Design changes, modifications, revisions, rework, production errors,
retrofits – How do you handle or correct these typical and
recurring manufacturing headaches?

We have all seen the group at the end of the production line trying to figure out what went wrong. After all the review meetings are done, the decision is made to correct or rework the parts, rather than scrap the whole lot. Now you are faced with several hundred – or even thousands – of parts that need an added hole, or even some new feature, that just can’t be done easily with hand tools. Modular Hard Dies can usually do it for you, with accurate, precise placement of the added feature – part after part. This can often be done easily and at typically low cost – even after forming in many cases.

Adding standard features or special modifications to already formed or pre-punched flat blank stampings can typically be accommodated with Whistler die systems. With standard holders and a rush order for the necessary tooling, you’re often able to have the stampings reworked in a just a few days. And as you accumulate and build your tooling inventory, you may find nearly everything you need to quickly resolve these headaches – already available in-house.

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 for family groups. 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 (2) rework applications to show how using Modular Hard Dies can maximize your tooling dollars. In these examples, each jobis punched complete in a single hit.

[one_half]APPLICATIONS

This customer needed to add a rectangle slot to already punched and formed parts. Modular XimmiX® dies let him do it quickly, at minimal cost and with only minor alterations to standard tools. As mentioned in the Extrusions and Formed parts section, customers find many uses for Modular Hard Dies, their flexibility and reuse allows production problems to be resolved quickly, accurately and imaginatively. [/one_half][one_half_last]APPLICATIONS

In this rework, the user needed to punch holes in already contoured parts. He already owned the punch tools and needed to purchase only a few special gauges to do the job. Whether your requirement is to pierce a hole that was missed in the original setup or to accommodate a revision, Whistler tooling systems give you an alternative way to recoup your investment and rework those errors into useable, saleable product.[/one_half_last]

SOLUTIONS:

For POST-PRODUCTION PROBLEM SOLVING, the Adjustable die system offers the most flexibility, since you determine the setup.

If rework deadlines are critical and your work is flat, XimmiX ® dies can usually provide the lowest low cost solution for medium run quantities, in the shortest period of time.

For higher volume reworks and retrofits on formed jobs or jobs needing the addition of tabs, small embossments or extruded holes, Magna Die ® may be your best choice, but justification on a single job may be difficult unless an adequate Master Set is already on-hand.