Vortool Manufacturing Ltd.: metal

Showing posts with label metal. Show all posts

Edge bending tool and die of laser cut parts

Edge bending tool and die for laser cut parts

Edge bending, or wiping die bending is achieved by holding the sheet between a pad and die than sliding the wiping flange across the face and bending the sheet metal which sticks out.

Low volume part production
Laser cut metal parts
Four edges of the laser cut part is bent in bending tool and die. Three of the part edges has a 90 degree angle. The forth edge has a different angle.

Bending tool and die

Footprint: 10" x 18"

Storage height: 7.2

Weight: 205 lbs

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Manufactured in Canada

Perforating metal stamping tool and die

Perforating tool and die punching 282 holes.

Made for two different coil widths: 7.5” and 8.75”

Progression: 6.0”

Closed height: ~8.350

During operation, the perforating tool and die should never contact with the limit stops. Set closed height (shut height) above limit stop by ~0.020 – 0.040.

Storage dimensions: 19.1" x 20.2" x 8.35"

Weight: 410 lbs

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Rotary bender forming tool

A three station rotary bender forming tool was designed and manufactured by Vortool Manufacturing. Made in Canada.

This form tool is the second tool for the part operation. The previously stamped aluminum flat bars are being bent here in three side by side stations.

The tool's foot print is 16" x 28". The nearly 33" long flat bar needs to be bent into a kind of "U" shape, so the tool require enough inner space for the part to fit once bent. The overall height of the tool is 32 inches. The tool is designed to operate in a 50 ton hydraulic "H" frame press.

The first station in this tool is to process the shorter part that was made with the previous tool. The required shape was being done in a single stroke.

The longer part needed two stations. In the middle station the two ends of the aluminum flat bar was bent at 3 places. The third station was designed and built to bend the parts to a "U" shape with 18 degrees over bend.

Standard wipe form style tooling could bend only up to 90 degrees or rather less as most material has some degree of spring back. This rotary bender employed a custom designed and built pair of rotary benders, allowing a great amount of over bend.

The tool has 6 lifter springs on top to automatically open the tool after each stroke. Most "H" frame presses use a bottle jack style hydraulic cylinder, so it can push things downward but can't pull. The auxiliary springs overcome this problem and lift the tool to open position by default.

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Multiple set punch metal stamping die

Multiple set punch metal stamping die

Save money with a multi set up metal stamping die.

It can punch different set of holes in two different lengths of metal.

This metal stamping die was designed and manufactured by Vortool Manufacturing.

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Metal stamping of U clips

Metal stamping of U clips by Vortool Manufacturing

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Metal stamping tool and die design considerations

When designing metal stamping dies a tool and die maker or tool and die designer must have the following information prior to start. There are several types of tools that could be built for the same part. They have special purposes to best suit both parts and metal stamping production.

The cost of the tool and die to be produced may be greatly affected by the following considerations:

Estimated number of metal stamped parts the tool and die should produce monthly, yearly, or in total

Eg. if the customer needs 2000 parts in total and possibly never again, then it is not wise to build a tool designed for high volume metal stamping and productivity. Make something simple and inexpensive, yet produce the correct metal stamped parts.

If the amount of 2000 is for a day or for a week and possibly for many years to come, then you must build a tool that lasts, very efficient and easy to use or has the capability for automation. The customer may have a request for manual, semi-automated or fully automated part production.

The quality of the metal stamping part

Some production parts may require absolute burr-free edges without a second operation to remove the burrs. Some metal stamping production parts require straight edges all the way. Other stamped parts have such tight specifications that special tools need to be built for that request.

Punch press

The metal stamping die must physically fit the punch press it is intended for, so you need the punch press specifications that may limit how you build the tool.

The metal stamping part itself

Some metal stamped parts are best suited for a certain type of tool and die design for the best result. Don’t try to build something else, if you are not sure of the outcome. To decide what type is the best for that part, take a look at the sample designs, made for the same part. Vortool Manufacturing will discuss each version’s strong points that can help you to make a decision about which to choose.

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Progressive die - two progression blanking tool design

Precision progressive die - two progression blanking tool design

Metal stamping tools are essential for producing components in a cost effective way. In order to reduce the cost per unit, parts must be made faster, more accurately and reliably. This actual project was focused on a criteria that was essential to the design and the building of this tool. This information helps to choose the type and number of features to design as well as selecting tooling components and the right materials to be used etc. As a result, the tool will have all the necessary functions, nothing less and nothing more that will keep the budget under control.

The design was based on a low to medium production amount of 8,000 - 32,000 parts to be stamped per month. The plan was to cut the parts from CRS (Cold Rolled Steel) strips that were sheared from sheets. The material type, the operation method and the required monthly usage gave the basic guidelines. Not only that but what features the tool should have and to meet or exceed the minimum requirements. Other factors were also taken into considerations such as easy operation, and eliminate operator error that could be costly if the tool was damaged from improper use. To further reduce the cost of the unit price of the stamped parts, the customer requested that they would build the tool in house at their facility. It is a great way and a proven method that Vortool Manufacturing has developed over the years to help customers with their projects.

A special package was created with super detailed shop drawings, a Bill of Material and special illustrated instruction pages how to build the components properly and then the best way to operate the tool once in production. As an addition there were instructions about punch press preparations and set up information that ensures trouble free production time after time.

Based on European precision and decades of experience, any tool design produced by Vortool Manufacturing is the most comprehensive design method that any company could ask for. The tool will fit the press or presses with no surprises.

We always have a press mock up made with the essential dimensions, shut height stroke and adjustment information, mounting, etc. to ensure that the tool will fit the first time and will operate within the specifications of the press regardless of its type and origin. With the help of the great features of possibly the best CAD software SolidWorks, the 3D models are always put in motion to simulate the movement of the press and the tool. A number of design verifications ensure that the tool is put to the test before it was even built, regardless of the complexity. It is either a simple two step progressive tool like this one or a sophisticated sixteen progression tool. The result is the same. You expect it to run trouble free. This is why you should choose Vortool Manufacturing.

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Corner skin form tool for low volume metal stamping production

Corner skin form tool and design

Low volume products such as this "Corner Skin" require cost effective tooling to keep the budget under control yet keep the quality high to be competitive on the market.

The flat parts also known as flat blanks were laser cut and then inserted into the single station two post die set to form the edge of the specified angle and dimension.

Low Production Metal Stamping

The tool consists of a form punch, a form die and a heavy spring loaded pressure plate to ensure that the part remains flat where needed. This should allow the part to be pressed against the form cavity by the upper punch.

As a result the outer rounded edge of the part formed upward in an angle, that became a perfectly smooth geometric shape for this flange.

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Modular press using multiple punch stations

The modular press using multiple punch station product line by Vortool Manufacturing Ltd. contain a number of individual (portable) presses that are linked together and activated as one.

• For generic or budget oriented projects C frame presses are the most suitable.

• Other models may be used as well as custom solutions that are designed for the specific need of the process.

• Modular presses are excellent to process aluminum extrusions with great lengths and multiple holes, slots, etc. to be punched at once at the full length of the extrusion.

• The process time is minimal, compared to conventional methods where individual holes had to be drilled or punched one at a time. The quality is more predictable and repeatable.

• Multi axis power unit mounts are available to work horizontally or in an angle within the same machine.

• Drilling units can be also used to work along with the cylinders.

• Extrusion positioning and clamping can be automated. The function can be monitored by a PLC to ensure trouble free operation and keep the required quality under control.

• Safety devices may be installed, depending of your company or government requirements.

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Ball bearing guided high precision progressive metal stamping tool and die for high speed automated production

The picture shows the bottom die set and

some of its components are being inspected,

aligned and assembled.

Ball bearing guided high precision progressive tool for high speed automated production

Stamped metal parts usually require more than one operation in one. This progressive metal stamping tool produces a high volume mounting bracket that pierces holes, blanks out a shape by cutting the strip into separate parts and finally folds the part into an L shape. At each hit a final product falls off at the end of the tool. It is made for a high production automated punch press using coil and an air feeder for continuous operation.

This progressive die design consists all the necessary features that any stamping tool should have from ease of use through high accuracy to reliable operation for a long time. It includes strip feed and guide, stripping, slug separation, and feeder actuation. As an option the tool can be used as a manually operated tool without the air feeder using strips instead of coil.

The cutting components are designed to be made of hardened tool steel that ensures the long usability. Choosing the right alloy for the application and the proper design of the tool can greatly effect the life of the tool. As a result it can operate trouble free for longer, saving on maintenance. It can also reduce or eliminate downtime and minimize costs that are associated with the value of the final product.
The progressive tooling was designed using SolidWorks 3D CAD. Shop drawings, and files generated from the models are seamlessly fit into any machine shop or tool room's profile.

Vortool Manufacturing Ltd.

Unit 240 19358-96 Ave.

Surrey, BC V4N 4C1 Canada

Call: 604-239-7218 | Email

Made in Canada

Design considerations for stamping tools and dies

Design considerations for metal stamping tools and dies

Metal stamping die design considerations or decisions are driven by a number of factors in tool and die design.

However there are a few mayor points that should not be missed and must be included in the decision making process. You could design and build an inexpensive fabricated tool or you could make one that is a top of the line master piece.

How do You Decide Which One to Make?

Your customer will tell you what they need, what material the stamped parts are, how many parts should be stamped, when they want the finished parts, and how much they are willing to pay and so on.
These are important guide lines toward the metal stamping die design. They tell you what you can do and what you can’t. They set some boundaries.

The part itself is one of the major contributors that guide you through what the minimum requirements are toward the tool. It will help you with what you need in order to produce the particular part.
You may raise questions that need to be answered. How efficiently will the parts be produced? How long will the tool last? How user friendly should the tool be? What are the variables that can be implement in the design?

The Above General Guide Lines Should be Specified More in Detail

How many parts will be produced per run, monthly or in the lifetime of the tool? If the amount of production is low, you will know that the tool will likely be manually operated and be budget oriented. If e.g. 5,000 parts are to be made every week for the next two years, than you know it is a high demand tool and automation and continuous operation is required. The tool must be designed accordingly. More time and money can be spent to make the suitable tooling.
Low production rate equals inexpensive tooling components, unsophisticated guides, supports, etc.
On the other hand if the metal stamping tool is running all the time, then you will need to build a tool that lasts. It will require less frequent tool and die maintenance, and be built for high speed automation. The tool steel should be higher quality, and more suitable for extended use. In this case instead of using e.g. A2 or D2 material, consider using M2 with coated surfaces or Vanadis 4 Extra or comparable. For the extra cost, these tool steel will last many times longer before sharpening is required. Use a ball bearing guide system, instead of standard bronze plated bushings and standard die pins. The ball guided system is better for high speed punch presses and high speed stamping.
Pressure plates require springs behind them to generate enough force. Consider using gas springs. They are generally suitable for high speed stamping, and about 250 spm and rated about 1 million strokes before servicing. They are also more powerful than conventional die springs with the same footprint. You can use punches with ejector pins in them to push off slugs that are serious obstacles in automated stampings. You can also use die buttons with slug control that keep the slugs in the die button, preventing slug pulling. Slugs pulled back onto the die surface area can jam the strip and cause the feeder to buckle the coil. If this happens, your tooling may be at risk for serious damage.
Bending is generally done using a wipe form method. The parts eventually gull and have heavy marks. The form sections constantly require polishing, causing downtime and quality issues. Ready benders can eliminate most of these problems, where the bends have simple straight features. This method completely eliminates parts sticking into the form die, as they require less pressure and will not mark the part as much or just simply eliminate it altogether. It is a perfect solution for pre-painted strips to stamp.
Stock pushers are designed for automated stamping and have a superior feature that make their use a preferred choice.
At upstroke of the press, they release the force applied to the edge of the strip or coil entirely, allowing a resistance free strip advancement. The applied pressure is adjustable, and you can design the engagement timing as you need it. The pilot punches can locate the strip perfectly before you lock its position for the duration of the cut.
Another contributor to your metal stamping tooling design is to know what press or presses will be used for stamping. Your tool must be compatible and fit the desired press or presses. You may want to consider making 3D models of the presses with the vital features that are necessary for your tool design.
The general requirement toward any stamping tool and for their design is that it should cost as little as possible, yet produce the most amount of parts at the best quality, should not break down, and will last longer than the anticipated life span of the tool. This perfect scenario should be achieved at all times. Compromises sometimes must be made and accepted, but not be part of your design.
The guide lines or restrictions that are set by your client, your tool and die manufacturing facility or your ability, will have an impact of the outcome of your design and ultimately of the stamping tools and the produced parts.