The world’s original Modular Hard Die system, Adjustable Dies provide the ultimate in press working flexibility – ideal for prototyping, rework, retrofitting and for those infrequent or “one-time only” production runs. Simple punch-to-die alignment procedures allow the user to punch ultra-thin materials with metal-to-metal die clearances, or materials up to 1/2″ (12.7 mm) thick mild steel.
Adjustable Dies consist of these basic components: The T-slotted Die Set which is the base or heart of the system; punch and die holders, which are secured to the Die Set with T-bolts; the punches and die bushings, referred to as the cutting members, specified with the proper die clearance for the material being punched and secured into their holders with setscrews; strippers, which are placed around each punch to perform two functions – 1) to hold the material in place just prior to punch entry and 2) to strip the material off the punch point after piercing. The final components are gauges, used to position the work piece in the proper location for punching.
Adjustable Dies are typically assembled by hand, inside the press. This means there is some press down time for setup, which can be minimized by keeping one sample part from the previous production run to permit faster setup. Since the sample contains all desired features, it can be used as a setup template. The tools themselves can be placed into the sample holes then bolted in position, reducing setup and downtime accordingly. Once the die assembly is completed and all tools are in place, production can begin. When the run is completed, tools can be repositioned for use on another job. The modularity of Adjustable Dies insures that the tools can be reused repeatedly, while still providing the desired accuracy. A degree of mechanical skill with a sense of “touch and feel” is desirable for the user, but this is easily acquired in short time with practice.
APPLICATIONS
Below is an overview of the capacity choices available with Adjustable Die systems. If you believe any of these matches the requirements for your application, you can request a quotation by completing the quote request steps identified on our request page. Before making your choice, however, we do encourage you to continue reading to learn more our other systems. There’s no obligation for the quote.
Available in three (3) basic styles, each designed to pierce
a specific range of material thickness and hole sizes.
[one_third]U 375 SERIES
Mild steel up to .062″ (1.5mm)
Maximum hole .750″ (19.05mm)
[/one_third][one_third]STANDARD
Mild steel up to .250″ (6.3mm).
Maximum hole 4.00″ (101.64mm)
[/one_third][one_third_last]HEAVY DUTY
Mild steel up to .500″ (12.7mm).
Maximum hole 4.00″ (101.64mm)
[/one_third_last]
LAYOUT and SETUP
Whistler provides design aids to help you with layout of your application. Whether you have CAD systems or only simple tools for hand-scribing a blank for conventional drilling, you can easily design and make a setup template to achieve your final product. The most common setup procedure uses a pre-sheared blank with .093” (2.36 mm) drilled holes located at the center coordinates of each feature to be punched. Once completed, gages and die retainers with .093” (2.36 mm) pilot bushings are installed into the lower section of the T-slot die set. For non-round hole features, drilling (2) holes in the template will permit accurate radial alignment and proper orientation of your shape. For those with CAD systems, complete layouts can be computer-generated by using our DXF disk, which is filled with all the standard system components. Our disk helps you quickly identify the items you need for your job and lets you create a layout that can be used in the shop for setup.
At the center of each feature, drill a .093” (2.36 mm) hole. For other features such as rectangles and ovals, drill two (2) holes on centers identified by the proper setup insert
Start by opening your subject and simply insert each of the tool holder blocks from the DXF disk. Position each on the subject and review the completed layout for Die Set attachment and fit.
SERIES FEATURES
Each Adjustable series includes standard and accessory items available for correct punching and notching of your subject. Each series is defined by its range of tool holder sizes for a given hole size. The retainer required is based on the hole size being pierced. For conditions of close hole centers, punches and dies can be made into configurations known as multiples. This utilizes one of the common punch diameters while accommodating more than one feature on the selected size. Multiples can reduce the number of hits and or tools required for a given part.
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u 375 series |
standard |
heavy duty |
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Series 375 |
Series 50 |
(Punch bodies are upsized one unit from Standard series, with series 100 being the smallest for heavy duty.) |
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Accessories |
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u 375 series |
standard |
heavy duty |
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Setup Plugs |
Setup Plugs |
Setup Plugs |
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3×3 Corner notch die* |
3×3 Corner notch die* |
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* Used for 90˚ corners and / or 90˚ edge notches, also can be used for Cutoff. |
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CUSTOM SUB-DIES
For those larger features on your subject or for hole groupings or clusters that exceed the size capacity of standard punch and die holders, Whistler provides custom “sub-die” tools, designed to operate in conjunction with standard Adjustable system tools. These sub-dies achieve the patterns that won’t fit in the standard retainer options and are limited in size by only the T-slot die set area. Sub-dies are often used for higher production volumes as a way to reduce the number of hits required to complete the part.
SPECIAL APPLICATIONS
For adding holes to formed stampings or extrusions, Whistler can provide punches, die bushings and strippers of varying heights and lengths to accommodate simultaneous punching of multiple elevations within the same subject. These “higher / longer / shorter than standard” cutting members provide the ultimate in modular tooling flexibility, further enhancing the potential capacity of the Adjustable Die system.
Send your prints to our engineering department via mail, courier or fax, or better yet – send them via email in DXF file format. We will review and discuss your requirements with you up front and recommend a modular die system best suited your specific application. Detailed system quotations will then be developed, clearly identifying all necessary system components. There is no charge for this service.
