Coil-fed, modular tooling for automated, high volume production – you can’t have this with custom dies. Turret punch presses can’t provide it either.

Whether you are a steel service center supplying cut-to-length flat blanks, or a production shop with high-volume assembly lines to feed, or a job shop stamping house serving different industries – Whistler die systems can provide the accuracy, the flexibility and the productivity you need to meet both your current demand and your future capacity requirements. Designed specifically for your press and feed equipment, Modular Hard Dies can provide alternative capacity for your cut-to-length lines, and simultaneously give you the choice to include progressively punched or notched features as a “value-added” option for your customers.

Standardized, modular design means simple and consistent setup procedures for your shop employees. Our coil guiding system consists of modular roller gages, air crowders, stock lifters and edge guides. These items are common for all applications and can be used repeatedly on other jobs – just like our modular punching tools. Some applications allow simple changeovers to be made right at the press, while others can be assembled in your tool room setup area, for quick installation in the press in a matter of minutes. No special tools or press adjustments are necessary – simply load the tooling into the press and change your feed unit stroke length to suit the job.

All Whistler tooling is designed to run at a constant shut height. Features such as knockout penetrations and extruded hole depths are controlled in the tooling lengths – not by the ram. For those applications where coil is not practical, consider running parts from hand-fed strips with internal cutoff, rather than from pre-cut blanks – gives you greater yield and faster production with less scrap.

Before selecting a tooling system, you first need to identify which press to use for the job. This process usually requires a thorough review of the potential work to be handled by both the tooling system and the press. Important press specifications to consider, in addition to its make and model number, include bed and ram areas, tonnage capacity, shut height (stroke down, adjustment up), stroke length, the amount of adjustment, and whether the press is a mechanical type, or hydraulic, or pneumatic. This information will be used to determine the correct size and fit of a Master Die Set and whether any additional features such as stop blocks or bolster plates may be necessary. Detailed press data will also be a factor in determining the number of hits necessary to complete your stamping.

Straight side, gap frame and OBI type presses are not the only possible choices. Many users have selected hydraulic or mechanical press brakes for use with Modular dies. Most brakes can be fitted with rigid support brackets to increase their front-to-back size capacities, but to protect against potential damage to both the brake and the tooling, consideration must be given to centralizing tonnage loads on a per job basis. Support brackets are often available in different sizes from the press manufacturer and they can also be supplied by Whistler.

During the press selection process for Magna Die ® and / or Adjustable systems, you may wish to consider the idea of getting maximum flexibility and best capacity utilization, by specifying a Master Die Set for use in more than one press.

Here we review two coil-fed applications to show how using Modular Hard Dies can maximize your tooling dollars.

[one_half]PART A

This application was designed to produce a series of (7) similar jobs on one master set, with a single common template. All modular coil control features are template-attached items. Due to the small part size (approx. 1-1/2” x 1-3/4″ / 38.1 x 44.45 mm) changeable sub press die cartridges were developed for each individual part, all cartridges sharing the same set of sub-base shoes. Changeover is done inside the press, simply by removing (4) bolts in each section. This modular design allows changeover in just minutes.[/one_half][one_half_last]PART B

One of our larger applications for a steel service center is shown above. By adding a press inside their cut-to-length line, they now provide their customers with pre-punched and notched blanks. The Master Set – 52” / 1321 mm square and fitted with 4-24” / 610 mm square template stations – is able to accommodate most any punching requirement. The system allows off-line setup of the next job and inventoried tools are shared for reuse among many of their customers[/one_half_last]

 SOLUTIONS:

For COIL and / or STRIP feeding, either Magna Die ® or XimmiX ® dies are the recommended options. In some cases strip feeding can be accommodated by Adjustable dies, although we suggest either of the first two for more consistent results. Both Magna Die ® and XimmiX ® tooling systems offer these basic features and options.

Both systems use a two-template alignment method unique to Modular Hard Dies. Two-template alignment ensures stamping accuracy and repeatability with excellent tool life, yet allows the tools to be reused over many different jobs.

Each system is designed to function same as a typical custom die would, while still providing flexibility and low tooling cost through amortization over multiple job applications.

As with any custom progressive die, issues of scrap handling and removal of finished stampings need to be considered. With Magna Die ® systems, punched scrap material is generally discharged through die retainer chutes to the top surface of master set die shoe. Depending on the specific job, air blow-off and / or scrap conveyors can also be successfully applied.

System modularity and flexibility with a wide range of coil control features permit you to determine the best number of progressions for your job. All components are designed for use on a wide range of material types and thickness.

As you review each system, consider how many of your higher-volume jobs might be better produced from coil-fed material using modular dies, if you did not have to purchase a single custom hard die for each job.