds the punch.

SCRAP CUTTER:
A shear or cutter operated by the press 6r built into a die for cutting scrap into sizes for convenient removal from the die or disposal.

SHAVING:
A secondary shearing or cutting operation in which the surface of a previously cut edge is finished or smoothened.

SHEAR:
(a) A tool for cutting metal and other material by the closing motion of two sharp, closely adjoining edges;
(b) To cut by shearing dies or blades;
(c) An inclination between two cuttings.

SLITTING:
Cutting or shearing along single lines; used either to cut strips from a sheet or to cut along lines of a given length or contour in a sheet or part.

SLUG:
A small piece of material, usually scrap, produced in piercing or punching holes in sheet material.



SPOTTING:
The fitting of one part of a die to another, by applying an oil color to the surface of the finished part and bringing it against the surface of the intended mating part, the high spots being marked by the transferred color.

SPRING-BACK:
The extent to which metal tends to return to its original shape or position after undergoing a forming operation.

STAMP:
(a) The general term to denote all press working;
(b) To impress lettering or designs by pressure into the surface of a material.

STRIPPER:
A device for removing the work piece or part from the punch.

STRIPPER PLATE:
A plate (solid or movable) used to strip the work piece or part from the punch; it may also guide the stock.

STRIPPING:
The operation of removing the work piece or part from the punch.

TRIMMING:
Trimming is the term applied to the operation of cutting scrap off a partially or fully shaped part to an established trim line.

GLOSSARY OF PRESS TOOL TERMS

GLOSSARY OF PRESS TOOL TERMS

ANNEALING:
A process involving the heating and cooling of a metal, commonly used to induce softening.
The term refers to treatments intended to alter mechanical or physical properties or to produce a definite microstructure.
BEAD:
A narrow ridge in a sheet-metal work piece or part, commonly formed for reinforcement draw:
(a) A bead used for controlling metal flow.
(b) Rib like projections on draw ring or hold-down surfaces for controlling metal flow.
BED, PRESS:

The stationary and usually horizontal part of a press that serves as a table to which a bolster plate or lower die assembly is mounted.

BEND ANGLE:
The angle through which a bending operation is performed.

BENDING:
The straining of material usually flat sheet or strip metal, by moving it around a straight axis which lies in the neutral plane.

BEND RADIUS:
(a) The inside radius at the bend in the work
(b) The corresponding radius on the punch or on the die.

BLANK:
A precut metal shape, ready for a subsequent press operation.

BLANK DEVELOPMENT:
(a) The technique of determining the size and shape of a blank.
(b) The resultant flat pattern.

BLANK HOLDER:
The part of a drawing or forming dies which holds the work piece against the draw ring to control metal flow.
BLANKING.
The operation of cutting or shearing a piece out of stock to a predetermined contour.


BOLSTER PLATE:
A plate secured to the press bed for locating and supporting the die assembly.

BUCKLING:
A bulge, bend, kink, or other wavy condition of the work piece caused by compressive stresses.


BULGING:
The process of expanding the walls of a cup, shell or tube with an internally expanding
segmental punch or a punch composed of air, liquids, or semi liquids, such as waxes or Rubber and other elastomers.
BURNISHING:
The process of smoothening or plastically smear¬ing a metal surface to improve its finish.
BURR SIDE:
The side of a punched blank that presents a rough edge around its periphery or around a hole or opening in it.

CAM ACTION:
A motion at an angle to the direction of an applied force, achieved by a wedge or cam.

DIE HEIGHT (SHUT HEIGHT):
The distance from the finished top face of the upper shoe to the finished bottom face of the lower shoe, immediately after the die operation and with the work in the die.

DIE HOLDER:
A plate or block upon which the die block is mounted.

DIE RADIUS:
The radius at the edge of a female die over which metal is formed or drawn into the die.

DRAWABILITY:
(a) A measure of the feasible deformation of a blank during a drawing process;
(b) Percentage of reduction in diameter of a blank when it is drawn to a shell of maximum practical depth.

DRAWING:
A process in which a punch causes flat metal to flow into a die cavity to assume the shape of a seamless hollow vessel.

EMBOSSING:
A process that produces relatively shallow indentations or raised designs with theoretically no change in metal thickness.
EXTRUSION:
The plastic flow of a metal through a die orifice.

IRONING:
An operation in which the thickness of the shell wall is reduced and its surface smoothened.

KNOCKOUT:.
A mechanism for ejecting blanks or other work from a die. Commonly located on the side, but may be located under the bolster.

NOTCHING:
The cutting out of various shapes from the edge of a strip, blank, or part.

PARTING:
An operation usually performed to produce two or more parts from one common stamping.

PIERCING:
The process of die-cutting holes in sheet or plate material. Pilot pin or projection provided for locating work in. subsequent operations from a previously punched or drilled hole.
PRESS:
A machine having a stationary bed or anvil, and a slide (ram or hammer) which has a controlled reciprocating motion toward and away from the bed surface and at right angles to it. The slide being guided in the frame of the machine to give a definite path of motion.

PUNCH:
(a) The male tool part, usually the upper member and mounted on the slide;
(b) To die-cut a hole in sheet or plate material;
(c) A general term for the press operation of producing holes of various sizes in sheets, plates, or rolled shapes.

PUNCH HOLDER:
The plate or part of the die which holds the punch.

SCRAP CUTTER:
A shear or cutter operated by the press 6r built into a die for cutting scrap into sizes for convenient removal from the die or disposal.

SHAVING:
A secondary shearing or cutting operation in which the surface of a previously cut edge is finished or smoothened.

SHEAR:
(a) A tool for cutting metal and other material by the closing motion of two sharp, closely adjoining edges;
(b) To cut by shearing dies or blades;
(c) An inclination between two cuttings.

SLITTING:
Cutting or shearing along single lines; used either to cut strips from a sheet or to cut along lines of a given length or contour in a sheet or part.

SLUG:
A small piece of material, usually scrap, produced in piercing or punching holes in sheet material.



SPOTTING:
The fitting of one part of a die to another, by applying an oil color to the surface of the finished part and bringing it against the surface of the intended mating part, the high spots being marked by the transferred color.

SPRING-BACK:
The extent to which metal tends to return to its original shape or position after undergoing a forming operation.

STAMP:
(a) The general term to denote all press working;
(b) To impress lettering or designs by pressure into the surface of a material.

STRIPPER:
A device for removing the work piece or part from the punch.

STRIPPER PLATE:
A plate (solid or movable) used to strip the work piece or part from the punch; it may also guide the stock.

STRIPPING:
The operation of removing the work piece or part from the punch.

TRIMMING:
Trimming is the term applied to the operation of cutting scrap off a partially or fully shaped part to an established trim line.