Introduction
Press tool design is an integral part of the mold-making process and one that will help determine how well your plastic parts come out. Here are some of the basic elements to consider when designing press tools for your molds.
Press tool design and production may sound intimidating, but it’s not something that should scare you. In fact, it’s an important skill to learn if you want to continue growing as a designer and producing high-quality parts. That’s why we’ve put together this overview of press tool design and production that can help you understand this process so you can produce excellent parts every time!
Press Tool Design Components
The major press tool die components are the punch and the die holder which help in fixing the die to the press machine. With regard to the manufacturing processes of press tools, it is necessary to utilize three main manufacturing methods: stamping/coining (sheet metal pressing), machining (metal shaping by using rotating cutting tools like mills or lathes), and wire-cut EDM (Electrical Discharge Machining). For the manufacture of special parts – rotor discs for axial turbines – you can apply other types of moldings with limited dimensional tolerances as well as the use of plasma spraying or powder metallurgy.
Press Tool Design Components
Press Tool Adjustment
Backing plates, punch plates and adjusting the height of the die are all important aspects of your tools. It is quite common for press tooling to work at extreme angles and that’s why backing plates and punch plates made of cast iron are an industry standard. The material provides a durable, long-lasting backing that can withstand any kind of stress when clamped down. An adjustable-height die allows you to test different depths and clearances without wasting expensive sheet metal punches or time on trial cuts. These features all make for a better-designed tool and ultimately make production more efficient because it cuts down on error and keeps products moving smoothly.
Selection of Materials
The most efficient way to select steel for press tools is to use a computer-controlled process that enables engineers, in a matter of minutes, to review all possible combinations of hardness, yield strength, elongation, tempering treatments, and surface finishes, etc. Thus software will help you sort through such materials as 17-4PH S73400 4140 or 4142 that come in various tempers. The right material selection results in tool life at least twice as long as normal and usually three times longer than typical carbon steels.
Press Tool Efficiency
The accumulation of tool defects in die stamping, also known as punch cracking, occurs through press force and die tool-steel interaction. To minimize punch cracking you need an efficient press tool. This will help reduce excessive punch deflection while reducing tool wear due to crushing between steel punches. The steel type that you use for punch tools needs careful selection because not all types of steel can provide enhanced performance, toughness, and high yield strength, which are essential for effective press tool design. Steel grades that possess a high degree of impact toughness, such as HPM970 or HPM990 (Hitachi Press Steel), will help minimize tool wear by providing increased ductility at low temperatures. This property results in improved fatigue resistance, leading to longer life spans. At higher temperatures, such steels will offer higher impact strengths to resist punch cracking.
