Trouble Shooting in Sheet Metal

TROUBLE SHOOTING
IN
METAL STAMPING
INTRODUCTION
A wide verity of problems can be encountered in the use of
different dies
Many caused by improper press selection
Or poor alignment, poor manufacturing, and poor design, etc
Some common die problems, their causes, and suggested
remedies
CLASSIFICATION
Cutting dies
Forming dies
Drawing dies
CUTTING DIES
1. Burring Of Stamping
Cause
Remedy
Dull cutting steel
Sharpen cutting steel
Improper clearance
Reset correct clearance
Thickness is too large

Material not lying flat
during blanking
operation
2. Premature Dulling Of Punch Or Die
Cause
Remedy
Faulty hardening
More carefully hardening
Wrong type of steel
Selection of higher carbon tool

steel
Lack of cutting coolant

Non uniform clearance
Misalignment
Use coolant or die lubricant

Relocate punch or die
3. Faulty Stripper Action
Cause
Remedy
Unbalanced stripping force

(broken springs or poor selection
of springs)
Refit stripper to punch allowing

more clearance
Binding of stripper
Sloppy fit of stripper to punch
Balancing of the spring
4. Loading Of Punches And Dies Or Cutting Steels
Cause
Remedy
Insufficient clearance
Provide more clearance
Rough surface on cutting steels
Polish cutting steels
Lack of cutting coolant
Use coolant or die lubricant
5. Concave Surface Around Edge Of Blank
Cause
Remedy
Too much clearance between

stripper and punch
Make stripper fit closer to punch
6. Tapered walls on pierced holes
Cause
Remedy
Found on thick stock which

required large clearance
Follow punching operation with

shaving operation
Decrease clearance
7. Poor shedding of scrap on trim dies
Cause
Remedy
Scrap extend too far around

dies
Add more scrap cutters
8. Slugs jamming on die
Cause
Remedy
Insufficient clearance angle

on die
Allow (1.6mm) minimum

land on cutting edge
More land area
Back taper 2 minimum angle
9. Breakage of punches and cutting steels
Cause
Remedy
Misalignment of ram of press.
Align ram of press.
Loose fit on guide pins.
Refit guide pins.
Dull cutting steels.
Sharpen cutting steels
Cocked punch or die.
Be sure that punch and die shoes

are clean and free from burrs and
slugs.
10. Blanks not flat
Cause
Remedy
Wrong type of die operation.
Use return-type die.
Poor stripping action.
Keep shear equal to metal

thickness or less.
Too much shear.

Excessive clearance.
11. Blanks or holes not to specified size
Cause
Remedy
Worn punch or die.
Replace punch and/or die.
Incorrect punch or die.
Sharpen punch and die.
Material characteristics.
Align the die and press properly
Material not lying flat during

operation
Optimum stripping force
12. Slug pulling
Cause
Remedy
Incorrect clearance.
Replace punch or die.
Excessive lubricant.
Keep lubricant to a minimum.
Magnetize punch.
Check magnetization.
Not enough punch penetration

through die
Consider shedder pins in

punches.
13. Miscuts
Cause
Remedy
Poor feeding
Check setup of knockout for

depth.
Improper stock location

Poor knockout action.
Careless operator.
Broken shedder pins.
Observe and assist operator.

Proper piloting
Proper material guiding
Proper stripping
Clean die surface
14. Misfeeds
Cause
Remedy
Feed line not set properly
Use misfeed detector
Burr and scrap on die

surface
Use proper lubricant
Press speed too fast
Proper material guiding
No proper stoppers
Clean die surface
Proper piloting
FORMING &DRAWING DIES

1. Spring Back
Cause
In bending operation the elastic
limit of the metal in process is
exceeded, but its UTS is not.
Therefore some of the original
elasticity of the material will be
present on it
Raw material is not flat
Remedy
Raw material thickness

variation
Over bending
Incorrect punch and die

clearance
Offset on punch
Punch is not heeled properly

Punch is too thin and weak
Proper bottoming
Use effective coining pressure

on metal flow area
2. Earing (Or) Rugged Edge
Cause
Remedy
When sheet metal is rolled at the mill,

a fiber structure is formed in the
direction of rolling
Use good materials
Impurities in material
Give more trimming allowance
Earing becomes Severity when the

sheet metal is cold worked
Tool to be aligned properly
Non uniform blank holding force
Make uniform blank holding force
3. Wrinkling
Cause
Remedy
Insufficient the blank holding force

(mostly in flanges).
Increase spring pressure
Too large area of unsupported metal

between punch and draw ring
Use draw beads
Broken spring behind blank holder
Redesign punch and die
Use homogeneous
material
4. Puckering
Cause
Remedy
Wrinkling is called as puckers if they

appear in any other part of the cup like
sidewall. It may be due the improper
clearance between punch and die.
Reset correct clearance
In addition, it will occur when the die

radius is too large.
Use optimum die radius

Proper blank holding force
5. Tearing
Cause
Remedy
Too much blanking holding pressure
Reduce spring pressure
Too severe a reduction in area
Large radius is needed
Rough spots on draw ring, punch,

blank holder
Add stages in draw
Poor draw ability of material
All friction surface are polished
Anneal the part before draw
Use lubricant
6. Fracturing
Cause
Remedy
Too thin sheets Starts from the

cleavage fracture and grow big
Use polyurethane sheets for lubricant
Excessive blank holding pressure

Die radius too small
Press speed is too large
Blank too large
Die surface to be cleaned properly

Use smooth corner for smooth
material flow
Reduction percentage should be
optimum
7. Orange Peel
Cause
When metal is stretched, it loses the
shiny surface produced by rolling.
Stretching causes the surface to
become dull and in severe cases quite
rough.
Large grain size means more
possibility of getting orange peel-effect.
Most frequently occurs on the lower
cylindrical wall where tension is high.
Remedy
Expensive polishing or buffing could be
used to compensate this kind of defects
Other alternatives would be to use metal
having smaller grain size
8. Thinning
Thinning
Cause
Remedy
Insufficient metal flow
Use flat draw beads
Reduce blank holding force

Use proper lubricant
9. Burnish Marks
Cause
Remedy
When the top of the cylindrical cup

wall is highly polished
Larger clearance would eliminate this

condition
Optimum polish
The metal has been burnished or

ironed.
11. Necking
Cause
Strain ratio is more on stock material
Non uniform force
Blank development is too small
Remedy
Use draw beads
Anneal the part before draw
Use homogenous material
Proper punch and die radius
12. Stretcher Strains
Cause
Non-uniform yielding of the metal due
to trapped gases within the metal.
Rim steels are responsible for this
defect
The lines in figure may disappear as
drawing continues
Remedy
Aluminum killed steels are free of this
defect
13. Pitting
Cause
Remedy
Due to Scales on the sheets
Clean stock material
Poor quality of sheet
Clean die surface

Clean lubricant
14. Scratching
Cause
Remedy
Tool fails to keep the blank with

contacting the die surface
Give proper clearance
Small particles of sheet metal become

welded to the die
Raw material is too hard or
inconsistent
Better or higher-pressure
lubricants
Quality steels should be
punches
More frequent polishing of
the die will prevent severe
THANK YOU

Trouble Shooting in Sheet Metal

Uploaded by

Copyright:

Available Formats

Trouble Shooting in Sheet Metal

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Trouble Shooting in Sheet Metal

Uploaded by

Copyright:

Available Formats

TROUBLE SHOOTING

Dull cutting steel

Sharpen cutting steel

Reset correct clearance

Thickness is too large

2. Premature Dulling Of Punch Or Die

More carefully hardening

Wrong type of steel

Selection of higher carbon tool

Lack of cutting coolant

Use coolant or die lubricant

3. Faulty Stripper Action

Unbalanced stripping force

Refit stripper to punch allowing

Balancing of the spring

4. Loading Of Punches And Dies Or Cutting Steels

Provide more clearance

Rough surface on cutting steels

Polish cutting steels

Lack of cutting coolant

Use coolant or die lubricant

5. Concave Surface Around Edge Of Blank

Too much clearance between

Make stripper fit closer to punch

6. Tapered walls on pierced holes

Found on thick stock which

Follow punching operation with

7. Poor shedding of scrap on trim dies

Scrap extend too far around

Add more scrap cutters

8. Slugs jamming on die

Insufficient clearance angle

Allow (1.6mm) minimum

More land area

Back taper 2 minimum angle

9. Breakage of punches and cutting steels

Misalignment of ram of press.

Align ram of press.

Loose fit on guide pins.

Refit guide pins.

Dull cutting steels.

Sharpen cutting steels

Cocked punch or die.

Be sure that punch and die shoes

10. Blanks not flat

Wrong type of die operation.

Use return-type die.

Poor stripping action.

Keep shear equal to metal

Too much shear.

11. Blanks or holes not to specified size

Worn punch or die.

Replace punch and/or die.

Incorrect punch or die.

Sharpen punch and die.

Align the die and press properly

Material not lying flat during

Optimum stripping force

12. Slug pulling