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Posted by stephens on Mar 9, 2010 in Engineering Decisions, Tips & Techniques | 0 comments

I blogged a while back about the changes we made to automotive die standards that inadvertently revolutionized how dies are designed and built.

As promised, here is the long awaited list of top 10 things I would do today, in no particular order, if given a clean sheet to re-write die standards:

1. Screws: Use M10 socket head cap screws for everything and fewer of them.
2. Materials: Use application-appropriate materials.
3. Castings: Lighten up the walls and ribs by another 30%.
4. Adapters: With NC machining, loose adapters are no longer needed.
5. Retainers: Set perforating punches with the NC dowel.
6. Cushions: No more springs in dies. Use upper and lower press cushions instead.
7. Inserts: Make no local inserts the best inserts the rule for new tools.
8. SPA: Dump Safety Pad Areas. Use press-mounted blocks and save room in the die.
9. Surfaces: Reduce fitted sculptured surfaces by another 30%.
10. Protection: Use signature waveform on the press instead of die-mounted sensors for panel presence and panel leaving.

I know some of these items will raise eyebrows. The goal here is to reduce the tool bill and overall stamping costs. Period.

Keep in mind, I got death threats the first time around when we broke all the rules. Today, no one gives these broken rules a second thought.