The document provides an overview of forming solutions and techniques for increasing efficiency in manufacturing operations. It discusses why forming is useful for eliminating secondary operations and reducing tool wear. Various forming methods and considerations for setup are covered, including maximum forming heights, material properties, machine capabilities, and tool recommendations. Common forming tools like clusters and extrusions are explained in detail.

1. INCREASE EFFICIENCY AND EXPAND YOUR OPERATIONS WITH FORMING MATE SOLUTIONS TRAINING

8. FORMING BASICS MATE SOLUTIONS TRAINING

12. STANDARD PUNCH PRESS TYPICAL TURRET LAYOUT = Forming Tool = Adjacent stations without tooling 20 Station Turret

14. CONVENTIONAL STATION VS. UPFORMING STATION This lance and form could never be achieved in a conventional machine. Machine with forming station makes it possible! Forming die operated by forming cylinder Die Line

19. Amada P&F Only for EM machines with Z-turret

20. Amada P&F Amada P&F

23. MINIMUM SPACING BETWEEN FORMS Minimum = 3 x material thickness to sheet edge or form on sheet Minimum = 6 x material thickness to like forms 3 x T Minimum Material Thickness (T) 6 x T Minimum 3 x T + R Minimum Radius (R) Radius = 1/2 x T

24. SPRING LOADED VS. NON-SPRING LOADED Non-Spring Loaded Die Line Spring Loaded Die Line

25. ULTRAFORM™ LENGTH ADJUSTMENT Adjustments up or down in easy steps of 0.05mm

29. AIR/LUBRICATION DELIVERY Air/lubrication mist enters here Upper shedder Upper Insert AFKB2 (Ultraform Upper) Vent to Outside Escaping Air/ Lubrication Lower Insert Stripper Plate Die Note : * Not avbailable for UltraForm XT * Option on UltraForm FX

32. SOME FORMING TOOLS IN DETAIL MATE SOLUTIONS TRAINING

38. Clusters: Solid or Insert Insert Style Solid Style Features Solid Insert Fully Guided Available Yes Yes Initial Cost Lower Higher Replacement Costs Higher Lower Punch Point Spacing Closer Farther Pattern Size Larger Smaller Punch Point Size Recommended Larger Smaller Sharpening Easier Harder

46. CALCULATING CLUSTER TONNAGE PUNCHING FORCE FORMULA = linear length of cut x material thickness x shear strength = punching force in kilonewtons (kN). PUNCHING FORCE SHOULD NOT EXCEED 75% PRESS CAPACITY. EXAMPLE: Grid of .250(6.35) diameter holes. Area of punch covers 48 holes; punch every 4th hole (12 holes). Mild steel .060 (1.52) thick. (Linear length of cut = 3.14 x diameter x number of punches). Spring pressure of the spring-loaded cluster assembly runs under a ton (9 kN) and can be ignored in calculations for machine capacity. SHEAR STRENGTH IN US tons/in 2 (kN/mm 2 ): Aluminum 5052 H32 = 15.0(0.2068) Brass = 17.5(0.2413) Mild Steel = 25.0(0.3447) Stainless 304 = 50.0(0.6894) Clusters: Tonnage

48. Clusters: Tool Life Using cluster tools reduces the number of hits…and machine and tool wear Cluster tooling will produce patterns with just 172 hits vs. current 2,064 hits

53. Piercing and Forming Clusters

54. Piercing and Forming Clusters

58. Extrusion

61. Extrude, OR … Punch and Shave Finished hole size is the starting point. Punch #1 = finished hole size – clearance (20%) Die #1 = finished hole size + 0.1 mm Punch #2 = finished hole size (full mat’l contact : Maxima !) Die #2 = die #1 .

65. Lance and Form The ‘form’ part of the operation takes place as the work piece is squeezed between the lower unit and an inverted die in the upper unit. The ‘lance’ is normally performed by the lower unit using an inverted punch.

67. Lance and Form: Design Considerations Lower tool travel is what typically limits the form height. Spring Back Thicker materials may break before completing form and cause too much abuse on lower insert. Angle is typical, may be increased if form height decreased. SHEET METAL PARAMETERS Maximum Height .250(6.4mm) R = .060(1.5mm) Minimum 85º Maximum Maximum Thickness .120(3.0mm) OPEN END 85º Maximum 45º Maximum OPEN END CLOSED SHAPE

69. Lance & Form Snaplock™

70. Lance & Form Snaplock™

74. Knockout: Sample 50 Ton Application 100 mm

75. Knockout

81. Countersink Countersink Up Countersink Down Solid body die available for up.

86. Countersink A=Major diameter B=Minor diameter C=Form angle D=Form depth E=Approximate pre-pierce T=Material thickness Typical: Metric= 90, Inch=82, Rivets=120 Material Considerations and Maximum Depths

89. Emboss - Formed

90. Emboss - Formed

91. Emboss - Formed Example of emboss down UltraTEC punch holder with special punch Special form-down die

94. Louvers

97. Louver Spacing

101. V-Line Emboss

102. V-Line Emboss

105. Shear Button

106. Shear Button One tool produces the form in each mating part. Using shear buttons to square large sheets... Conventional use of shear buttons... Shear buttons in lower plate fit into matching holes in upper plate... Shear buttons used as weld projections for precision placement of plates to be welded together...

112. EasySnap™ Use for easy part removal and skeleton breakdown Use when a formed flange needs extra material for gauging and forming. Snap off extra after form is made

116. LIT 00002

117. LIT 00002

124. HINGE TOOLS Tool 1 makes 2 hits: Pre bending and rising the pre-bended tap with axis movement in between Tool 2 makes one hit and finishes the hinge Tool 1 Tool 2

125. HINGE TOOLS Tool 1 Tool 2

128. RAM CONTROL TOOLS Press must be capable of holding the ram down while the sheet is moved in the X and or Y direction .

131. Rollerball Examples

132. Rollerball ® Beading in 1mm mild steel Detail inside corner Roller Ball Beading

134. SHEETMARKER ™ Three springs, two points (120 & 150) allow control of depth and width of the line scribed Flexible, programmable marking

135. Score Plastic Protection for removal before laser cutting or fabrication ( bending lines etc.) Cuts trough the protective plastic film without leaving any marks on the metal surface .

136. Mate EasyMark Springs: 3 Types to be used for diamond or Brass Inserts Spacer: Use for dead weight on top of Ink Marker Punch: for installing and removing inserts Ink Marker pen Insert Holder 3 Inserts (2 diamond, 1 brass) Allen Wrench: for installing and removing inserts Die: Used for SheetMarker and InkMarker Spacer: Use with SheetMarker A-station Holder

137. Mate EasyMark Applications with Inkmarker Pen

138. MATE SOLUTIONS TRAINING PROBLEM-SOLVING CHECKLIST

140. MATE SOLUTIONS TRAINING SUMMARY

142. THANK YOU! MATE SOLUTIONS TRAINING