Featuring a Master Die Set with template-positioned tooling, Magna Die ® systems provide the user with off-the-press setup and rapid die change with minimum press downtime. The Master Die Set remains in the press while job-specific templates are shuttled in and out as needed. Die changes can be completed in just minutes. Larger Master Die Sets are made with segmented template stations to insure that setup and changeover operations remain simple and manageable. Magna Die ® systems are ideal for moderate to high production volumes of intermittent, repetitive stamping jobs. The system readily adapts to either hand-feeding of cut blanks and strips or coil-fed material with cutoff and is targeted for accurate punching and notching of materials from 22 GA up through 1/2″ (12.7 mm) thick mild steel.

Magna Die ® systems consist of these basic components: The Master Die Set which is the heart of the system; match-machined template sets that locate the tool holders in accordance with the desired hole pattern; punch holders which are positioned through the punch template and secured to the Die Set with powerful, permanent magnets; die holders which are positioned through the die template and held in place inside the Master Die Set by simple gravity; 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 gages, which attach to the die template for accurately locating the work piece for punching.

Templates and tools are assembled manually offline and away from the press, quickly and easily and without any special skill requirements or tools. When ready to run the job, assembled templates are loaded into the press in just a few minutes, and secured with four (4) clamp screws each. Once installed, production can begin and there is no need for first-part inspection.  When the production run is completed, tools can be reused on another job if needed, or stored as assembled, or disassembled for cabinet storage. The unique modularity of Magna Die ® insures that the tools can be reused repeatedly on many jobs and produce consistently accurate stampings, every time.

 

 

APPLICATIONS

Below is an overview of the capacity choices available with Magna Die ® tooling systems.  If you believe either 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 Two (2) basic styles-each designed to pierce a specific range of material thickness and hole sizes.

[one_half]Standard
Mild steel up to .250″ (6.3mm)
Maximum hole 4.00″ (101.64mm)
[/one_half][one_half_last]Heavy Duty
Mild steel up to .500″ (12.7mm)
Maximum hole 4.00″ (101.64mm)
[/one_half_last]

 LAYOUT and SETUP

Accuracy of punched stampings depends on the accuracy of machined template sets. Template accuracy is achieved by machining a set of two (2) plates together, using any conventional or CNC mill. Whether you have CAD or only simple layout tools, you can design your template to achieve the final product by simply identifying the center coordinates of each hole feature, then accurately machining or boring respective tool holder positions. 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 will need and lets you create a layout that can be used in the shop for fabricating the template set, as well as for tool and template assembly of each job.

Identify the center coordinates for each hole feature. The machining or bore size for each series is provided in the User Guide. For special shapes, a slot is cut to engage an orientation pin on the body of every shaped punch and bushing. Locate gages, pilots and notch dies as needed and release the details to the shop for template fabrication.

 

 

Start by opening your subject and simply insert each of the tool holder blocks, gages and pilots as needed from the DXF disk. Position each on the subject and review the completed layout for correctness and fit. The inserted blocks contain layers, which once ungrouped, allow you to view only the machining requirements for the templates.

 

 

SERIES FEATURES

Each Magna Die ® 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.

 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 Magna Die ® system tools. These sub-dies achieve the patterns that won’t fit in the standard retainer options and are limited in size only by the Master Die Set and template area. Sub-dies are typically 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 Magna 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.