WARNING WARNING - Minster Machine Co.
Contents
1. The total procedure for installing dies in a press com prises several distinct yet related steps Those steps to be performed include preparation of the press to receive the die actual die installation securing attachment of the die to the press necessary adjustments of the press die and auxiliary equipment installation of a point of opera tion guard and or safeguarding device appropriate for the operation to be performed Press size stroke length speed and capacity must be suitable for the die that will be installed If additional components such as die cush ions knockouts or feeds are required the press should be arranged for and equipped with these items The actual procedure for setting and removing dies may vary slightly depending upon press type and size type of guiding arrangements quick access features and the type of operation to be performed The steps outlined below are of a general nature and may be amended to suit a particular press and die combination however never should they be amended to the extent that the job is done unsafely Observe all warnings Setting The Die 1 When installing dies always observe the Die Setter s Safety Precautions included in this safety manual 2 Before attempting to remove or set dies and if feasi ble to reduce any possible movement the main drive motor should be turned off the press mode selector switch locked to the off position the flywheel has stopped turnin2. press and set it in the desired location Fasten the lower die shoe loosely Check alignment of openings in the die if applica 10 Die Setting Procedure ble with related openings in the bolster plate before the die is clamped into position If these openings are not properly aligned stampings scrap pieces or slugs may catch and pile up inside the die This con dition could cause the die to fracture and may result in possible injury to the operator due to flying die particles Good lighting and a mirror can be quite helpful when checking alignment Never use fingers to line up or locate holes If die cushion will be used raise pressure pins by pres surizing the cushion USE ONLY LOW PRESSURE Check alignment of pressure pins with the die If the die is not located properly it may be lifted slightly by one or more of the pins or pin misalignment may prevent the cushion from expanding fully If neces sary reposition the die slightly or use other safe con venient means to assure correct alignment of pressure pins with the die Adjust the slide down until it nearly touches the top IF DIE CUSHION PRESSURE IS EXCESSIVE DURING THE PIN ALIGNMENT CHECK AND THE DIE IS MISALIGNED A HAZARD COULD BE CREATED BY THE SUDDEN RELEASE OF THE RESTRICTING PARTS DURING THIS CHECK APPLY ONLY THE PRESSURE NECESSARY TO RAISE THE CUSHION PRESSURE PAD 11 12 13 of the upper die Then bolt or clamp the upper die
3. a die storage area or die repair shop depending upon the results of the inspection step If a die cushion was used raise the cushion using low air pressure only Remove the pressure pins and then exhaust the cushion Clean the slide and bolster surfaces
4. mass of metal Consequently a slide that is set too low may cause damage to the press or failure in the die a condition that could also be hazard ous to personnel 18 Adjust the knockout mechanism if required Ifa die cushion is to be used pressurize the cushion and adjust for the proper operating pressure If spring 30 SAFETY MANUAL 19 20 21 Power Press pads are used adjust them so that the parts will be formed correctly Check the installation and adjustment of all auxiliary equipment used in conjunction with the particular die set Check the following items as applicable a Set the automatic feed equipment and scrap cut ter for correct feed line height b Adjust the automatic feeding equipment for proper timing length of feed and application of lubricant to the stock c Connect and time any die malfunction detector switches Install point of operation safeguards and or safe guarding devices Make certain that the safeguard installed is proper for the type of operation being performed and that it is correctly installed and adjusted Report any defect or malfunction of any safeguard or safety device to the proper supervisor for immediate correction Adjust parts conveyors and chutes if used Install tote pans or other mate rial handling equipment in the proper location If additional safety handling equipment or tools are required for a specific job obtain the required items and have
5. them placed in a convenient area for the operator s use Start the main drive motor and INCH the slide NEVER USE PRESS UNLESS ALL POINT OF OPERATION SAFEGUARDS AND OR SAFEGUARDING DEVICES 22 ARE INSTALLED AND OPERATIONAL through at least one cycle Then insert the material and run a few sample parts preferably on INCH Inspect the workpieces and make further slide height adjustment if necessary At this point all changes in slide adjustment must be small with special care being taken not to set the slide too low Make certain the slide adjustment mechanism is locked and that bolster bolts are tight before cycling the slide Run several sample parts using the SINGLE STROKE mode of operation Check the parts produced during the trial run to make certain that they meet production specifica tions Missing holes may indicate improper roll punch elongated holes may indicate improper roll feeding Marks on the parts may mean that slugs are accumulating Large burrs on the parts can indicate that the punch or die block is dull or that too much clearance exists between the punch and die When Die Setting Procedure inspecting drawn parts look for cracked sections especially near the bottom radius Cracks can develop because of improper lubrication improper die clear ances improper die cushion pressure hard stock or a combination of these conditions 23 After all checks and adjustments have been made observe oper
6. Refer to Fig 16 for a conceptual example Most metal forming employers should have an appropri ate maintenance department and associated fabricating equipment to construct such devices If the user does not have the equipment or manpower to build these type devices sketches detailing the required dimensions of the stock guide can be provided to local fabricating shops for outside construction After becoming accustomed to the design and fabrication of these devices the press user may want to include these devices as part of the actual die construction specifications By using these type of stock guiding arrangements the risk of injury to the press operator can be greatly reduced Such devices can also decrease stock threading time reduce operator fatigue and increase the efficiency of a metalforming system oe yee Die Setting Procedure Power Press SAFETY MANUAL Exit Side of Feed Stock Guide Arrangement Lower Die Figure 16 Conceptual example of a die stock guiding arrangement Die Removal Procedure 1 When removing dies always observe the Die Setter s Safety Precautions included in this manual After stopping slide in the stroke up position turnoff 7 the main drive motor and set the Stroking Selector switch in the OFF mode Wait for the flywheel to stop turning completely then install the press safety blocks Clean the die and thoroughly inspect it for pos sible damage wear and general cond
7. ation of the machine for a sufficient period of time to determine that it is working correct ly and safely Keep the floor area around the press clean and free from obstructions Die Stock Guiding Arrangements In automatic production systems to ensure the proper threading of coil stock material through a die blanking progressive etc the user must employ a stock guiding arrangement from the feed device to the first stage of the die Due to the many different die configurations that could be installed in a press the user is the only one that can accurately define and utilize this type of device With such a device and with the control available with your feed unit the operator should be able to thread the material through the die and keep their hands out of the die area completely If the operator would be required to position the stock material in the die area appropriate hand tools must be provided by the employer and used by the employee The press user may determine that a separate stock guid ing arrangement should be constructed and maintained for each particular die These devices should be con structed to withstand its operating environment The width of the stock guides will be dependent upon the stock material employed and the length of the device will be determined from the placement of the die within the bolster area and the resultant distance from the first sta tion of the die to the feed s outgoing stock guide
8. g completely and install safety blocks if the slide is opened Clean the die bolster plate and slide face surfaces Note On presses equipped with hydrostatic guiding systems and pressurized hydraulic quick access arrange ments it will be necessary to maintain power to the presses hydraulic system These hydraulic arrangements may not allow the die setter to use the interlocked die safety block If necessary the slide may be positioned at bottom dead center of stroke in lieu of installing safety blocks 3 Install all necessary bolster inserts slide and bolster IMPORTANT If a turnover bar is used to turn the crankshaft it should have a spring and collar arrangement that will prevent it from being accidentally left inserted in the barring hole OSHA 1910 217 d 9 ii spacer plates together with any auxiliary equipment that may be required to obtain proper working height for the die and material handling components 4 Make certain that the bolster plate is securely clamped to the press with bolts that are in good con dition Loose or broken bolts may allow the bolster to shift out of its correct position during press opera 8 mT es tion A bolster plate that has shifted from its proper position can cause serious die damage and endanger the safety of the operator If die cushioning is required pressurize the cushion and insert pressure pins in applicable bolster plate holes Use only clean straight pressure
9. hat no tools bolts or other obstruc tions are left in the die area slide flange or anywhere else on the press where they could fall and cause damage or an accident 16 Restore power to the press control and start the main drive motor and INCH the slide to the top of its stroke If separator blocks or other die storage components are used shut off the main drive motor and turn the mode selector switch to the OFF posi tion Wait for the flywheel to stop turning If you must place hands into the die area install safety blocks and perform established lockout tagout pro cedures Remove the die storage straps or separator blocks whichever are used and place them in a storage area After the die is cleared and ready for use remove the safety blocks if they were previously inserted 17 Adjust slide for the correct operating height and lock the adjustment Adjustments relating to depth of setting are vitally impor DO NOT SET THE SLIDE TOO LOW DAMAGE TO THE PRESS AND DIE AS WELL AS INJURY TO PERSONNEL COULD RESULT tant because the safety of the operator is involved as well as stress on the press and its tooling Cutting dies should be set so that the punch will enter the die opening only far enough to pierce the part Excessive punch penetra tion may result in scoring and high die repair cost On forming dies bottoming of the die members occurs when forming takes place and at that moment the press is working against a solid
10. ition If the die should require sharpening servicing or repairs make certain that it is routed to the die repair department immediately after removal from the press Discharge 8 all air pressure from the die cushion if used If wooden separator blocks or other type spacers are d to be inserted between the upper and lower parts of the die for storage purposes adjust the slide height upward at least 1 16 inch 1 58 mm more than the thickness of the separator block Install the separator blocks as required Remove the safety blocks and return them to the proper storage area INCH or BAR the slide down to the bottom of its stroke If the main drive motor was started turn it off and have the press mode selector locked to the off position Make certain the flywheel has stopped turning completely Install die storage straps or clamps if required The slide height may have to be adjusted slightly for this opera tion Unbolt the die making sure that all bolts and clamps 32 are removed Adjust the slide up to a height that will permit adequate space for removal of the die from the press Pull the die from the press and load it onto the die truck Make certain the die truck is chocked securely to prevent it from moving away as the die is being transferred Fasten die to the truck for safe transport Be very careful when moving the die move the die truck slowly and proceed over solid level floors only Route the die to
11. pins of equal length Never use pins that are bent mushroomed or otherwise deformed After inserting the pins recheck location and exposed pin length Plug all of the exposed pressure pin holes Lower the die cush ion to permit pins to drop below top surface of the bolster Remove safety blocks if they have been previously NEVER PRESSURIZE DIE CUSHION WITHOUT THE BOLSTER PLATE INSTALLED AND BOLTED DOWN SECURELY inserted in the slide area Turn on power to the press control and then INCH or BAR the slide to bottom dead center of its stroke If the drive motor was started in order to lower the slide turn it off and turn the press mode selector switch to the OFF posi tion Make certain the flywheel is not turning Now measure overall height of the die and height of the opening in the press Use the press micro shutheight indicator if one is furnished Adjust the slide to a posi tion that will allow adequate working space for loading the die into the press Install and use only dies that are safe Dies that are NEVER INSTALL WORN OR DAMAGED DIES INSTALL ONLY DIES THAT ARE IN GOOD CONDITION AND PROPERLY SIZED FOR THE PRESS TO BE USED worn or improperly sized can cause injuries to per sonnel and damage to the press Place the die in position for loading into the press Check top and bottom of the die for any slugs metal particles or dirt that may have adhered Make certain these areas are clean Load the die into the
12. shoe securely to the slide If standard nuts are used the bolt must be threaded fully through the nut Use a single washer under every bolt head or standard nut never stack washers Use only bolts that are in good condition Discharge all air pressure from the die cushion if one is used If storage straps are used between the upper and lower dies they should now be removed and secured in their proper place either on the die or away from the press All other die storage accessories bolts and other unused components should be marked for identification and placed in a storage area away from the press Bolt down or clamp the lower die shoe securely to the bolster If bolts are used they must be in good condition If a clamping arrangement is used the fulcrum block should be a single block which is the same height a the die shoe Do not use shims or stacked washers for this application however com Power Press SAFETY MANUAL mercial type adjustable height heel blocks designed for this purpose are acceptable The clamping bolt must always be located nearer the die shoe than to the fulcrum block Be sure to use enough clamps to keep the die in position 14 Adjust the counterbalance air pressure to properly counterbalance the weight of the slide and upper die For instructions on setting counterbalance air pres sure see the Counterbalance Data Plate located on the press or refer to the press service manual 15 Make certain t
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