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CL TECH |
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TOOL & DIE FACTS
Metal Stamping Dies
A Progressive die is constructed of hardened tool steel blocks, punches, etc. which are mounted on metal plates called die shoes.
They are designed to operate in a particular fashion when placed in a metal stamping press. The "die" actually forms a portion of
a metal strip into a particular shape through a series of movements through the die. The "press" provides the pressure to cause
the metal to form around the various die blocks and to be pierced, notched, bent, etc. to form a final part. Once the material
reaches the end of the progression it is separated from the strip of metal.
A Blanking die is a simpler operation. The blocks are mounted on die shoes. The metal is cut and pushed through the die by the
pressure of the press much as a cookie cutter is used to cut out cookies. Particular attention must be paid to clearances allowing
the part to exit the die with the minimum burr and/or distortions to the part.
A Forming die is also simple though more complex to design than a blanking die. The die must form the material to a particular
shape with a high degree of accuracy to ensure that the form meets the exact tolerances required for the form or bend.
Special Machines:
Frequently companies require a special machine to form metal into a particular form, which a press cannot accommodate or for which
the cost of a press run die would be too expensive. Then the customer comes to the tool & die company for help in designing and
building a "Special Machine" which is dedicated to producing one individual part or a series of parts. The Customer meets with the
Tool Shop to begin the process of determining how best to produce the particular part. Once the process is determined to be correct
the die shop designs the machine. Once design is approved the die shop begins the process of building the machine. In many
instances the tool & die shop may design and build a series of machines that produce various parts for a single product such as a
folding step stool.
Fixtures & Gages:
Fixtures are another specialty product produced in tool & die shops. Often a customer will want a fixture to hold a piece in place
while something is being done to it. That may be welding, riveting, cutting or many other processes. The fixture may be fixed in
place or may be required to hold the piece while rotating or otherwise moving from one location to another. There are many adaptations
for fixture uses.
Gages are used throughout the manufacturing process to determine the accuracy of the work while it is in process. The tool & die
shop will generally provide a final piece gage for the customer as well as in process gages if needed.
Production:
Short Run Production may be required by a customer for parts which they only need in a limited quantity or are not sure will go into
full production. In these cases they may ask the tool & die shop to provide them with a short run of up to 2500 pieces. This work
is also performed for those manufacturers who have determined that the volumes are insufficient to allow them to be cost effective
in producing the parts. Since tool shops are not production oriented and work more by the hour or job this type of short run can
fit very well into their schedules. This type of work can be stampings, CNC machining, Lathe work, etc.
Long-term production generally refers specifically to parts that the customer has made a definite decision to send outside for lack
of sales volume. Often these are service parts and the customer may have long-term commitments with the tool & die shop to produce
these parts on an on demand basis. The tool shop will "keep them on the shelf" or produce them as required. There are also those
parts which are needed monthly but for which the volumes are insufficient for the customer to justify producing them in-house. Thus,
the tool shop becomes the supplier for these parts.
Prototypes:
A prototype is a single part or a combination of parts that form a product. Often a customer will have a new product that they wish
to put into full production. They go to the tool & die shop to produce the first runs of these products. This allows them to "get
any kinks out before full production begins". If all is successful they will begin mass production. The tool & die shop may design
and build the dies, fixtures, gages, etc. to enable them to do this. Besides stamped parts these may also be machined, welded, or
ground parts.
Fabrications:
A fabrication is simply that. A tool & die shop may be asked to design and build many types of products from shelving units, conveyors,
machine guarding systems, etc. Each designed with a particular purpose in mind that meets the customer’s particular needs.
Die Repair:
Many modern metal stamping houses have excellent quality control standards and in-die/press sensor systems. However, when things go
wrong, a block or punch breaks, the die "galls up", the form is off, etc. the expertise of the Tool & Die shop is still needed. A
qualified Tool & Die Maker can examine a part coming off of the Die or Machine and tell what problems are occurring within the
tool/die, machine. Many customers set up die repair contracts with tool shops to ensure that help is always available on a timely
basis should the need arise.
The Stamper or OEM Manufacturer must be confident that the "Tool" shop has the expertise to design, build and diagnose the dies,
special machines, fixtures, gages, fabrications, production runs, etc. that they require to continue in business.
CLTech, Inc is a dedicated "Tool & Die" shop. We work with our customers to develop the best possible solutions to assist them in
producing their products efficiently and profitably. We offer each of the above services as part of the work we do. If you are
interested in finding out more about us please contact us at: CLT@cltech.info on the web or call: 812-526-0995.
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