Bolting of Dies PDF
Bolting of Dies PDF
Bolting of Dies PDF
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Many die clamps use threaded fasteners. The clamping system may be as simple as a T-
bolt, nut, and special heavy washer. This is very simple and effective if U-shaped cutouts
having a constant tie-down height are provided in the die.
Hydraulically powered clamps may be cost-effective when many die changes are
performed daily. Automatic die changes on large tandem lines and transfer presses
require pneumatic or hydraulically actuated clamps. However, they are not a cure-all for
reducing setup time when manually setting dies.
Figure 1. The heads of bolts often specified for diesetting have distinctive head
markings. SAE-ASTM grade eight bolts (A) are identified by six markings. The metric
fasteners are ISO 10.9 (B) or ISO 12.9 (C) property class bolts. All SAE-ASTM and ISO
fasteners meeting these specifications are identified with the manufacturer's logo or
identification.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
The clamping examples discussed and illustrated in this paper are not suitable for all
classes of work. It is to be noted that clamping practices suitable for clamping
workpieces in machine tools are not necessarily suitable for die fastening. Presswork
involves dynamic forces and often shock loading.
Safe pressworking depends on the use of a sufficient quantity of clamps to securely hold
the die in the press. The attachment of the die buildup including parallels and sub-plates
also requires an adequate size and number of high-grade fasteners to insure against
failure.
Some classes of work may require fastener safety factors several hundred times the static
weight of the die and buildup alone. Note that a safety factor of as much as 300 not
300% is stated. A safety factor of 300 is 30,000% of the static load. High-speed work
involving rapid cyclical loading is an example of an application requiring large safety
factors. The shock and impact loads occurring in slow operations can also be quite
severe. Typical causes are snap-through energy release in heavy punching operations as
well as heavy cam and pad return impact.
Recommended Fasteners
It is highly recommended that only SAE grade eight or equivalent fasteners are used for
diesetting applications. These bolts are made of heat-treated alloy-steel having a
minimum yield-strength of 130 KSI (896 mPa). An ASTM equivalent is specification
designation number A354, grade BD threaded fastener. Both of these fasteners are
identified by six markings on the head illustrated in Figure 1 (A).
It is worth noting that all specification-grade fasteners made in the United States have a
manufacturer's mark or logo in addition to the grade marking. If there is no
manufacturer’s identification, the bolt may be imported.
Some imported bolts have failed to meet specifications. Diesetting fastener safety is too
critical to leave fastener safety to chance. Require the seller to properly identify all
fasteners and supply certified test results. 1
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Applicable safety rules including those of some government regulatory agencies, may
simply state that the die to be securely fastened to the bolster and slide. This simple
requirement leaves a lot to the imagination.
When threaded fasteners are used, specifying a sufficient size and quantity of heat-treated
alloy-steel bolts is highly recommended. Avoiding the use of plain carbon-steel or soft
bolts actually saves money. High-grade bolts last much longer. The heads do not round
off, nor do the threads stretch and wear out rapidly. Rapid wear, stretching, and thread
damages are frequent problems with inexpensive fasteners.
The writer is aware that many light duty pressworking applications do use all thread rod
and nuts welded to the rod to produce low cost fasteners quickly. Here extreme caution
should be observed and a metallurgical engineers judgement used to approve the
application
Diesetting fasteners must withstand the cyclical loading from both the dynamic action of
the press and re-tightening with re-use. The die clamping system should incorporate
redundant fasteners. Analyze and correct the root cause should any one fastener fail.
Many factors affect the endurance limit and fatigue strength of mechanical systems.
Consult standard engineering references should establish safe fastening standards for
each class of work, and to analyze any failures that may occur. 2
2 B. Tapley "Eshbach's Handbook of Engineering Fundamentals", Fourth Edition, John Wiley & Sons,
Inc., New York, 1990. Section 4.8, which treats the mechanics of deformable bodies including theories of
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 2. A high-strength alloy-steel T-slot bolt and nut permits the use of a large strong
fastener, and visual inspection for proper thread engagement. Smith & Associates
One advantage of the T-slot bolt is that a larger fastener can be used than is the case with
the hex-head bolt and a T-slot nut system. A 1.000-inch (25.4 mm) diameter T-slot bolt
has approximately twice the strength of a comparable 0.750-inch (19.05 mm) hex-head
bolt and T-slot nut.
2. The screw may bottom out on the T-slot bottom if too long.
strength and failure is a good reference for those wishing to understand some current theories of the limits
of fasteners subjected to cyclical loading.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 3. The use of a T-slot nut requires the use of a smaller hex-head bolt, and does
not permit visual inspection of thread engagement. Smith & Associates
The nuts used for diesetting applications should be made of the same high-grade heat-
treated material as the bolts. The height of the nut should be great enough to permit a
length of thread engagement at least one and one-half times the thread diameter.
Diesetting Wrenches
Only proper heavy-duty wrenches designed for diesetting should be used. Lightweight
automotive and adjustable wrenches are not suitable. Heavy-duty ratchet wrenches are
suitable if they are of very robust construction. Special heavy forged diesetting wrenches
are available that have captive tubular handles. Pipe extensions or wrenches fabricated
by welding should not be used.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
A means to insure that proper torque values are reached is needed. Diesetters should
check the final tightening with a torque wrench from time to time to be sure that the tool
is operating properly. In critical applications final hand tightening with a torque wrench
is advisable.
Figure 4. Example of three simple ways to adapt dies to a constant clamp height.
Pockets (A) milled to provide a constant clamp height. Spacers (B) attached to the edge
of the die shoe. A horseshoe-shaped spacer attached to the die (C). Smith & Associates
In cases where more than one tie-down height is required, a system of uniform
increments of clamping heights should be used. For example, the distance from the
clamping surface to the ram and bolster can be standardized in one inch or one centimeter
steps.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 4 illustrates three simple methods of correcting differing die shoe or sub-plate
thicknesses to a constant clamp height. In the case of a shoe or sub-plate that is too thick
(A), small pockets can be milled to provide a common clamping height. If it is too thick
(B), the correct thickness spacers are attached to the edge of the die shoe or sub-plate to
provide the correct dimension. In some cases, tack welds can be used, but screws are
preferable to avoid warping the shoe. Where T-slot bolts and washers are used (C),
differing heights can be corrected by milling, or attaching a horseshoe-shaped spacer as
shown.
An exception might be provided in diesetting rules for setting a large die with toe clamps.
This provision is normally for running small quantities of initial production material or
die tryout work. In such cases, the usual requirement is to obtain competent engineering
management approval as to exactly how the toe clamping is to be accomplished.
The many factors that pressroom personnel must deal with to insure a safe working
environment may require safety procedures that inspectors from regulatory agencies
might not be aware of. The die design and engineering department must specify the
requirements for safe diesetting, as well as safe part loading and unloading when the
process for a new stamping is approved.
Adopting safe methods requires much more than conducting safety training for
pressroom personnel. Management must:
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
The use of spacer or setup blocks to provide support for a strap clamp may be an
acceptable practice depending upon die weight and engineering data. The use of a single
spacer block equal to the standard clamping height is conditionally permissible.
Supervised die tryout work is an exception. However, most large dies are not set with
straps and spacers. This method, often termed bridge clamping is suitable for light duty
work not involving shock or impact loads and die tryout work with engineering approval.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 6. A recessed parallel clamping ledge is less apt to be damaged than the exposed
style illustrated in Figure (4). Smith & Associates
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
An advantage of the clamps illustrated in Figures 7 and 8 is that the hole is easy to drill
on location using a light-duty radial-arm drill press. Horizontal milling machines are
ideal for cutting clamping flats in parallels efficiently. Shops lacking such mills usually
have a suitable drill press for drilling the tie-down holes.
Figure 9 shows a forged gooseneck clamp that engages a ledge on a die shoe or parallel.
All of the forged commercially available clamps shown use swivel washers, and either
swivel head capscrews, or swivel nuts.
A washer may be needed under the spring to keep it from catching in the T-slot. A
second washer may be needed on top of the spring if a long U-shaped bridge clamp is
used. Figures 10 and 11 show an alternative the use of a spring to support the clamp.
Figure 8. A straight type forged steel clamp. The clamp has a round projection that
engages a drilled hole in the die shoe. The opposite end is designed to span a T-slot to
eliminate the need for a setup block. Smith & Associates
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 10. This small one-piece “Danny Morgan” toe clamp is easily shoved into
position. Smith & Associates
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
The simplified design has a lead on the portion of the clamp that engages the die-
clamping ledge. The palm of the hand is placed on the large chamfer at the rear of the
clamp. It is simply pushed into place. Figure 11 illustrates the clamp in position. This
clamp is used in light duty applications, and is not recommended for heavy work. The
clamp can be machined from SAE 1018 steel and gas carburized for wear resistance.
Danny Morgan is the owner of Morgan Tool and Die in Bellfontaine, Ohio.
A consideration in the use of this design is that there is a stress concentration where the
edge of the clamp attaches to the body. The radius at this point should be made as
generous as possible. If substantial clamping forces are anticipated, the clamp should be
made of alloy steel and heat-treated for maximum toughness.
Figure 11. The clamp illustrated in Figure 10 in position. A limiting factor is the
allowable stress concentration at the radius under the clamping lip. Smith & Associates
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 12. An example of a mechanical half-turn die clamp employing a toggle locking
mechanism. Optima USA
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
the bolster. In cases where the plate is warped, the serrated nut must be pre-tightened
with a special spanner wrench. If this extra effort is required, the advantage of the clamp
for quick die change is lessened. Development of new designs of the type of clamp is
expected to result in greater clamping forces and clamping plunger travel.
Figure 14. An example of a self-positioning hold down or swivel clamp. These clamps
are widely used in machine tool setups because they accommodate a wide range of
clamping heights. They are recommended only for short run light-duty presswork subject
to competent in-plant engineering approval.
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D. Smith, Quick Die Change Video Course, tape two, session eight has animated footage of how the
swivel or "banana" clamp works. The case study is from W. C. McCurdy Company, Troy, Michigan. This
company is now a unit of Masco Stamping Technologies, Inc. The workbook has a description of the
clamp on pages 107 to 108. The same description is in the Facilitators Guide on page 136. A second video
case study, tape five session 22, shows a different brand of swivel clamp used for short run production.
This case study is from Webster Industries, Tiffin, Ohio. The workbook has a description of the Webster
application on page 238. The same description is in the Facilitator’s Guide on page 278. The video
training series, is copyrighted material available from The Society of Manufacturing Engineers, Dearborn,
Michigan, © 1992.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 15. Another view of the self-positioning hold down or swivel clamp illustrated in
Figure 14. The design accommodates different heights without the need for a setup
block. These clamps are made by several manufacturers. They are only recommended
for light-duty short run work subject to competent in-plant engineering approval.
The tooling is capable of producing a great variety of product styles with a modest
investment in tooling. If an individual die were used for each product style, the tooling
cost and die storage space requirements would be several times greater than the split die
system.
However, the designer has overlooked a basic problem that the diesetter will have in
changing over the dies. The inside T-slot bolts cannot be inserted once the dies are in
position. By overlooking this factor, the designer has created a difficult task for the
diesetter. The problem is illustrated in figure 16.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 16. Two dies set in the same press results in a problem placing T-slot bolts to
clamp the inner die edges. Smith & Associates
The toe clamps used with T-slot bolts are simple and low in cost. The hydraulic ledge
clamps may be more cost-effective if many die changes are performed each shift --
especially if the access to tighten the conventional bolts is limited by the size of the die
and or press opening.
Figure 17. Two ways of solving the problem of inside bolt placement shown in Figure
16. Both the upper and lower dies can be retained by either simple one-piece toe clamps
or T-bolts. Another choice for frequent changeovers is the use of hydraulic ledge clamps
that are actuated when in position. Smith & Associates
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Safe pressworking involves many disciplines. The die designer and process engineer
must apply accurate pressworking formulas when determining press requirements.
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This clamp is considered to be covered by a United States patent and manufactured by Shanley
Enterprises - 9088 Highland Drive - Grosse Ile, Michigan. It is considered available through fastener
dealers who should be consulted for suitability for a specific application.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
When large stamping die pads stop on the pad keepers, all of the inertia of motion of the
pad is suddenly dissipated, resulting in severe shock and noise. The result is rapid keeper
wear as well as broken die shoes. In extreme problem cases, the bolts used to fasten the
upper die to the press slide fail, permitting the upper shoe to become detached from the
press. This case study shows how to solve the problem with automotive pull-rod shock
absorbers.
When the pad is suddenly lifted by the pad keepers on the press upstroke, the sudden
acceleration of the pad resting on the lower die results in severe shock and noise. In
addition, the following failures are likely to occur:
1. The bolts used to fasten the upper die to the press ram may fracture and fail.
Figure 19. A Frequent cause of upper die attaching bolts failure is upper die pad impact
of the pad keepers. The use of heavy-duty automotive shock absorbers is an effective
way to deal with the problem in large automotive dies. Smith & Associates
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Woodhaven, Michigan Stamping Plant The die was attached to the ram with 15 one inch
(25.4 mm) grade 8 bolts. Typically, eight would be required if shock were not a problem.
The impact problem was quite serious—as many as 12 of the 15 bolts failed due to
fatigue fracture on several occasions.
For this application, Monroe Magnum series 70-shock part number 74408 was chosen.
These shock absorbers are designed as an OEM product for General Motors city buses.
Each shock was determined to have a lifting capacity or resistance to extension of 1600
pounds (725.76 Kg) the press ram velocity several inches into the upstroke. A 50%
safety factor for a 6,520-pound (2957-kg) pad requires a control force in extension of
9,780 pounds (4436 kg). Six shock absorbers were specified.
During the modification, the nitrogen pressure system supplying pad pressure was
eliminated. The weight of the pad together with the compression force of the shock
absorbers provided sufficient holding pressure.
The use of shock absorbers permits the pad to come to a gentle rest on the keepers
resulting in very little keeper wear. By preventing keeper wear, a great deal of needless
die respotting and flange steel shimming in order to maintain correct checking-fixture fit
can be avoided. Heat buildup and the maximum speed of operation are limiting factors in
applying this shock abatement system. Engineering the shock absorber application must
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
be done in conjunction with the shock manufacturer to assure a safe effective system.
Aftermarket shock absorbers may not have the same specifications as the OEM
product—check with the manufacturer’s engineering department to verify suitability for a
given application. 5
Figure 20. An example of an alternative method for installing shock absorbers to control
pad impact problems. Note the cautionary information in footnote 5. In addition, this
type of shock abatement system is recommended for slow speed stamping applications.
Heat buildup must be calculated using simple engineering formulas.
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D. Smith, "How to Solve Die Impact and Noise Problems with Automotive Pull Rod Shock Absorbers",
SME Technical Paper MF91-259, Society of Manufacturing Engineers, Dearborn, Michigan, 1990. This
paper provides the basic information for using automotive pull-rod shock absorbers to control upper die
pad keeper impact problems on the press upstroke. Anyone attempting to use this information is advised to
contact the specialty product-engineering department of The Monroe Auto Equipment Company, Monroe,
Michigan. Aftermarket shock absorbers may not have the same valving characteristics as OEM products.
The work by the author is the basis for Ford Motor Company die standard W-DX14-50M. Upper pad
impact problems are considered a root cause of die fastener failures. In some cases, this is considered to
have resulted in amputations and pressroom fatalities. Severe pad impact is especially a problem with
large automotive deep flange and redraw dies.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 22. A T-slot bolt, large carburized steel strap and heavy-duty spring washer in
place after hand tightening. The bolting assembly (B) illustrated in (A) after it is
properly tightened. Ford Motor Company
Figure 23. A T-slot bolt, large carburized steel strap and heavy-duty spring washer in
place after it is properly tightened. Ford Motor Company
Spring Washers
For decades, Ford Motor Company, and other manufacturers engaged in heavy stamping,
have had excellent standardized die fastening methods. Features include U-shaped
cutouts in the die shoes, and uniform clamping heights. Grade eight or equivalent T-slot
bolts and nuts are used. The U-shaped slots are bridged with thick carburized steel
plates.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Figure 22 illustrates a T-slot bolt, carburized steel strap and heavy spring washer in place
after hand tightening. The large square spring washer serves several purposes. First, it
helps prevent the nut from working loose under high impact loads. The pressure of the
nut is distributed over a large area by the heavy strap.
The spring washer also serves as a visual indicator. Should the bolt loosen in service, a
gap will be visible under the washer. Figure 23 illustrates the bolting assembly after it is
properly tightened. 6
Figure 24. A die shoe or sub-plate having drilled tie-down holes (A) usually must be
fastened to the ram or bolster with cap screws and T-slot nuts. T-slot bolts are preferable.
Milling tie-down slots for T-slot bolts (B) permits the use of a strong fastener that can be
tightened with a fraction of a turn.
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Ford Motor Company, "Die Design Standards for North American Operations", Body and Assembly
Division, Dearborn, Michigan. Standardized diesetting fasteners are generally used in the automotive
industry. The grade eight fasteners used are Danly Gold-Bond brand. The plates used to bridge the U-
shaped cutout and special spring washer is made to Ford specifications and available from Jolico
Industries, Utica, Michigan.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
Some dies, such as the example shown in Figure 24 (A), may have drilled holes rather
than tie-down slots. T-slot bolts cannot be put in place easily. T-slot nuts and cap
screws, which are not advised for heavy-duty diesetting, must be used.
If T-slot bolts are required, they must be in place before the die is set. When setting the
die, getting the T-slot bolts to line up with the holes in the lower die can be time
consuming and often dangerous. The diesetter may be exposed to hazardous trial-and-
error work in positioning the bolts.
Aligning T-slot bolts placed in the ram with drilled holes in the upper die can result in
mechanical interference when inching the press closed. A diesetter may attempt to place
his or her hand between the ram and the upper die to align the bolts as the press is being
inched. This is an extremely unsafe practice.
Providing a constant clamping height can permit the same T-slot bolts to be used with
many dies. An added advantage is that only a fraction of a turn is required to tighten the
fastener.
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Overview of Mechanical Die Fastening - D16 - rev July 1, 2005
Smith & Associates, 530 Hollywood Drive, Monroe, Michigan 48162-2943 © 1990 - 2005
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