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Perforating Basics
Perforating Basics
The Perforating Process
The Perforating Process
Effect of Clearance
Effect of Clearance
Define Die Clearance
Define Die Clearance
Illustrate the Six Steps of the
Illustrate the Six Steps of the
Perforating Process
Perforating Process
Explain the Advantages of using
Explain the Advantages of using
Engineered Die Clearance
Engineered Die Clearance
Simplify Maintenance of Ejector
Simplify Maintenance of Ejector
Type Punches
Type Punches
Perforating
Perforating
Part Material
Part Material
5% to 20%
5% to 20%
" Making a hole by removing a slug
" Hole size determined by punch point diameter
Clearance
Clearance
Regular
Regular
Engineered
Engineered
Clearance
Clearance
Clearance
Clearance
T = Stock
P
5%T 9-20%T
= Clearance per side
The Perforating Process
The Perforating Process
Punch
Punch
Shock
Shock
Impact Penetration Break Snap Bottom Withdrawal
Impact Penetration Break Snap Bottom Withdrawal
Thru
Thru
Impact
Impact
Regular
Regular
Engineered
Engineered
Clearance
Clearance
Clearance
Clearance
Direction
Direction
of Punch
of Punch
Increased Reduced
Increased Reduced
Bulge Roll-Over Bulge
Bulge Roll-Over Bulge
Penetration
Penetration
How Clearance Effects
How Clearance Effects
Compressive & Tensile Stress
Compressive & Tensile Stress
Regular Engineered
Regular Engineered
Clearance Clearance
Clearance Clearance
Direction
Direction
of Punch
of Punch
High High
High High
Compressive Tensile
Compressive Tensile
Stress Stress
Stress Stress
Increased
Increased
Die Force
Die Force
Torque
Torque
Punch Force
Punch Force
Punch Force
Punch Force
Break
Break
Regular Engineered
Regular Engineered
Clearance Clearance
Clearance Clearance
Direction
Direction
of Punch
of Punch
Compressive Tensile Increased
Compressive Tensile Increased
Stress Stress Roll-Over
Stress Stress Roll-Over
Greater
Greater
Less
Less
Penetration
Penetration
Penetration
Penetration
Before Break
Before Break
Crack
Crack
Before Break
Before Break
Snap Thru
Snap Thru
Regular Engineered
Regular Engineered
Clearance Clearance
Clearance Clearance
Direction
Direction
of Punch
of Punch
Spring
Spring
Vacuum
Vacuum
Pocket
Pocket
Reversal of
Reversal of
Vent of (Air)
Vent of (Air)
Perforating
Perforating
Vacuum Pocket
Vacuum Pocket
Stress
Stress
Bottom
Bottom
Regular Engineered
Regular Engineered
Clearance Clearance
Clearance Clearance
Press Fit Slip Fit
Press Fit Slip Fit
.030
.030
Held Slugs
Held Slugs
Free Slug
Free Slug
Ref.
Ref.
Withdrawal
Withdrawal
Regular
Regular
Engineered
Engineered
Clearance
Clearance
Clearance
Clearance
Direction
Direction
of Punch
of Punch
.0001 -.002 .0001 -.0015
.0001 -.002 .0001 -.0015
Press Fit Slip Fit
Press Fit Slip Fit
(Excessive Wear) (Minimum Wear)
(Excessive Wear) (Minimum Wear)
Stripping Force
Stripping Force Stripping Force
Stripping Force
Negligible
High Negligible
High
Tight Clearance
Tight Clearance
Hole Characteristics
Hole Characteristics
Engineered
Engineered
Regular
Regular
Clearance
Clearance
Clearance
Clearance
+.0001
-.0001
-.0001
P P
P P+.0001
+.0015
+.0015
-.002
-.002
Roll Over
Roll Over
20 to 40% T
40 to 60% T Burnish
T = Stock
T = Stock
Break
Burr
Burr
Hole Size Comparison
Hole Size Comparison
Regular Engineered
Regular Engineered
Clearance Clearance
Clearance Clearance
+.0005
+.0005
Punch Point Dia.
Punch Point Dia.
-.0005
-.0005
Clearance as %
Clearance as %
5 10 15 20 25
of Stock Thickness 5 10 15 20 25
of Stock Thickness
Clearance per side
Clearance per side
Burr Generation
Burr Generation
Tight Regular Engineered
Tight Regular Engineered
Clearance Clearance Clearance
Clearance Clearance Clearance
Aluminum
Aluminum
.002
.002
Cold Rolled Steel
Cold Rolled Steel
.0015
.0015
.001
.001
Stainless Steel
Stainless Steel
.0005
.0005
0
0
Clearance as %
Clearance as %
of Stock
of Stock
5 10 15 20 25
5 10 15 20 25
Thickness
Thickness
Clearance per side
Clearance per side
Burr Height
Burr Height
Productivity
Productivity
.004
.004
71,00
71,00 Maximum
Maximum
221,000
221,000
0
.003 0 Burr.
.003 Burr.
Engineered
Engineered
.002
.002
.001
.001
25 50 75 100 125 150 175 200 225 (1,000)
25 50 75 100 125 150 175 200 225 (1,000)
Production
Production
(Average Number of Hits Between Grinds)
(Average Number of Hits Between Grinds)
Burr Height
Burr Height
Regular
Regular
Hole Size to Stock
Hole Size to Stock
Thickness Association
Thickness Association
1 1/2 to 1 or greater
1 1/2 to 1 or less 1 1/2 to 1 or greater
1 1/2 to 1 or less
Reduced
Reduced
High
High
Compressive
Compressive
Compressive
Compressive
Stress
Stress
Stress
Stress
1.0 T 2.0 T
1.0 T 2.0 T
T = Stock
T = Stock
Hole Size to Stock
Hole Size to Stock
Thickness Association
Thickness Association
1 1/2 to 1 or
1 1/2 to 1 or 1 1/2 to 1 or
1 1/2 to 1 or
greater than T
less than T greater than T
less than T
1.0 T 2.0 T
1.0 T 2.0 T
T = Stock
T = Stock
Higher Reduced
Longer Higher Reduced
Longer
Burr Burnish Length
Burnish Burr Burnish Length
Burnish
and Burr Height
and Burr Height
Hole Characteristics
Hole Characteristics
Point Chipping
Resharpening
Pin Retracted
Grinding Burr
Stone edge after
Jektole Punch
regrind on punch
and matrix
Side Hole
Key Keeper
Punch Retainer Plate
Hole Diameter to
Hole Diameter to
Stock Thickness Ratio
Stock Thickness Ratio
Clearance Testing
Clearance Test Example
Hole # 1 2 3 4 5 6
% Thickness 3.2% 4.8% 6.4% 8.1% 9.7% 14.5%
Amount 0.001 0.0015 0.002 0.0025 0.003 0.0045
Hole Size 0.187 0.187 0.1874 0.1877 0.1879 0.1879
Burr Height 0.0058 0.0014 0.0013 0.0012 0.0007 0.0009
Holes produced by .1875 diameter punch.
Clearance percent & amount given as per side.
1 Inch
4 Inches
An Exclusive Research Service by Dayton Progress Corporation
DAYTON PROGRESS CORPORATION
500 Progress Road " P.O. Box 39 " Dayton, Ohio 45449-0039
Telephone: [phone] " Fax: [phone]
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