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  • Web043 Safe Reliable Die Clamping

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    The document discusses safe and reliable die clamping. It addresses common clamping issues like bolts breaking and dies becoming loose. The root causes are applying too much or too little clamp force or using incorrect clamp parts. The document provides guidelines for selecting proper clamp parts like bolts, nuts, washers and eyebolts. It emphasizes applying the correct torque and using techniques like keeping components clean and organized to ensure safe and effective die clamping.

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    The document discusses safe and reliable die clamping. It addresses common clamping issues like bolts breaking and dies becoming loose. The root causes are applying too much or too little clamp force or using incorrect clamp parts. The document provides guidelines for selecting proper clamp parts like bolts, nuts, washers and eyebolts. It emphasizes applying the correct torque and using techniques like keeping components clean and organized to ensure safe and effective die clamping.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    Download as pdf or txt
    64 views40 pages

    Web043 Safe Reliable Die Clamping

    Uploaded by

    sinr
    The document discusses safe and reliable die clamping. It addresses common clamping issues like bolts breaking and dies becoming loose. The root causes are applying too much or too little clamp force or using incorrect clamp parts. The document provides guidelines for selecting proper clamp parts like bolts, nuts, washers and eyebolts. It emphasizes applying the correct torque and using techniques like keeping components clean and organized to ensure safe and effective die clamping.

    Copyright:

    © All Rights Reserved
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    of 40

    Safe Reliable Die Clamping

    Alex Monroe 1/18/2011


    Outline
    •  Background and Motivation
    •  Clamps, Die Carriers
    •  Bolts, Washers, and Nuts
    •  Eyebolts and Lifting of Dies
    •  Organization
    •  Torque and Clamping Force
    Clamping Issues
    •  Bolts break
    •  Platen T-slot break
    •  Die falls off platen
    •  Die becomes loose, and either shifts
    downward or rotates during
    production.
    •  One die half is pulled off a platen
    during opening
    •  Clamps break
    Root Causes
    •  Too much or too little
    clamp force
    •  Wrong, Under, or
    un-rated clamp parts
    •  T-Slot Bolt
    Figure  3:  Fixed  height  die  clamp  kit  designed  for  die  
    cas8ng  die  clamping  (Advance  Products)  
    Clamp Parts
    •  T-bolts 1.5*Bolt Dia

    •  Nuts
    •  Washers
    •  Clamp

    Figure  2:  A  high-­‐strength  alloy-­‐steel  T-­‐slot  bolt  and  


    nut  permits  the  use  of  a  large  strong  fastener,  and  
    visual  inspec8on  for  proper  thread  engagement.    In  
    this  case  the  nut  has  the  correct  thickness  allowing  a  
    thread  engagement  of  one  and  one-­‐half  8mes  the  
    bolt  diameter.      (Smith  &  Associates)  
    Physics of Clamping
    •  How many clamps?
    –  Weight of die half
    –  Friction
    –  Torque applied
    –  T-Bolt Diameter
    –  Distance of t-bolt from die edge
    –  Parallelism of mold clamps
    –  Presence of die items engaging into platen (Shot Sleeve,
    T-slot Keys ,or Locating Pins, Pull Back Rods)
    –  Safety Factor
    •  Prevent Die Slipping
    –  Clamps and Die Carrier
    •  Prevent Pushing Die Off Machine
    –  Clamps
    Tools
    •  Visually Inspect
    Tools
    –  Before Using
    –  After Possible
    Damage
    •  Properly Sized
    –  Should Fit Snug
    •  Cleaning Tools
    •  Cheater Bars
    Used with Care
    Clamps
    •  Clamps
    •  Use the Correct
    Clamp
    •  Proper Size
    •  Proper Height
    •  Aligned
    Clamp Types
    •  Die Casting Die
    Clamps
    •  Use Die Carriers
    –  Large Dies
    –  Large Machines
    –  Reduce the Number
    of Clamps Needed
    Clamp bolt torque

    Figure  15:  T-­‐Bolt  installed  in  the  correct  posi8on,  close  to  
    Figure  14:  Example  of  t-­‐bolt  installed  too  far  from  the  
    the  die.    This  will  result  in  a  majority  of  the  clamping  force  
    edge  of  the  die.    Most  of  the  force  is  in  the  heel  of  the  
    being  applied  to  clamping  the  die.    Also  no8ce  the  nose  of  
    clamp  instead  of  the  nose  of  the  clamp  onto  the  die.3    
    the  clamp  is  pushed  onto  the  die  clamping  surface  
    adequately,  but  may  be  able  to  be  pushed  even  father  in  
    for  beQer  results.  (Smith  &  Associates)  
    Clamps
    •  Place Bolts as Close to Die As
    Possible
    •  Clamping Force Depends on Bolt
    Location

    No Clamping Force Best Clamping Force


    Clamps
    Clamps

    Too Many Nuts Too Many Washers


    Clamps
    •  Remove Un-used Clamps and Bolts
    •  Ideally Safety Wire in T-slot
    T-Slots
    •  Provide Base for
    Clamps
    •  Should not Be
    Broken
    •  Should be Cleaned
    •  T-Slot Cleaners
    –  Easier Clamping
    –  Better Contact with
    T-Bolts

    Figure  12:  T-­‐Slot  Scrapers  (J.W.  Winco)  


    Never Use T-Slot Nuts

    Figure  5:  The  use  of  a  T-­‐slot  nut  requires  


    the  use  of  a  smaller  hex-­‐head  bolt,  and  
    does  not  permit  visual  inspec8on  of  
    thread  engagement.    (Smith  &   Figure  4:  T-­‐Slot  Nut,  not  recommended  
    for  die  clamping    
    Associates)    
    Bolts, Washers, and Nuts
    •  Keep Clamp
    Components Clean
    –  After Use
    •  Difficult To Use
    •  Cannot Achieve
    Needed Clamping
    Force
    •  Dirty Bolts Require
    up to 50% More
    Torque
    Bolts, Washers, and Nuts
    •  One Bolt, Nut, and
    Washer
    •  1.5 X Diameter
    Thread Engagement
    (150%)
    •  Do Not Bottom Out
    Threads
    •  Correct Bolt Length
    Washers

    Figure  10:  Die  clamp  washer  28-­‐32  RC  hardness  150,00  PSI  tensile.    
    This  washer  is  designed  to  withstand  die  clamping  forces  (Quad  Steel  
    Co.)  

    Figure  11:  This  clamp  will  loosen  because  a  thin  washer  of  the  wrong  
    material  type  was  used  causing  it  to  bend  under  the  clamping  force.3    
    Tools and Techniques

    Figure  6:  Never  use  washers,  nuts  and  slugs  to  increase  clamping  height.    Slugs,  nuts  
    and  washers  are  seldom  flat  and  normally  have  burrs  that  compress  and  will  cause  
    the  clamp  to  loosen;  also  these  parts  are  not  designed  for  clamp  spacing  applica8ons.
    3    
    Eyebolts and Lifting
    •  Correct eye bolt
    thread length
    •  Eyebolt is not
    damaged or bent
    •  Check for cracks
    •  Corrosion
    •  Wear
    •  Working load limit
    Eyebolts and Lifting
    Correct Chain Length
    •  Angular loading Chain Length > Chain Spread

    •  Chain Length

    Direction of Pull Adjusted Working Load


    45 degrees 30% of rated working load
    90 degrees 25% of rated working load
    SPREADCHAINLENGTHDIE
    HOISTEYEBOLTCHAIN
    90o45oIN-LINE
    Eyebolts and Lifting
    •  Swivel Hoist Ring
    •  Use Whenever
    Possible
    Eyebolts and Lifting
    Organization
    •  Keep Clamps and Tools Organized
    •  Safer

    Why  is  this    


    –  Use Correct Item Every Time
    •  Clamps, Wrenches, Bolts, Etc…
    –  Recognize Damage Immediately

    Hard  to  Do?  


    •  Faster
    –  Eliminate Searching for Tools
    •  Easier
    –  Less Stress
    –  Less Rushing
    Organization
    Work Toolbox Home Toolbox
    5S – A Way To Organize
    •  Sort: Remove Unnecessary Items
    •  Set in Order: Arrange Items
    •  Shine: Clean workplace
    –  Tools, Clamps, Machine, etc…
    •  Standardize: Simplify Job Content
    •  Sustain: Maintain 5S habit
    •  Safety: Common Sixth ‘S’

    11
    Presence of Shot and Ejector parts
    •  Do not Rely on Shot and Ejector System to Hold
    the Die
    •  Do not Rely Solely on Die Carrier
    •  Shot System
    –  Shot Sleeve
    –  Allows Rotation
    –  Shot tries to Push
    Cover Off Platen
    •  Ejector System
    –  Knockout Rods
    –  Pullback Rods
    –  Can Seize up
    –  Ejection Tries to Push
    Ejector off Platen
    Clamp Number Location
    •  How Many Clamps are Needed?
    •  Where Should They Be?
    •  Factors Considered
    –  Die Weight
    –  Torque
    –  Position and Number
    –  Etc…
    •  Typically Use as Many As Possible
    Die Weight
    •  How Many Clamps?
    •  How heavy?
    –  Each half
    •  Weight Engraved on Side of Die
    Clamping Friction
    •  Coefficient of Friction
    Dry Steel on Steel ~ 0.75
    •  Cleanliness
    –  Clamp
    –  Die
    –  Platen
    –  T-Slots

    Figure  13:  BoQom  fric8on  clamp  must  prevent  slippage  at  points  
     
    A,  B,  and  C  in  order  to  hold  the  mold  securely.  1

    Figure  12:  T-­‐Slot  Scrapers  (J.W.  Winco)  


    Torque

    (Courtesy of SPS Technologies, Aerospace Fasteners Group)


    Torque
    •  Use Feel
    –  Example 40 ft-lb = 20 lbs at 2’ breaker bar
    –  Inaccurate at Best
    •  Best Measure using
    Torque Wrench
    •  Measured Torque Wrong
    –  Dirty Threads
    –  Cross Threaded
    –  Rusted Threads
    –  Etc…
    •  Keep Bolts Clean
    –  25%-50% added Torque
    •  Final Tighten at Lock-up
    Torque Alternative
    •  Turn-by-Nut Method
    –  No Undue Damage to Clamp System
    –  Snug bolts
    •  Full Effort using Spud Wrench
    –  Turn XX Angle
    –  Angle Depends on Bolt Size
    Clean Clamps and Platen
    Estimated Torque
    Estimated Torque for Clamping
    (May vary depending on application,
    material type and grade)4

    Thread Size Max Torque Bolt Force

    1/2”-13 125 ft lbs 100 lbs

    5/8”-11 245 ft lbs 160 lbs

    3/4”-10 425 ft lbs 233 lbs

    1”-8 591 ft lbs 245 lbs

    1-1/4”-7 800 ft lbs 264 lbs


    Estimated Torque for Clamping
    (May vary depending on application,
    material type and grade) 4
    Thread Size Max Torque Bold Force
    ½”-13 17.29 m kgs 45.35kg
    5/8”-11 33.8 m kgs 72.57kg
    ¾” - 10 58.7 m kgs 105.6kg
    Clamping Force
    •  Calculate Bearing Load
    •  Steel on Steel CoF µ ~ 0.75
    •  X/Y ~ 0.5

    Y
    X
    Check
    •  After 15-20 shots
    •  Check clamps
    –  Are they loose?
    –  Have the Nuts Backed off?
    –  Die Flopping on Platen?
    –  Ejector Operating Smoothly?
    –  Slide Operating?
    Conclusions
    •  Safe and Reliable Clamping Requires
    Consistent Practices
    –  One Bolt, One Washer, One Nut
    –  Clean Components for Reproducible
    Clamp Force
    –  Never Use T-Slot Nuts
    –  Use Estimated Torque Values
    •  Consider Turn by Nut Method
    •  5S Enables Better Clamping and
    Faster Setups

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