Catalogue of High Performance Punches,

Transcription

1 Catalogue of High Performance Punches, Dies and Other Parts

2 Overview 1. Precision Punches 2. Dies 3. Pilot and Locating Pins 4. Other Die Support Parts 5. Ejector Pins 6. Carbide Parts 7. Other Parts 1

3 Introduction The TD Coating Centre (Pty) Ltd has been supplying high performancee manufactured parts since Our first FANG development was the range of piercing punches with the heavy duty TD coating. As we addedd further coatings and surface treatments to the company s portfolio, so have we further expanded our range of standardized performance products and we are continuously adding items as we see the need for an improved product. We currently supply manufactured items to several industries ncluding sheet metal forming, piercing and perforation, automotive, mining, explosives, ammunition andd plastics to name a few.. Our locally developed products equal or outperform similar international items and at a very competitive price. Should you have any queries about our products or services, please contact us. If you would like to also see any additional items included i in our range, please inform us. Surface Engineering Surface Engineering is the science of modifying the surface of a component to provide properties not normally available from just the base metal. Surface treatments and coatings aree very effective in reducing adhesivee wear (galling and scoring) and abrasive wear. It extends part life significantly to reduce maintenance, replacement costss and downtime. When combined with the correct base metal, it provides a significant leap in performance. The TDCC mainly uses the following coatings. Thermal Diffusion (TD) coating: a hot process which diffusion-bonds surface. TD is used in applications requiring utmost wear resistance ass it has the highest adhesion strength and even at ± an ultra-hard, low friction layer of vanadium carbide layer to the steel 90 HRc the coating still shows excellent toughness. Many ferrous and non-ferrous materials can be worked with TD. PVD-NANO TiAlN coating: a mediumm temperature coating process which minimises distortion while offering high hardness (±90 HRc) ) with good adhesion strength. The NANO coating has improved toughness and ductility over similar PVD coatings. A very versatile coating for applications from punching to core pins. PVD-TiN coating: the familiar gold PVD coating but with lower hardness (± 858 HRc) and good toughness making it ideal for higher stress applications. The TiN coating is compatible with many steels and materials, except copper and copper alloys. PVD-DLC coating: the Diamond Likee Carbon coating is a new coating development with super low friction, good toughness and a high hardness (± 80 HRc). Widely used from metalworking to plastic moulding, itt can often bee run unlubricated. Chrome Plating: thin layer of chrome for low friction and improved wear resistance while providing good corrosion resistance HRc. Electroless Nickel: nickel-phosphorous coating that provides low friction and good corrosion resistance. Since the process is autocatalytic, an even layer is deposited, sharp corners can be treated and contours are closely followed. EN can be heat h treated to HRc. 2

4 Diffox: similar to the well-known nitriding process, Diffox optimises the treatment based on the application to give superior performance. Provides a low friction, high hardnesss surface (50-72 HRc). Sub-Critical Nitriding is a medium-low temperature process suited to stainless steels. The corrosion resistance is still maintained while the surface hardness is increased to ± 72 HRc which makes the stainless highly resistantt to galling and sticking. Thee low treatment temperature also prevents sensitization. Manufacturing Custom Punches and Parts Should you require standardizedd parts with modification or custom-made parts not shown in the catalogue, we are able to supplythese to your specification using thee same principles of selecting the correct combinationn of base material, heat treatment and coating. We can manufacture parts from conventional steels, tool steels, powder metallurgy steels or carbide - 1 offs to 1000 s off. Please supply us with a drawing or enquire with us. Examples TD coated plastic granulator blade (3 x increase in sharpening interval) 2. HSS Nano coated rotary slitter (5 x life increase) 3. TDCC developed CNC cluster punches for cable tray perforation (4 x increased punch life). NAAMS Global Standard Components NAAMS standardization is a collaboration between several USA motor companies to define approved components used in the design and manufacture sheet metalworking g tooling andd parts. Several of the FANG items are NAAMS compatible and indicated as such in the catalogue. For more information on NAAMS Global Standard Components for Assembly and Stamping visit /. Final Sizes Dimensions shown are for uncoated items. For coated items, sizes may m increase by 2 5 µm per surface. If exact sizes are required after coating, pleasee inform us as manufacturing sizes will be adjusted accordingly. This is particularly important when thin metals, paper and plastics are worked. Units of Measure and Dimensions All sizes shown are mm unless otherwise specified

5 FANG Piercing Punches Table of Contents Introduction 2 Selection of Punch Head Type 2 Base Materials 2 Coating Selection 3 Punch And Die Clearance Recommendations 3 Punch Technical 4 Punch Force Calculation 4 Further Reducing Piercing Stress 4 Modifying the Punch Tip or Die 4 Re-sharpening of Punches 5 Other Factors 5 Variation in Punch Standards 5 NAAMS Compatibility 5 Final Sizes 5 Manufacturing of Custom Punches and Parts 5 Countersunk Head (C) 6 Countersunk Head (C) Cont./ 7 Countersunk Head, Stepped, Round Tip (Cs) 8 Cylindrical Head (O) 9 Cylindrical Head, Stepped, Round Tip (Os) 10 Round Head (R) 11 Round Head, Stepped (RS) 12 Trombone Head (T) 13 Trombone Head, Stepped Round (TS) 14 Shoulder Punches (D) 15 Shoulder Punches, Stepped (DS) 16 Shoulder Punches (S) 17 Shoulder Punches, Stepped (SS) 18 Heavy Load Shoulder Punch (H) 19 Heavy Load Shoulder Punch, Stepped (HS) Taper head/bottleneck Punches (B) Taper Head Punches, Stepped (BS) 22 Ball Lock Punch Light Duty (L) & Heavy Duty (K) 23 Ball Lock Punch, Stepped Light (LS) & Heavy Duty (KS) 23 Carbide Punches 24 Carbide Punch Blanks 24

6 Other Carbide Punches 24 FANG Punch Modifications 25 Punch Tip Shapes 25 Head Modification 25 Special Sharpened Tips 26 Ejector Pins 26 Head Dowel Pins 27 Punch Ordering Information 27 Punches - 1

7 Introduction The TD Coating Centre has developed its own FANG range of high performance piercing punches and dies branded which have the following advantages: Tough, chip resistant base materials with high fatigue life Increased life re-sharpening intervals increased (5 to 40 times depending on material worked) Highly resistant to wear and tip blunting Steels are compatible with our range of coatings Less sticking, seizing and pick-up due to the surface coating Selection of Punch Head Type Guidelines for the correct selection of a punch are shown below. Should you have any queries, please contact us. Punch Type Head Comments Countersunk Head Cylindrical Head, Dayton Punches, Shoulder Punches Common and relatively inexpensive type, however of limited strength, prone to head breakage and has low fatigue strength. Not available in carbide. The cylindrical head offers more strength than countersunk, during both the piercing and the extraction phase Round Head Locates easily due to round head design but is still of low strength. Not available in carbide. 30 Bottle Neck Improved strength over countersunk, improved extraction strength Heavy Load Punches, Dayton Tuff Punch Increased head height provides very high strength in both piercing and extraction Trombone Low stress concentration head provides exceptional strength in piercing and extraction Base Materials Fang punches are made from different steels/materials to accommodate different working conditions and different surface coatings. Steel Type Comments K-Type Similar to the versatile 12% Cr steel. Should however be used for short to medium runs as it is prone to edge chipping. Can be TD coated but PVD can only be done for limited applications. D-Type 8% Cr cold work steels for medium to long runs. These steels are tougher, more resistant to edge chipping, breakage and pick-up even in uncoated form. High precision parts should be PVD coated otherwise steels are well suited for TD coating which gives a very cost effective, high performance solution. H- Type High Speed Steel (HSS) used for high precision punching working thin to medium gauge materials. The H steels are used when high strength and high precision is required. PVD coating only. Coating TD, PVD* TD, PVD PVD Punches - 2

8 S- Type Powder Metallurgical (PM) steels have highh resistance to edge chipping, cracking, fatigue and breakage. The S-PM steel is extremely tough and the parts can cope with high production runs and working thin to thick gauge materials. PVD coating recommended. Z- Type The Z-PM steel is of very high hardness (>64 HRc) with good toughness. Recommended forr thinner gauge steels and where very high punchh life is required - similar to t carbide - without the danger of drop-and-break. PVD or TD coating possible. C- Type Tungsten Carbide is an extremely hard base materiall with the highest compression strength, greatest wear resistance and best support for TD and PVD coatings. Made from WC- 18% % Co it is suited to low impact, high volume piercing operations of thinner gauge steels. If high shock loading is experienced coated PM punches are recommended. Other Other steels can be used basedd on application or customer requirements *- under certain conditions TD*, PVD TD, PVD TD*, PVD Coating Selection Surface coatings are very effective in reducing edge wear, maintaining sharpnesss and reducing flank friction. When combined with the correct base metal, it provides a significant leap in performance. Punches with coating can be re-sharpened ass the punch face experiences less wear, howeverr the performance is dependent on the wear resistance of the base steel and a the adhesion strength of the coating. TD Coating: Superior adhesion, ability to work various many ferrous and non-ferrouss materials, significantly reduces pick-up and coldd welding, and stresses during d piercing and extraction. Designation: T. As TD is a hot process, if the part length to Ø ratio exceeds s 20:1, or the shank s diameter is 3mm or less, PVD coatings should be used, unless carbide is specified. PVD-NANO TiAlN: For high precisionn high, performance punches especially fine blanking. NANO is very versatile coating. Designation: N PVD-TiN: Lower hardness and good toughness making it ideal for higher stress applications. Designation: G. Not recommendedd for working copper and copper c alloys. PVD-DLC: ultra-low friction coating for punching aluminium or o other softt materials. Designation: D Punch and Die Clearancee Recommendations To maximize part life and durability, the correct engineered clearancee between the punch and die is of utmost importance. The clearance is highly dependent on the type of material punched. Use the accompanying graph as a guide to t determine the correct engineered clearance for your application. The correct engineered clearance will lower punch stress, minimise burr height due to lower drag, maintain sharpness and give longer punch and die life for increased uptime and lower maintenance. Data: Dayton Progress Corporation For materials ± 1.5 mm For further information on punch/die clearance on other materials, please p contact us. Punches - 3

9 Punch Technical Punch Force Calculation To calculate the basic force required to pierce a hole, use the following method: Force (N) = Hole Ø [mm] x π x Thickness of Steel [mm] x Shear Strength [MPa] x Number of Holes Since shear strength ~ 0.8 x Tensile strength, the simplified equation becomes: Force (N) = x Hole Ø [mm] x Thickness of Steel [mm] x Tensile Strength [MPa] x Number of Holes Example: Determine force required to pierce 20 holes of Ø 8 mm simultaneously in 0.8 mm stainless steel sheet (tensile strength 600 MPa). Force = x 8 x 600 x 20 = N ~ kg or tonne (excl safety factor) Staggered Punch Lengths When numerous holes have to be pierced in a part, consider splitting punches into sets of different lengths, each set shorter by ± 30% of sheet metal thickness. The total force required to pierce the initial set of holes is reduced and the momentum of the first pierce will assist the second pierce. Note that the peak piercing stress will still be experienced by each punch and the increased stroke length must be considered. Further Reducing Piercing Stress For flat tipped punches, peak compression force Fk is experienced when the punch penetrates ± 30% into the steel after which shearing and snap-through occurs (see figure 1). The following techniques can be used to reduce the stress on the press or punch; Modify the tip shape to bevelled, double bevelled or triple bevel Keep punches sharp and sharpened correctly Modifying the Punch Tip or Die Modifying the tip shape to a bevelled, double bevelled or a triple bevel (Mercedes) shape can reduce the peak piercing stress by 33% - 50% (figure 2). Alternatively, the die can also be modified to achieve the same effect. Punches - 4

10 Re-sharpening of Punches Only remove the necessary damage in order to obtain a sharp edge. PM and coated punches may show very little flank wear and excessive grinding can unnecessarily reduce the life of the part. A good finish on the punch face after grinding will show improved performance over a rough ground surface. Sharpen punches (and dies) in a non-directional manner as this improves fatigue life versus punches sharpened directionally on a flat-bed grinder. For coated punches and various PM steels the preferred grinding wheel is CBN which is harder than either the TD or PVD coatings or the high hardness carbides found in PM steels. After grinding, de-burr punches, particularly coated punches as small burrs of coating that dislodge during first piercing will damage the remaining coating. Other Factors Ejector pins assist in forcing the punched slug into the die but it may reduce the fatigue life of stepped punches in some cases by up to 50%. A dowel pin in the punch head that is used for locating purposes but it also reduces the head strength. Variation in Punch Standards Punches from different manufacturers may vary in design and tolerances. Please ensure that the punches required are ordered correctly with regards to the aforementioned as the TDCC cannot be held responsible for these errors and omissions. Please carefully check the following: Head Ø and height Shank tolerances Overall length and tip length Shank and tip tolerances General tolerances NAAMS Compatibility NAAMS compatible products are indicated on the item page. Final Sizes Sizes shown are for uncoated items but for coated items, sizes of tips and shank may increase but 4 10 µm on the Ø. Should exact sizes be required after coating, please inform us as the manufacturing sizes will be adjusted accordingly. Manufacturing of Custom Punches and Parts Custom-made piercing punches and other parts can also be manufactured or parts can be reverse engineered. Please discuss this with the TDCC. Punches - 5

11 Countersunk Head (C) Similar to DIN 9861 Type D Not available in carbide due to low head strength Available with: Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank/Tip d 1 Head d 2 h K r Shank/Tip d 1 Head d 2 h K r (0/+0.2) (0/+0.3) Standard Lengths L 1 : 71, 80, 100, 120 mm Above sizes not available with ejector pin Ordering Example: Countersunk head (C), Ø6 shank (06.0), 71 long (071), D-type steel (D), TD coated (T) Code: C D-T (see pg. 27) (0/+0.3) (0/+0.4) Punches - 6

12 Countersunk Head (C) Cont./ Similar to DIN 9861 Type D Not available in carbide due to low head strength Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank/Tip d 1 Head d 2 h K r Shank/Tip d 1 Head d 2 h K r (0/+0.4) (0/+0.5) Standard Lengths L1: 71, 80, 90, 100, 120 mm - available with ejector pin (0/+0.5) (0/+0.5) Ordering Example: Countersunk head (C), Ø12 shank (12.0), 100 long (100), H-type steel (H), PVD-Nano coated (N) Code: C H-N (see pg. 27) Punches - 7

13 Countersunk Head, Stepped, Round Tip (Cs) Similar to DIN 9861 Type C Not available in carbide due to low head strength Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank d 3 Tip d 1 Tip L 2 Head d 2 h K r Standard Lengths L 1 : 71, 80, 90, 100, 120 mm - available with ejector pin Not available in carbide (+0.3/0) (+0.4/0) (+0.5/0) (+0.5/0) Ordering Example: Countersunk head, stepped round shape (CS), Ø 4 tip (04.0), tip length 13 mm (013), Ø 6 shank (06.0), 71 mm long (071), H-type steel (H), NANO coated (N) Code: CS H-N (see pg. 27) Punches - 8

14 Cylindrical Head (O) European Standard ISO 8020, Shape A The punches are not similar to Dayton type punches (pg. 15). Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank/Tip d 1 Head d 2 T r Ejector pin Ø Standard Lengths L 1 : 63, 71, 80, 90, 100, available with ejector pin Ordering Example: Cylindrical head (O), Ø 8 shank (08.0), 80 mm long (080), D-type steel (D), TD coated (T) Code: O D-T (see pg. 27) Punches - 9

15 Cylindrical Head, Stepped, Round Tip (Os) Similar to ISO 8020, Shape B The punches are not similar to Dayton type punches (pg. 15). Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head H Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating L Pin (pg. 27) Shank d 3 Tip d 1 L 2 Head d 2 T R Ejector pin Ø Standard Lengths L 1 63, 71, 80, 90, 100, 120,130 With ejector, minimum tip Ø 1.6 mm No lead (D-0.01/-0.03) in if tip size D-0.03 Ordering Example: Cylindrical head, steppedd round tip (OS), Ø 7.5 mm tip (07.5),, 13 mm tip length l (013), Ø 8.5 shank (08.5), 90 mm long (090), Z-type steel (Z), DLC coated (D) Code: OS Z-D (see pg. 27) ) Punches - 10

16 Round Head (R) Similar to DIN 9844, Shape A Not available in carbide due to low head strength Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank/Tip d 1 Head d 2 h r Standard Lengths L 1 : 71, 90, 112 mm Ordering Example: Round head (R), Ø 4 shank (04.0), 71 mm long (071), K-type steel (K) Code: R K Punches - 11

17 Round Head, Stepped (RS) Similar to DIN 9844, Shape B Not available in carbide due to low head strength Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank d 3 Tip d 1 L 2 Head d 2 h r Standard Lengths L 1 : 71, 90, 112 mm Ordering Example: Round head stepped (RS), Ø 4 mm tip (04.0), 7 mm tip length (007), Ø 6.0 shank (06.0), 90 mm long (090), Z-type steel (Z), NANO coated (N) Code: RS Z-N Punches - 12

18 Trombone Head (T) European standard Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank d 1 Head d 2 k a r Shank d 1 Head d 2 k a r Standard Length L 1 : 71, 80, 90, 100, 120, 150, 200 mm Ordering Example: Trombone head (T), Ø 3.5 shank (03.5), 70 mm long (070), Z-type steel (Z), NANO Coated (N) Code: T Z-N Punches - 13

19 Trombone Head, Stepped Round (TS) European standard Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank d 3 Tip d 1 L 2 Head d 2 k r / / / / / Standard Lengths L 1 : 71, 80, 90, 100, 120, 150, 200 mm Ordering Example: Trombone head, Stepped round tip (TS) Ø 4 mm tip (04.0), 10 mm tip length (010), Ø 5.0 shank (05.0), 90 mm long (090), H-type steel (H), NANO coated (N) Code: TS H-N Punches - 14

20 Shoulder Punches (D) Punches are similar to Dayton-Type punches Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank D Head (D+3) T Standard Lengths L 1 : 40, 50, 56, 60, 63, 70, 71, 80, 90, 100mm Ordering Example: Shoulder Punch, Dayton Type (D), Ø 3.2 mm shank (03.2), 100 mm long (100), H-type steel (H), NANO coated (N) Code: D H-N Punches - 15

21 Shoulder Punches, Stepped (DS) Punches are similar to Dayton-Type punches Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank D Tip P Head D T L /13/19 8/13/19/25 13/19/25/30 19/25/30/ /30/40 Standard Lengths L : 40, 50, 56, 60, 63, 70, 71, 80, 90, 100 mm 1 - unless otherwise specified, this underlined the standard tip length for ØD No lead in if tip size D-0.03 Ordering Example: Shoulder, stepped, Dayton Type (DS), Ø 12 mm tip (12.0), 8 mm tip length (008), Ø 13.0 shank (13.0), 100 mm long (100), D-type steel (D), TD coated (T) Code: DS D-T Punches - 16

22 Shoulder Punches (S) JIS standard (Misumi etc) Also available in carbide Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank D Head H T R Standard Length L: 20, 25, 30 (for D 1.0), 35, 40, 50, 60 (for D 2.5), 70, 80, 90 2, 100, 110, 120 mm 1 recommended carbide max Ø 2 - recommended max length for carbide Ordering Example: Shoulder type (S), Ø 6.2 mm shank (06.2), 100 mm long (100), Carbide (C), NANO coated (N) Code: S C-N Punches - 17

23 Shoulder Punches, Stepped (SS) JIS standard (eqv to Misumi) Also available as carbide Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank D P Head H T L /13/19 1 Standard Lengths L: 40, 50, 60, 70, 80 2, 90, 100mm 1 other tips lengths are also available 2 recommended max length for carbide No lead in if tip size D-0.03 For Carbide: Shank D Ø 16 mm L2 = 8 mm only Ordering Example: Shoulder type stepped (SS), Ø 12 mm tip (12.0), 8 mm tip length (008), Ø 13.0 shank (13.0), 100 mm long (100), D-type steel (D), TD coated (T) Code: SS D-T Punches - 18

24 Heavy Load Shoulder Punch (H) JIS standard, Similar to Dayton Tuff Punch Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank/Tip D Head H L max 1 T Standard Lengths L 1 : 40, 50,60, 70, 80, 90, 100, 110, 120 mm 1 - Due to heavy loads expected, long punches may buckle. Ordering Example: Heavy Load type (H), Ø 12 mm tip (012.0), 8 mm tip length (008), Ø 13.0 shank (013.0), 100 mm long (100), S-type steel (S) Code: HS S Punches - 19

25 Heavy Load Shoulder Punch, Stepped (HS) JIS standard, Dayton Tuff Punch Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank D Tip P Head H (D+5) L1 max 1 L / / / Standard Lengths L 1 : 40, 50, 60, 70, 80, 90, 100, 110, 120, 130 mm 1 - Due to heavy loads expected, long punches may buckle. No lead in if tip size D-0.03 Ordering Example: Heavy Load type, Stepped Round (HS), Ø 12 mm tip (012.0), 8 mm tip length (008), Ø 13.0 shank (013.0), 100 mm long (100), H-type steel (H), NANO coated (N) Code: HS H-N Punches - 20

26 30 Taper head/bottleneck Punches (B) Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank d1/d3 h Head d Standard Lengths L 1 : 71, 80, 90, 100mm Ordering Example: Bottleneck 30 punch (B), Ø 6.0 mm shank (06.0), 100 mm long (100), H-type steel (H) Code: B H Punches - 21

27 30 Taper Head Punches, Stepped (BS) Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Head Modification (pg. 25) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Shank d1 Tip P Head H Head d Standard Lengths L 1 : 71, 80, 90, 100, 120 mm L Ordering Example: Heavy Load type, Stepped Round (HS), Ø 12 mm tip (012.0), 8 mm tip length (008), Ø 13.0 shank (013.0), 100 mm long (100), H-type steel (H), NANO coated (N) Code: HS H-N Punches - 22

28 Ball Lock Punch Light Duty (BL) & Heavy Dutyy (BK) Not available in carbide Heavy Duty Designs NAAMS Compatible Available with: Ejector Pin (pg. 26) Special Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) Light Duty Balll Heavy Duty Ball Lock Lock Shank Ball Shank Ball d2 d55 d2 d Standard Lengths L 1 : 63, 71, 80, 90, 100, 110, 1 125, 140, 150, 175, 200 Ordering Example: Heavy duty type t (BK), Ø 12 mm shank (012.0), 100 mm long (100), H-type steel (H), NANO coated (N) Code: BK H-N Ball Lock Punch, Stepped Light (BLS) & Heavyy Duty (BKS) Not available in carbide Heavy Duty Designs NAAMS Compatible Available with: Ejector Pin (pg. 26) Various Tip Shapes (pg. 25) Special S Sharpened Tips (pg. 26) Head Locating Pin (pg. 27) 1 light duty only Ball Shank S d5 d2 Light Heavy P L (P<2. 2.2), (P<2.2), 13, , ,19, , 25, n/aa ,25,30 Standard S Lengths L 1 : Light - 63,,71, 80, 90, 1000 mm,, + heavy 110, 125 mm Ordering Example: Heavy Duty Stepped (BKS), Ø 6 mm tip (06.0), 199 mm tip length (019), Ø 13.0 shank (013.0), 100 mm long (100), H-type steel (H),, NANO coated (N) Code: BKS H-N Punches - 23

29 Carbide Punches Further carbide punches are available. Please enquire with us. Carbide Punch Blanks Grade: WC ± 18% Co, sintered and HIP ed Hardness: HRA Std Ø D mm 2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0 Lengths available: 50, 100, 200, 300, 400, 500, 600, 700 Ø can be made to ± 0.5 µm, Roundness Tolerance 0.3 µm, Surface Finish Ra µm Other Carbide Punches Other carbide punches are available on request. Please enquire with us regarding standard sizes of items shown below, or discuss your particular requirements with us. Available with: Ejector Pin Various Tip Shapes Head Modification Special Sharpened Tips Head Locating Pin Punches - 24

30 FANG Punch Modifications Punch Tip Shapes Various tip shapes can be supplied and are available on all punch types. Common shapes are shown below. For custom shapes, please provide us with details. Head Modification Punches can be prevented from rotating by either using the stripper plate, or by modifying the head. On tip shapes SG, SR, SRR, SGR and SH a head modification can be included to avoid punch rotation as shown below. Add code : F Add Code : FR Punches - 25

31 Special Sharpened Tips Standard Flat Tip Type : no code Single Bevel, Type: SB Use on rigid punches only tips to avoid deflection. Indicate bevel height or angle, e.g. 1.2 mm = SB1.2 or 5 = SB5d Double Bevel, Type: DB Indicate bevel height or angle A, e.g. 1mm = DB1 or 3 = DB3d Triple Bevel or Mercedes, Type : M Indicate bevel height or angle A, e.g. 1.2 mm = M1.2 or 10 = M10d Ejector Pins The ejector pin Ø is based on the shank size. Ejector pins reduce punch life due to weakening of the tip and the head. To ensure highest possible tip strength, leave at least 0.4mm per side between the tip Ø/P/W and the ejector pin. Ejector Pin Diameters Countersunk (C) Cylindrical (O) Round (R) Trombone (T) Shoulder (D) Shoulder (S) Heavy Load (H) Shank Ø Punches - 26

32 Head Dowel Pins Head dowel pins assist in locating punches. These are only available if the shank Ø 10 mm. Dowel pins are standard Ø 6 x 25 mm with a protrusion length of 12 ~ 14 mm. Punches can be supplied with ejectors and locating pins. Punch Ordering Information Punch coding can be performed using the selection matrix. See the examples below Example 1 Countersunk head (C), Ø 6 shank (06.0), 71 mm long (071), D-type steel (D), TD coated (T) Item Type Code 1 Punch Type Countersunk Straight C 2 Tip shape if stepped no n/a 3 Tip P mm or shank Ø d1 (P W) 6 mm Tip W mm n/a n/a 5 Radius R on tip n/a n/a 6 Tip Length L2 n/a n/a 7 Shank Ø d2 (if stepped) n/a n/a 8 Overall Length l1 71 mm 071- Options - 9 Special Tips Double Bevel 1.2 mm n/a 10 Head Modification none n/a 11 Head Locating Pin no n/a 12 Ejector pin Yes n/a 13 Steel Base D-type D- 14 Coating TD T Punch Code: C D-T Punches - 27

33 Example 2 Heavy Load Shoulder punch (H) stepped with tip shape round (S), tip Ø 10 mm (10.0), tip length 13 mm (013), shank Ø 13 mm (13.0), overall length 80mm (080), with double bevel tip height 1.2 mm (DB1.2), ejector pin (E), centring pin in head (P), Head modification F orientation, Z steel, NANO coated (N). Item Type Code 1 Punch Type Heavy Load Shoulder H 2 Tip shape if stepped Round S- 3 Tip P mm or shank Ø d1 (P W) 10 mm Tip W mm n/a n/a 5 Radius R on tip n/a n/a 6 Tip Length L Shank Ø d2 (if stepped) n/a n/a 8 Overall Length l1 80 mm 080- Options - 9 Special Tips Double Bevel 1.2 mm DB Head Modification Normal F- 11 Head Locating Pin Yes P- 12 Ejector pin Yes E- 13 Steel Base PM Z-type Z- 14 Coating PVD-NANO N Punch Code: HS DB1.2-F-P-E-D-T Example 3 Dayton Shoulder punch (D) stepped with tip shape rectangular with radius (SRR), major tip dimension P = 9.5mm (09.5), minor tip dimension W = 6.5 mm (06.5), radius R on tip 5 mm (05.0), tip length 13 mm (013), shank Ø 13 mm (13.0), overall length 80mm (080), double bevel tip of height 1.2 mm (D1.2), centring pin in head (P), Head modification normal (F), Z steel, NANO coated. Item Type Code 1 Punch Type Dayton Shoulder D 2 Tip shape if stepped Rectangular Round SRR 3 Tip P mm or Ø d1 (P W) 9.5 mm Tip W mm 6.5 mm Radius R on tip 5 mm l2 Tip Length 13 mm Shank Ø d2 (if stepped) 13 mm Overall Length l1 80 mm 080- Options - 9 Special Tips Double Bevel 1.2 mm D Head Modification F F- 11 Head Locating Pin yes P- 12 Ejector pin no n/a 13 Steel Base PM Z-Steel Z- 14 Coating NANO N Punch Code: SG D1.2 F-P-Z-N - - Punches - 28

34 FANG Dies Table of Contents Introduction 1 Base Materials 1 Coating Selection 1 Variation in Die Standards 1 Manufacturing of Custom Dies 1 Standard Die ISO 8977 (D) 2 Fang Die Modifications 3 Die-Piercing Shape 3 Die Rotation 3 Provision For Dowel Pin 3 Die Ordering Information 4

35 Introduction The sustained performance and sharpness off the die is also essentiall in maintaining a highly effective punching operation. The FANG range of dies combines specific base metals and coatings (if required) ) to achieve maximum performance. The advantages of our dies are: Very high resistance to edge chipping and breakage Highly resistant to wear thus less re-sharpening required Less sticking, seizing and pick-up duee to the surface coating Dies can be coated to extend life Base Materials D-type steelss are recommended for good edge retention andd can be PVDD coated for improved i wear resistance H-type of steels are often used due to good wear resistance, hardness and ability to be coated PM steels provide the ultimate combination between toughness, edge holding and wear resistance. PVD coating further f improves he performance of PM steels. Carbide dies are sintered and HIP edd to provide full strength.. They have excellent wear resistancee but should not be used under high shock loading. Coating Selection Due to tight tolerances PVD coating is the preferred coating. PVD-NANO: most versatile coating for working many materials. PVD-TiN: not to be usedfor copper and copper alloys. Variation in Die Standards Several variations of the same basic die design exist between different manufacturers, e.g. Fibro, Dayton and Misumi. Should you require dies to a specific supplier, pls informm us, otherwise use the guidelines below. Manufacturing of Custom Diess For geometries and sizes not listed, please enquire with us. We can supply s to your specifications. Dies - 1

36 Standard Die ISO 8977 (D) Type A without collar, Type B with collar Also available in carbide NAAMS Compatible Type B d1 1,2 Type A and B OD d2 Collar OD d3 d4 L2 L , 20, 22, 25, 28, 30, , , , , 22, 25, 28, 30, 32, , 6, , 12, Ø40-43/ 40/ /37 25, 28, 30, 32, Ø /40/45/50/56/63/ /76/85/90/ , 28, 30, 32, 35, 40 1 smaller sizes available 2 if other piercing shapes are used, P and W have restrictions, pls confirm sizes with us. 3 NAAMS Compatible Type B h 5 Dayton tolerances without collar: d2 - n4 Dayton tolerances with collar: d2 - m4, d , h For Type A, recommended mounting hole size is H7. Dies - 2

37 Fang Die Modifications Die-Piercing Shape The same shapes as punch tips can be supplied, plus allowance for clearance. Die Rotation In order to prevent die rotation on shaped dies, the die body or collar can be modified as shown below. Collar Modification: Code FX where X is the angle, for example F0, F90, F135 etc. Provision for dowel pin: Code PX where X is the angle, for example P0, P30, P90, P135, etc. For dowel pins specify Ø d (see table below). Provision For Dowel Pin Distance from centre of die to centre of locating pin is given below. Dowel Pin Ø d2 1 d = Ø6 (die OD) d = Ø3 d = Ø4 Ø 6 x M4 thread for larger die sizes please enquire about exact distance 2- NAAMS Compatible, recommended dowel Ø 6 x M4 thread Dies - 3

38 Die Ordering Information To order dies, please refer to the die selection matrix as shown below. Example 1 Standard die (D), round ID of 10 mm (10.0), OD 20 mm (20.0) and length 40 mm (040) from D steel, TD coated. Item Type Code 1 Die Type DIN 8977 D- 2 Hole shape Round n/a 3 Hole P mm or hole Ø d1 (P W) 10 mm Hole W mm n/a n/a 5 Radius R on hole n/a n/a 7 Outer Ø d Overall Length l1 20 mm 020- Options - 9 Collar Modification and Angle, or Normal F0-10 Head Locating Pin and Angle Ø 3 mm, 90 C P90-11 Steel Base Carbide C- 12 Coating None n/a Die Code: D F0-C Example 2 Standard 8977 die, rectangular round hole shape with major dimension P = 8.5 mm, minor dimension W = 6.0 mm and radius R = 10 mm, OD 16 mm and length 30 mm, A-steel with NANO coating. Item Type Code 1 Die Type DIN 8977 D 2 Hole shape Rectangular, radiused SRR- 3 Hole P mm or hole Ø d1 (P W) 10 mm Hole W mm 8 mm Radius R on hole 4 mm Outer Ø d Overall Length l1 20 mm 020- Options - 9 Collar Modification and Angle, or n/a n./a 10 Head Locating Pin and Angle Ø 3 mm, 90 C P90-11 Steel Base PM Z-type Z- 12 Coating Nano N Die Code: DS-SRR P90-Z-N - - Dies - 4

39 Cemented Carbides Table of Contents Introduction 1 Coatings 1 Carbide Blanks 1 Carbide Custom Tooling 2

40 Introduction Cemented Carbides are a family of ultra-hard materials obtained by cementing metal carbides together with a metal binder. Typically fine tungsten carbides (WC), mixed with a cobalt (Co) binder, is generically known as carbide and these high hardness, hard wearing materials can effectively be used in many applications from cutting tools to forming dies. Due to the unique structure, carbides are highly resistant to pick-up and suited to long runs, but are of low toughness and cannot tolerance tensile strengths. Coatings If additional surface hardness and wear resistance is required, the following coatings can be used: TD coating: high cobalt carbides are well suited to TD coating with no distortion after treatment. PVD-Nano: good addition to carbides for improved surface hardness Carbide Blanks Grade: WC + Co, sintered and HIP ed Std Ø D mm 2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0 Lengths available: 50, 100, 200, 300, 400, 500, 600, 700 Ø can be made to ± 0.5 µm, Roundness Tolerance 0.3 µm, Surface Finish Ra = µm Various grades available 2 25%Co in: Coarse, medium and fine grain Submicron grain Nano grain Carbide - 1

41 Carbide Custom Tooling Various custom-made parts can be supplied from carbide in either sintered or sintered and HIP ed condition. For highly corrosive conditions, the t cobalt binder can be replaced with nickel. Below are some items supplied to t various industries. For more information about parts made from carbide, please contactt us. Carbide - 2

42 FANG Die Support Products Table of Contents Introduction 1 Base Materials 1 Coatings 1 Standards 1 Custom Manufacturing 1 Pilot Pins 2 Steels 2 Coatings 2 Locating Pins 3 Steels 3 Coatings 3 Burring and Extrusion Punches 4 Steels 4 Coatings 4 Burring Punches 4 Modified Tips Scrapless Burring Punches 4 Custom-made Burring Punches 4 Extrusion Punches 4

43 Introduction Several components for the manufacturing industry benefit from correct material selection and surface engineering to provide excellent performance. The advantages of our parts are: Steel and heat treatment fully compatible with the coating Very high resistance to sticking, seizing and pick-up. Significant part life extension Improved quality of parts produced Base Materials Various alloy steels and tool steels compatible with surface coatings and treatments are used. Cold work tools steels High speed steels Powder Metallurgy steels Carbide of various grain sizes and binder content. Specify type. Coatings Several coatings are used on items depending on the required wear rate and /or cost. TD coating: highest durability and best wear resistance. PVD NANO: very good sliding wear resistance. PVD TiN: good all-rounder for less demanding applications. Standards Several variations of the same basic parts exist between different manufacturers, e.g. Fibro, Dayton and Misumi. Should you require parts from a specific supplier, please inform us, otherwise use the guidelines below. Custom Manufacturing For geometries and sizes not listed, please enquire with us. We can supply to your specifications. Die Support - 1

44 Pilot Pins Pilots are prone to pick up and wear. Our TD and PVD coated pins shown excellent wear resistance and thus the FANG parts provide guidance and location with consistent performance and accuracy. We can provide guidelines for standard designs otherwise provide us with your required designs. Steels K-type: HRc D-type: HRc H-type: HRc Carbide parts also available however not recommended for applications with shock loading Coatings TD and PVD coated pins shown excellent resistance to pick up and galling. Stepped - Parabolic Tip (also available as straight pin) Shank Ø D Tip Ø P Length L 42, 52, 62, 72, 82, 92, 102 Stepped - Tapered Tip (also available as straight pin) Shank Ø D Tip Ø P Length L 42, 52, 62, 72, 82, 92, 102 Stepped Sharp Tip (also available as straight pin) Shank Ø D Tip Ø P Length L 42, 52, 62, 72, 82, 92, 102 Custom Pilot Pins Parts We supply many custom-made pilot punches to industries. Please supply us the exact details of your requirements. Die Support - 2

45 Locating Pins Our FANG locating pins provide exceptional wear resistant and this accurate position of parts. Due to the vast number of locating pins available world-wide, only a few of our samples are shown below. Please discuss your exact requirements with us or with a part number. Steels K-type or D-type are mostly used for good wear resistant and toughness Coatings TD coated locating pins have exceptional performance. PVD coatings can be used for less demanding applications. Die Support - 3

46 Burring and Extrusion Punches The FANG coated burring and extrude punches are highly resistant to pick-up and galling and extrude a very smooth and defect-free hole and the surface coating maintain the sharp cutting corner for extended life. Basic designs are shown below, but please contact us with your exact requirements. Steels K-type: HRc D-type: HRc for improved edge holding and chip resistance H-type: HRc for improved strength PM type steels for excellent chip resistance and fatigue life with high hardness Coatings TD and PVD coated pins shown excellent resistance to pick up and galling. Burring Punches Available with: Ejector Pin Head Locating Pin Straight - Radius Tip Shank Ø Tip Ø Length D P L , 51, 61, 71 Stepped - Radius Tip Shank Ø Tip Ø Length D P L , 51, 61, 71 Modified Tips Scrapless Burring Punches Tips can be modified for scrapless formation of the initial pierce. The options are as follows: Custom-made Burring Punches We supply custom-made burring punches. Please supply us the exact details of your requirements. Extrusion Punches As many different designs are possible, please provide us with your exact requirement. Die Support - 4

47 FANG Parts for Plastic Processing Table of Contents FANG Plastics Processing 1 Base Materials 1 Coatings 1 Standards 1 Custom Manufacturing 1 Ejector Pins 2 Steels 2 Surface Treatments 2 Standards 2 Ejector Pin, Cylindrical Head, Straight (E) 3 Ejector Pin, Cylindrical Head, Stepped (ES) 4 Ejector Pin, Countersunk Head, Straight 5 Ejector Pin, Cylindrical Head, Stepped, Rectangular Tip 6 FANG Ejector TIP Modifications 7 Tip Shapes 7 Head Modification 7 Core Pins 8 Custom-Made Core Pins 9

48 FANG Plastics Processing Injection moulding requires quick injection, rapid solidification and then hassle free release and ejection, and wear should be prevented on dies and supporting equipment. The FANG TM range assists in achieving all this. The advantages of the FANG TM parts are: Steel and heat treatment fully compatible with the coating Very high resistance to sticking, seizing and pick-up. Good to excellent release properties Significant part life extension Improved quality of parts produced Base Materials The following materials are used on our products: Various alloy, mould and tools steels compatible with surface coatings and treatments are used. Stainless steel for improved corrosion resistance Powder Metallurgy (PM) steels provide exceptional performance in selected cases. Carbide of various grain sizes and binder content. Coatings In general, due to high precision required, PVD coatings and Diffox are well suited to mould components. Where very thin wall thickness is present or where virtually no distortion is required, we recommend low temperature processes such as chrome plating or electroless nickel. Variation in Standards Several variations of the same basic parts exist between different manufacturers, e.g. Fibro, DME, Misumi, etc. Should you require dies to a specific supplier, pls inform us, otherwise use the guidelines below. Custom Manufacturing For geometries and sizes not listed, please enquire with us. We can supply to your specifications. Ejectors/Core Pins - 1

49 Ejector Pins TM Coated or surface treated FANG T ejector pins shown excellent strength and sliding wear resistance. Ejectionn of the part becomes easier and more consistent. Guidelines are given below for standard designs however provide us with your exact requirements. Steels Hardness Max Operating HRc Temp C Hot work tool steel W Cold work steel D High speed steel H Stainlesss steel T lower cost option vs high speed steels but still with good thermal resistance Coatings/Surface Treatments Max Operating Coating/ /Treatment Temp C PVD Nano (N) 900 PVD TiN (G) 450 PVD DLC (D) 300 Diffox (F) 500 Chrome plating (C) 300 Electroless nickel (N) 250 Stainlesss nitriding (S) 500 *- Data not available 1- no lubrication required Surface HRc ~ 90 ~ 85 ~ 85 ~ 72 ~ 70 ~ 50 ~ 72 Friction Coefficient C Unlubricated/Lubricated /* 0.4/* / / / / /0.13 ~ 0.3/* 0 Variation in Standards Several variations in geometries exist between different companies such s as DME, FIBRO, MISUMI, etc. please ensure that the correct dimensions are provided for your application to the TDCC. The tables are to be used as a guideline. Ejectors/Core Pins - 2

50 Ejector Pin, Cylindrical Head, Straight (E) Shank ØD g6 Head T Head T Lengths Custom lengths also available 100, 125, 160, 200, 250, 315, 400, 500, 630, 1000 mm Ordering Example: Type E head, Ø 4 shank (04.0), 100 mm long (100), H-type steel (H), NANO coated (N). Code: E H-N Ejectors/Core Pins - 3

51 Ejector Pin, Cylindrical Head, Stepped (ES) Standard DIN 1530/ ISO 8694 Shank ØD Shank ØD T H Lengths/N Head Head /30, 80/32, 100/50, 125/50, 160/63, 200/80 mm Other sizes available on request 2 Other Lengths and Length/N combinations available on request Ordering Example: E-type head, stepped, round shape (ES), Ø 2 tip (02.0), N 30 mm (030), Ø 4 shank (04.0), 63 mm long (063), H-type steel (H), NANO coated (N). Code: ES H-N Ejectors/Core Pins - 4

52 Ejector Pin, Countersunk Head, Straight Shank ØD d1 Head d2 K Lengths , 60, 71, 80, 100, 125, 160, 200, , 315 mm Custom lengths also available Ordering Example: Countersunk head straight (C), Ø 4 tip (04.0), 125 mm long (125), W-type steel (W), Diffox treated (F). Code: C W-F Ejectors/Core Pins - 5

53 Ejector Pin, Cylindrical Head, Stepped, Rectangular Tip Similar to DIN ISO 8693 Head H Lengths/N 2 Shank ØD 1 Tip A/B 1 T Head 4.0 1/ /3.8, / / / /4.5 1/ / / / / / /9.5 2/ / / / / Other sizes available on request 2 Other Lengths and Length/N combinations available on request 63/30, 80/40, 100/50, 125/60, 160/80, 200/100, 250/125, 315/160 mm Ordering Example: Countersunk head, stepped rectangular shape (CR), A = 1.5 mm (01.5), B = 7.5 mm (07.5), N length 50 mm (050), Ø 10 shank (10.0), 100 mm long (100), Stainless Steel (T), Sub-critical nitriding (S). Code: CR T-S Ejectors/Core Pins - 6

54 FANG Ejector TIP Modifications Tip Shapes Various tip shapes can be supplied and are available on all punch types. Common shapes are shown below. For custom shapes, please provide us with details. Head Modification Punches can be prevented from rotating modifying the head. On tip shapes SG, SR, SRR, SGR and SH a head modification can be included to avoid punch rotation as shown below. Add code : F Add Code : FR Ejectors/Core Pins - 7

55 Core Pins The FANG core pins provide a low friction surface for ease of release with wear resistance and corrosion resistance provided by the surface coating. Below are examples of various core pins. Part dimensions vary between different suppliers and hence enquire about exact sizes. Steels Hot work Steel W HRc High Speed Steel H HRc Cold Work Steels D HRc Stainless Steel T HRc Coatings PVD NANO PVD TiN Chrome Plating Diffox Electroless-Nickel SC nitriding for stainless Tip Shapes Ejectors/Core Pins - 8

56 Custom-Made Core Pins We have specialized for many years and supply core pins and to matching parts. Tolerances are closely matched to provide free sliding with minimal play and to prevent flash. Often the thickness of the coating has to be considered as fits are extremely tight, and importantly, the correct selection of the base metal and associated heat treatment is of very high importance to stabilize the steels again size change over time to ensure hassle-free operation for many years. As core pins are designed for each unique application, please provide us with a drawing and contact us for technical advice. It is also important to discuss the matching die items ensure first-time fit and run. - - Ejectors/Core Pins - 9

57 FANG - Other Components Several other components are available from the TD Coating Centre although these are either currently not catalogued or internationally standardized. Please find below examples of these and should you required items, please enquire with us, or submit a drawing with dimensions and tolerances. Guide Pins Punch Bushes Drill Bushes Ejector Sleeves Straight/Stepped Guide Pins Guide Pins Guide Bush Guide Bush Steel Ball Retainer Oil-less Guide Bush Tapered Block Set Tapered Block Round

58 For any queries on our products and services, please contact us. FANG Product Catalogue