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Cataloging-in-Publication Data is on file with the Library of Congress
Copyright © 2006, 1998 by Ivana Suchy.
All rights reserved. Printed in the United States of America. Except as permitted under the United States
Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any
means, or stored in a data base or retrieval system, without the prior written permission of the publisher.
1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 1 0 9 8 7 6 5
ISBN 0-07-146271-6
The sponsoring editor for this book was Larry S. Hager and the production supervisor was Richard C.
Ruzycka. It was set in Times Roman by International Typesetting and Composition. The art director for the
cover was Handel Low.
Printed and bound by RR Donnelley.
This book is printed on recycled, acid-free paper containing a minimum of 50% recycled, de-inked fiber.
McGraw-Hill books are available at special quantity discounts to use as premiums and sales promotions, or
for use in corporate training programs. For more information, please write to the Director of Special Sales,
McGraw-Hill Professional, Two Penn Plaza, New York, NY 10121-2298. Or contact your local bookstore.
Information contained in this work has been obtained by The McGraw-Hill Companies, Inc. (“McGraw-Hill”)
from sources believed to be reliable. However, neither McGraw-Hill nor its authors guarantee the accuracy or
completeness of any information published herein and neither McGraw-Hill nor its authors shall be
responsible for any errors, omissions, or damages arising out of use of this information. This work is
published with the understanding that McGraw-Hill and its authors are supplying information but are not
attempting to render engineering or other professional services. If such services are required, the assistance of
an appropriate professional should be sought.
Copyright © 2006, 1998 by Ivana Suchy., McGraw-Hill
11/1/2007 8:46 AM
, Source: HANDBOOK OF DIE DESIGN
CHAPTER 1
BASIC DIE DESIGN AND
DIE-WORK INFLUENCING
FACTORS
1-1 SHEET-METAL STAMPING IN COMPARISON
WITH OTHER METAL FABRICATING PROCESSES
In today’s practical and cost-conscious world, sheet-metal parts have already replaced
many expensive cast, forged, and machined products.
The reason is obviously the relative cheapness of stamped, or otherwise mass-produced
parts, as well as greater control of their technical and aesthetic parameters. That the world
slowly turned away from heavy, ornate, and complicated shapes, and replaced them with
functional, simple, and logical forms only enhanced this tendency. Remember old bath-
tubs? They used to be cast and had ornamental legs. Today they are mostly made of coated
sheet metal, if not plastics. Manufacturing methods for picture frames, chandeliers, door
and wall hardware, kitchen sinks, pots and pans, window frames, and doors were gradually
replaced by more practical and less costly techniques.
But, sheet-metal stampings can also be used to imitate handmade ornamental designs of
previous centuries. Such three-dimensional decorations can be stamped in a fraction of time
the repoussé artist of yesterday needed.
Metal extrusions, stampings, and forgings, frequently quite complex and elaborate,
are used to replace handmade architectural elements. Metal tubing, metal spun products,
formings, and drawn parts are often but cheaper substitutes of other, more expensive
merchandise.
Metal stampings, probably the most versatile products of modern technology, are used
to replace parts previously welded together from several components. A well-designed
sheet-metal stamping can sometimes eliminate the need for riveting or other fastening
processes (Fig. 1-1). Stampings can be used to improve existing designs that often are
costly and labor-intensive. Even products already improved upon, with their production
expenses cut to the bone, can often be further improved, further innovated, further decreased
in cost.
The metal stamping die (Fig. 1-2) is an ideal tool that can produce large quantities of
parts that are consistent in appearance, quality, and dimensional accuracy. It is a press tool
capable of cutting the metal, bending it, drawing its shape into considerable depths,
embossing, coining, finishing the edges, curling, and otherwise altering the shape and the
outline of the metal part to suit the wildest imaginable design concepts. Figure 1-3 shows
samples of these products.
1
Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com)
Copyright © 2004 The McGraw-Hill Companies. All rights reserved.
Any use is subject to the Terms of Use as given at the website.
, BASIC DIE DESIGN AND DIE-WORK INFLUENCING FACTORS
2 CHAPTER ONE
FIGURE 1-1 Threaded part, replaced by other, less expensive means.
The word “die” in itself means the complete press tool in its entirety, with all the punches,
die buttons, ejectors, strippers, pads, and blocks, simply with all its components assembled
together.
When commenting on these little technical ingenuities, it is important to stress the role
of designers of such products, both artistic and technical. Their thorough knowledge of the
manufacturing field will definitely enhance not only the appearance, but the functionality,
overall manufacturability, and cost of these parts.
FIGURE 1-2 Metal stamping dies.
Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com)
Copyright © 2004 The McGraw-Hill Companies. All rights reserved.
Any use is subject to the Terms of Use as given at the website.
Cataloging-in-Publication Data is on file with the Library of Congress
Copyright © 2006, 1998 by Ivana Suchy.
All rights reserved. Printed in the United States of America. Except as permitted under the United States
Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any
means, or stored in a data base or retrieval system, without the prior written permission of the publisher.
1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 1 0 9 8 7 6 5
ISBN 0-07-146271-6
The sponsoring editor for this book was Larry S. Hager and the production supervisor was Richard C.
Ruzycka. It was set in Times Roman by International Typesetting and Composition. The art director for the
cover was Handel Low.
Printed and bound by RR Donnelley.
This book is printed on recycled, acid-free paper containing a minimum of 50% recycled, de-inked fiber.
McGraw-Hill books are available at special quantity discounts to use as premiums and sales promotions, or
for use in corporate training programs. For more information, please write to the Director of Special Sales,
McGraw-Hill Professional, Two Penn Plaza, New York, NY 10121-2298. Or contact your local bookstore.
Information contained in this work has been obtained by The McGraw-Hill Companies, Inc. (“McGraw-Hill”)
from sources believed to be reliable. However, neither McGraw-Hill nor its authors guarantee the accuracy or
completeness of any information published herein and neither McGraw-Hill nor its authors shall be
responsible for any errors, omissions, or damages arising out of use of this information. This work is
published with the understanding that McGraw-Hill and its authors are supplying information but are not
attempting to render engineering or other professional services. If such services are required, the assistance of
an appropriate professional should be sought.
Copyright © 2006, 1998 by Ivana Suchy., McGraw-Hill
11/1/2007 8:46 AM
, Source: HANDBOOK OF DIE DESIGN
CHAPTER 1
BASIC DIE DESIGN AND
DIE-WORK INFLUENCING
FACTORS
1-1 SHEET-METAL STAMPING IN COMPARISON
WITH OTHER METAL FABRICATING PROCESSES
In today’s practical and cost-conscious world, sheet-metal parts have already replaced
many expensive cast, forged, and machined products.
The reason is obviously the relative cheapness of stamped, or otherwise mass-produced
parts, as well as greater control of their technical and aesthetic parameters. That the world
slowly turned away from heavy, ornate, and complicated shapes, and replaced them with
functional, simple, and logical forms only enhanced this tendency. Remember old bath-
tubs? They used to be cast and had ornamental legs. Today they are mostly made of coated
sheet metal, if not plastics. Manufacturing methods for picture frames, chandeliers, door
and wall hardware, kitchen sinks, pots and pans, window frames, and doors were gradually
replaced by more practical and less costly techniques.
But, sheet-metal stampings can also be used to imitate handmade ornamental designs of
previous centuries. Such three-dimensional decorations can be stamped in a fraction of time
the repoussé artist of yesterday needed.
Metal extrusions, stampings, and forgings, frequently quite complex and elaborate,
are used to replace handmade architectural elements. Metal tubing, metal spun products,
formings, and drawn parts are often but cheaper substitutes of other, more expensive
merchandise.
Metal stampings, probably the most versatile products of modern technology, are used
to replace parts previously welded together from several components. A well-designed
sheet-metal stamping can sometimes eliminate the need for riveting or other fastening
processes (Fig. 1-1). Stampings can be used to improve existing designs that often are
costly and labor-intensive. Even products already improved upon, with their production
expenses cut to the bone, can often be further improved, further innovated, further decreased
in cost.
The metal stamping die (Fig. 1-2) is an ideal tool that can produce large quantities of
parts that are consistent in appearance, quality, and dimensional accuracy. It is a press tool
capable of cutting the metal, bending it, drawing its shape into considerable depths,
embossing, coining, finishing the edges, curling, and otherwise altering the shape and the
outline of the metal part to suit the wildest imaginable design concepts. Figure 1-3 shows
samples of these products.
1
Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com)
Copyright © 2004 The McGraw-Hill Companies. All rights reserved.
Any use is subject to the Terms of Use as given at the website.
, BASIC DIE DESIGN AND DIE-WORK INFLUENCING FACTORS
2 CHAPTER ONE
FIGURE 1-1 Threaded part, replaced by other, less expensive means.
The word “die” in itself means the complete press tool in its entirety, with all the punches,
die buttons, ejectors, strippers, pads, and blocks, simply with all its components assembled
together.
When commenting on these little technical ingenuities, it is important to stress the role
of designers of such products, both artistic and technical. Their thorough knowledge of the
manufacturing field will definitely enhance not only the appearance, but the functionality,
overall manufacturability, and cost of these parts.
FIGURE 1-2 Metal stamping dies.
Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com)
Copyright © 2004 The McGraw-Hill Companies. All rights reserved.
Any use is subject to the Terms of Use as given at the website.
