Computing Die Thickness and Margins
Computing Die Thickness and Margins
stress. The tensile stress depends upon the vertical force, inside and outside diameters and the thickness of the die. Hardened shearing dies can be safely stressed upon 160 N/mm2 Circular die height= Tc = Where ` V= Vertical shearing force [ Newtons (N)] ft= Permissible tensile stress (N/mm2) = 160 N/mm2 for hardened die. d= Inside of die (mm) D= Outside of die (mm) = 2d preferably Note : (D-d) should not be less than 6mm Height Tc should be increased by 3mm for resharpening. Example: Find the die height for piercing a 20 hole in 2 mm thick steel sheet having 350 N/mm2 shear strength. Solution: V= dTfx = x 20 x 2 x 250. = 43982.3 N Now Taking d= 20 mm D= 2d = 2 x 20 = 40 mm
= 11.66 mm = 12 mm. 3 mm resharpening allowance must be added to the computer value. Die thickness = 12 mm + 3 mm = 15 mm. Minimum section of die should be checked for shear strength. Di shear area = (D d)(Tc)
Shear stress on die = 183 N/mm2 Although higher than the tensile design stress, the stress is within the acceptable limit of 240 N/mm2. Rectangular dies are more convenient for rectangular piercing/blanking. Thickness of rectangular die can be found from the following formula:
Where Tr = Thickness of rectangular die (mm) V = Vertical force (N) ft = Permissible tensile stress (N/mm2) = 16 N/mm2 B = Width of slot/blank (mm). A = Length of slot/blank (mm).
Example: Find thickness of die for piercing 20 x 40 slot in an aluminium blank having 3 mm thickness. (fs = 250 N/ mm2). Solution: V = 2[20 + 40] x 3 x 250 = 90000 N ft = 160 N/mm2; B = 20 mm; A = 40 mm.
= 18.4 = 18mm Die thickness = 18 mm + 3 mm = 21 mm. Margin usually ranges from one to two times the die thickness. Taking the maximum value, M = 2 Tr
= 2 x 18 mm = 36 mm Let us check the shear stress on the die. Die shear area = 2 MTr = (2 x 36 x 18) mm2 = 1292 mm2 Shear stress = fs = 90000/1296 mm2 = 69.4 N/ mm2 As an exercise let us calculate the margin for shear stress 120N/ mm2 2 MT x fs = 90000 N. M = 90000/(2 x 18 x 120 N/mm2) Thus the margin can be safely be 20% more than the die thickness. Margin is the solid cross-section around the die cutting edge. The fixing screws and dowels should be placed outside the margin to prevent weakening of the die. In other words there should not be any hole in a 21 mm wide band around 20 mm x 40 mm die opening: in a 62 mm x 82 mm rectangle around the slot.