User's Guide for Tooling
Contents
1. 7 3 m C gt amp o m C gt T m C gt CD IUTO SUID SAS SU B M Checking Button Dimension with Tolerance Gauge Joint quality strength is monitored by measurement of the button dimension BD Button dimension is controlled by adjust ing punch penetration As the shut height is adjusted down the button dimension increases Backing off the shut height will decrease the button dimension Checking BD with a caliper Button dimensions as specified by BTM Corporation are intended to give the optimum combination of joint strength and tool life Increasing BD to exceed the recommended figure will increase peel strength without measurable effect on shear strength but will reduce tool life Reducing BD to less than the recommended figure will prolong tool life at the cost of reduced peel strength again shear strength is not greatly affected as long as a lock is achieved The joint button allows easy visual inspection Broken improperly adjusted or misaligned tools produce visually distorted buttons Defective strippers and part n Tolerance Gauge nonconformity will also show up in visual Go No Go Gauge inspection Refer to Trouble Shooting pages 13 15 for specific information The tolerance gauge is a reliable and easy method of monitoring joint quality These tools are made with a maximum and minimum gauge to allow for button growth resulting from standard m2. 3 blade sections in assembly base with 1 _ _ bottom larger outside diameter of blade in counterbore ASSEMBLY BASE Place elastomer with groove facing down over 2 9 O z2 m small end of assembly pin Push down to G beginning of tapered portion of pin ASSEMBLY PIN Place assembly pin and elastomer on top of blade set with pilot diameter in assembly pin surrounding the blades Slide elastomer over blades and remove assembly pin Remove blade sub assembly from assembly base Place top of blade sub assembly into pilot diameter in assembly pin and lubricate elastomer ight oil Push blade sub assembly into tapered hole in assembly base until it reaches counterbore for die assembly Place counterbore at end of assembly base over me top of guard on die assembly Push assembly pin until the blade assembly snaps past guard and is retained in die assembly Repeat steps 1 8 as required Install assembly pin in assembly base as shown for storage when not in use Tog L Loc Trouble Shooting The symbol at left represents a properly formed TOG L LOC joint viewed from the button die side and in section BTM TOG L LOC tools can commonly das C produce in excess of 200 000 good joints Problems can however occur The illustrations below represent possible problem variations of the joint Problems causes and their corrective actions are given in the order in which they should be checked Prob
3. 940 the metal around the Stripper Assembly Stripper Assembly Stripper Assembly punch MAEN 5 The Tog L Loc Lance N Loc Die Tog L Loc dies are available in many styles to suit differing application requirements The dies have a fixed anvil which is recessed from movable or pivoting blades A radius 1s given to the blades inside edge Dies are retained by ball lock set screws or socket head cap screws The 940 Tog L Loc and Lance N Loc dies feature a one piece anvil and shield A spring is used to close the 940 blades Lance N Loc dies are also available in various styles however all are two bladed The blades have cutting edges to the inside with a fixed anvil recessed from the blade surface Blade shields are supplied with several die styles These shields protect the die blades from the force of the stripper and help to retain the blade assembly to the die In some cases dies are mounted in pockets within a block which functions as the shield 940 Lance N Loc Die Tog L Loc Preferred Preferred Tooling Die 3 blades and elastomeric ring kG The spherical retainer is positioned here in this pocket The retainer and screw hold the die in place BTM Spherical Retainer 940 Tog L Loc Tog L Loc 3 Bladed Dies Lance N Loc Special Dies Preferred Tooling Special Dies Joint Data BIM BTM sheet metal joining tools are furnished with joint data documentation expressed in the following terms 1
4. Gauging Nesting Correct Parts or Gauging Dz O CRS to Fit A An 3 Parts Interfere with Tooling Correct Parts or Gauging to C C Operation Allow Clearance Continued BIM Problem Trouble Shooting Corrective Action Ill Deformed or Distorted Joints A Cracks Appear on Button Q Joint Cup ness or Hardness l Tooling Incorrect For Metals Punch and die Not Concentric Weak or Broken Stripper Spring s C _ 1 Chipped Tool Lump or lt Irregularity on Button 9 D Concentric 1 Missing or Non Functional Stripper Double Button S 1 Metals Not of Specified Thickness or Hardness 2 BD Too Large Tooling Over Adjusted 3 Incorrect Tooling for Metals 4 Punch and Die Not Concentric 5 Excessive Deflection B Cracks Appear Inside 1 Metals Not of Specified Thick OQ 2 Double Hit E No Backflow of Button LJS 1 Round Top Squeezed See also Item B pg 8 F Partial Back 1 Flow of Button si G Dimpling and Unformed Button 2 FL 2 1 Broken or Weak Stripper Springs Die Blade Missing or Opened Before Joining Deflection in Force Frame or Tool Holder Die Blades Missing Elastomer or Die Spring Broken Blades Open Continued Probable Cause Use Specified Metals or Change to Appropriate Tooling Back Off Shut Height Adjustment Verify Joint Data Change Tooling if Necessary Realign Tooling Check
5. Measuring Button Dimension BD 2 Bladed 3 Bladed 2 Bladed Tog L Loc Die Tog L Loc Die Lance N Loc Die BD Maximum obtainable BD Minimum BD Minimum measurement in direction obtainable obtainable measurement of blades opening measurement in direction of blades opening BD BD Joint quality strength is monitored by measurement of the button dimension BD Button dimension is controlled by adjusting punch penetration Button dimensions specified by BTM are intended to give the optimum combination of joint strength and tool life BD specification includes a tolerance to accomodate standard mill tolerances in the metals OTHER PERTINENT INFORMATION INCLUDES THE FOLLOWING 1 BTM numbers of punch and die tooling for reference and re ordering 2 Metal type and thickness as specified by the customer as well as orientation i e punch side die side 3 Location of Tog L Loc tooling within machinery where applicable Joining Theory and Quality Control In order to function reliably a Tog L Loc or Lance N Loc system must conform to the following guidelines The parts to be joined must allow adequate access for the tooling and mate without gaps at the joint locations The metals to be joined must be sufficiently ductile within the thickness capabilities of the system and the parts must conform to the tolerances the machine was designed around The machine must consistently produce sufficient force to form the joints T
6. BIM s Tog L Loc and Lance N Loc Patented Sheet Metal Joining Systems Cross Section of a Cross Section of a Lance N Loc Joint Tog L Loc Joint Tog L Loc amp Lance N Loc are protected by patents in the U S A and most other industrialized nations Tog L Loc amp Lance N Loc are registered trademarks of BTM Corporation Marysville Michigan U S A Contents Joining Systems Description Page 2 Tog L Loc Basics Pages 3 4 Joint Data Pages 5 6 Joining Theory and Quality Control Page 7 Maintaining Joint Quality Page 7 Checking Button Dimension With A Tolerance Gauge Page 8 Maintenance amp Adjustment Page 9 Changing The Die Blades Pages 10 12 Troubleshooting Pages 13 15 Tooling Record Page 16 CORPORATION BTM Corporation 300 Davis Road Marysville Michigan 48040 U S A Phone 810 364 4567 Fax 810 364 6178 o CD p 9 p o F a gt zj p te Revised 042508 Joining Systems Description B
7. Joint Size Expressed as the punch tip diameter Tog L Loc or width of the die anvil Lance N Loc For example a 18 Tog L Loc has a punch tip diameter of 180 4 6mm Common sizes are 12 3 0mm 18 4 6mm and 25 6 4mm with special sizes used on occasion 2 PTR Punch Tip Radius Tog L Loc only Expressed as a decimal figure example 010 0 25mm This dimension is determined at BTM to suit the application 940 Style Tog L Loc 940 Style Lance N Loc Punch Punch Stripper Stripper A De PTR Joint pan A Size Joint ko C Button Dimension AD Anvil Pa E Die Elastomer Style Tog L Loc Special Style Lance N Loc Punch 7 3 m C gt amp o m C gt T m C gt CD Punch Stripper Stripper Joint Joint Joint Size gt lt lt BD Button Dimension IUTO AD Anvil Woof Depth SUID SAS SU Joint Data continued B M Joint Data Continued 3 BD Button Dimension Diameter or width of the formed joint Button BD is ex pressed as a decimal figure and given a tolerance Example 295 010 000 7 49mm 25mm 000mm This highly repeatable dimension is used for quality control and is directly linked to joint strength 4 AD Anvil Depth Depth from the top of the die blades to the top of the die anvil Expressed as a decimal figure Example 035 0 9mm This dimension is determined at BTM to suit the application
8. TM s Tog L Loc and Lance N Loc joining systems produce clean strong and consistent joints in most coated or uncoated metals The joints are characterized by a button formed on the die side layer of metal and a recess formed in the punch side layer The button is a good indicator of joint quality and therefore simplifies quality control Two or more layers of metal typically ranging in thickness from 008 0 2mm to 157 4 0mm per sheet can be reliably joined in most cases Tog L Loc Die Side Button Cross Section Punch Side Tog L Loc is a circular leakproof joint formed by drawing the metals into a circular cup and expanding the diameter to form a 360 lock below the bottom sheet Clamp Draw Tog L Loc is generally preferred due to its omnidirectional strength characteristics excellent fatigue properties and exceptional tool life Lance N Loc L FS Die Side ay Button Cross Section Punch Side Lance N Loc is a joint formed by lancing the metals on 2 sides drawing them through the thickness and expanding the width to form a lock on 2 sides Lance N Loc is commonly used where metals are insufficiently ductile to join with Tog L Loc or in certain dissimilar combinations or multiple layers Tog L Loc Basics A Tog L Loc Lance N Loc system consists of 5 major components 1 The Force Mechanism A device capable of producing sufficient force to form t
9. auging Nesting Adjust or Replace Gauging Nesting to Suit 7 7 3 m C gt amp 7 C gt T 4 C gt 5 exh p o p o tie MN A PN aN CD PN 6 Incorrect Equalization Adjust Equalization Stop of units on part Tooling Record This Tooling Record form is provided for your convenience Fill in the form with your data to have this important information readily accessible Tooling records are provided with your tooling from BTM Metal Type amp Thickness Job No Notes
10. department BTM corporation has extensive experience with Tog L Loc in production environments and will provide expert support A Caution Observe common safety practices when working with any press tooling equipment 7 7 3 m C gt amp 7 Co T 4 C gt 5 exh p o p o tie MN A PN aN CD PN B M Changing the Die Blades THREE BLADE TOG L LOC DIE ASSEMBLY 1 Place the three blades on the anvil surrounding the top 2 Slide the elastomeric ring over the top of the blades and into its groove Anvil Blade Elastomeric Ring Die Body Tog L Loc three blade die assembly with elastomeric ring TWO BLADE TOG L LOC DIE ASSEMBLY 1 Drive the roll pins out of the die body with a punch amp hammer 2 Remove the springs and die blades 3 Replace with new die blades and springs if necessary 4 Replace new roll pins in die body Roll Pin Roll Pin Tog L Loc two blade die assembly Tog L Loc two blade die assembly with with internal spring external springs Changing the Die Blades continued 940 TOG L LOC DIE ASSEMBLY Canted Coil Spring 1 Remove spring with a small screw driver or tool to pry the spring out 2 Discard old spring Springs cannot be reused Set new blades together in a circle on a flat surface 4 Place spring over new blades and into groove Spring should flow around the blades in a clockwise direction 5 Press spring a
11. for Damage Use Specified Metals or Change to appropriate Tooling Verify Joint Data Change Tooling if Necessary Realign Tooling Replace Spring s Replace Tool Replace or Repair Stripper Check Controls Operator Replace Springs Replace Blade if Missing or Check for Intererence Causing Blade to Open upon Part Loading Check for Damage Replace Blades Replace Elastomer or Spring Trouble Shooting Problem Probable Cause Corrective Action H Button Restricted 1 Blade is Not Opening Check for Interference Asymmetrically 2 Deflection is Check for Damage Binding Blades Check Blade Guarding Witnessing Scarring 1 If Heavy Stripper Spring Replace With Correct is Bottoming Insufficient Stripper N Spring Travel NQ p 2 If Light Dies are not Add Blade Shielding lt Protected Adequately J Button is Out of Round 1 Flexing of Force Frame Check For Damage SS C 2 Punch and Die are not Realign Tooling Concentric K Button Restricted 1 Metal is Thick for Joint Generally not Detrimental Symmetrically Size or Metal is Soft to Joint Strength a Problem Probable Cause Corrective Action IV Distortion of Parts A Parts are Distorted 1 Insufficient Stripper Force ari Stripper Springs During Joining eei 2 Stripper Tip too Small Replace with Large Diameter Tip 3 Die Not Protected Add Blade Shield F 4 Die Blades Below Shield Adjust Shield Height 5 Misg
12. he joint s Hydraulic pneumatic or mechanical presses are generally used 2 The Force Frame Forces must be contained to prohibit flexing at the punch die Deflection will cause degraded joint strength and tool breakage 3 The Tog L Loc Lance N Loc Punch Tog L Loc punches are available in various tip diameters see joint size page 5 lengths and styles to suit differing application requirements The perimeter of the round Tog L Loc punch tip has a slight radius to prevent piercing Lance N Loc punches are also available in various lengths and styles The square Lance N Loc punch tip has cutting edges on two sides and angular ramps on the other two Tog L Loc Basics continued on following page Tog L Loc 940 CS se BTM Ball Washer Tog L Loc Punches D P crew lt gt Lance N Loc Punches lt gt j l Ball Lock Standard Standard Ball Lock 7 3 m C gt amp o m C gt T m C gt CD IUTO SUID SAS SU Tog L Loc Basics Continued 4 The Stripper Both Tog L Loc and Lance N Loc L requireuseofaspring A ZQ D stripper clamping Mle mechanism which surrounds the punch lal j tip The stripper must preload the Ss Ss parts before punch a aw entry and must allow full punch travel The spring force must be sufficienttoclampthe parts together during joining and prohibit upward extrusion of Double Spring Preferred
13. he machine must contain the force without excessive flexing The stripper clamp must apply sufficient force to contain the flow of metal within the die The tooling must be appropriate to the metals being joined i e Tog L Loc or Lance N Loc joint size AD and PTR Tools purchased for one metal type and thickness may not give the best results with a different metal The tooling must be adjusted amp aligned to properly form the joints and be secured to maintain these settings The machine and tooling must be maintained properly so that all components perform their intended function For example worn seals can reduce force output thereby affecting joining ability Maintaining Joint Quality The Lance N Loc Punch must have sharp angled edges See page 3 of this document Lance N Loc die blades must be sharp to maintain consistent joint quality Correct anvil depth in Tog L Loc and Lance N Loc dies is required to obtain a superior joint The force unit should be in proper operating condition A unit in poor condition could influence joint quality Tooling must be free from dirt paint chips or sludge that may develop after long use Inspect tooling at weekly intervals to ensure punches and dies are clean Punch and die must be in proper alignment to form a good joint Inspect for weak compressed or broken stripper springs and replace as necessary BTM recommends changing springs every 100 000 cycles or when changing tooling
14. ill tolerance within the metals being joined Monitoring Joint Quality With a Tolerance Gauge Tog L Loc Lance N Loc Good Not Good Not Good Not Good Joint Acceptable Joint Acceptable Joint Acceptable Joint EDE Maintenance amp Adjustment Tog L Loc tools are manufactured to be interchangeable so that replacing a punch and or die will not require any shut height adjustment While periodic adjustment may be necessary a machine which begins to require frequent shut height adjustments is indicating a problem Refer to items 3 and 4 below for typical causes Machines should be properly maintained as problems with seals friction lubrication loose or broken parts cracks in the force frame etc can adversely affect the Tog L Loc Joints If a problem with the Tog L Loc joints arises use the following checklist before adjusting tools Tog L Loc tools are full hard Rockwell C 60 Range and will not usually require adjustment due to wear eCheck part metals for thickness and hardness eCheck for damage to punch and die eCheck condition of stripper springs Replace after 100 000 cycles eCheck operating pressure eCheck machine controls sequence and positive down cycle eCheck adjusting mechanism for loose parts eCheck for flexing yielding or damage within the force frame We support our customers and want to know of any problems you may encounter Should you encounter problems with Tog L Loc tooling call our service
15. lem Probable Cause Corrective Action Total Failure of Joint See also III Deformed or Distorted Joints A No Button Formed 1 Broken Punch or Die Replace Tool 2 Loss of Operating Pressure Restore Pressure 3 Insufficient Force Check Force B Button Partially 1 Metals Not of Specified Thickness Use Specified Metals or Formed Change to Appropriate Tooling No Sa cal 2 Die Elastomer or Die Spring Broken Replace Elastomer or Spring gt 3 Pressure Drop Restore Pressure 4 Incorrect Tooling for Metals Verify Joint Data Change C Tooling if Necessary 5 Incorrect Shut Height Adjust Shut Height for Cor See also Tool Adjustment rect BD Refer to Maintenance Item E Pg 9 Section pg 7 C Piercing or crack 1 Metals Not of Specified Thickness Use Specified Metals or ing of Punch Side Change to appropriate Tooling Sheet Metal i es 2 Incorrect Tooling for Metals Verify Joint Data Change Tooling if Necessary 3 Weak or Broken Stripper Springs Replace Spring s _ 5 4 Punch and Die Not Concentric Realign Tooling ll Intermittent Failure 7 7 3 m C gt amp 7 C gt T 4 C gt 5 exh p o p o tie MN A PN aN CD PN A Same Tooling 1 Insufficient Stripper Force to Com Correct Parts to Conform Produces Intermit pensate for Part Variation or Non Increase Stripper Force tently Good and Mating Parts Bad Parts 2 Parts Do Not Fit
16. nd blade assembly over diameter of anvil being careful not to damage or pinch spring 6 If spring 1s crimped bent or breaks during assembly replace with a new spring A damaged spring will produce poor joint quality U Blade Anvil Spring Guard Die Body 940 Die Springs Clockwise Direction 3 blade 940 Style Die 940 LANCE N LOC DIE ASSEMBLY Anvil Bidde Elastomeric Ring 7 3 m C gt amp o m C gt T m C gt CD Die Body Lance N Loc 2 blade die assembly IUTO 940 TOG L LOC DIE ASSEMBLY Elastomer To change the die blades in the 940 Elastomer Series dies special tools kit numbers listed below are required to effectively install the elastomer and blade assembly into the die It will be necessary to also replace the elastomer because it cannot be removed without damaging it Size Took Kit No Size Tool Kit No 3 0 940 ri1400y 65 940 741900N 3 0o 940M__ 102006 6 5 940M__ 747700K SUID SAS SU 3 8 940 793900 _ 6 4 940 711600N 46 940 711500 64 940mM _ 710500x 4 6 940m _ 710100U __ i _ 7 6 940 779600P Changing the Die Blades continued 940 Elastomer Blade Assembly Instructions 1 First remove the old elastomer by digging it out of the die with a pick or a small screwdriver 2 Discard old elastomer as it cannot be reused 3 Replace blades and install a new elastomer as detailed in the procedure outlined below Place
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