3 Forming Tool Concepts Pvp

1. INCREASE EFFICIENCY AND
EXPAND YOUR OPERATIONS
WITH FORMING
MATE SOLUTIONS
TRAINING

2. AGENDA
•Why use forming?
•Forming basics
•Ways to use forming in your operation
•Summary

3. WHY USE FORMING?
•Increase efficiency
•Expand your capabilities
•Eliminate of secondary operations
•Increase machine time
•Reduce tool wear

4. •Secondary processing of machined countersinks is non
value-added time
•Make them on the turrets, forming up or down, as
required
EXAMPLE: ADDED COST AND
PROCESSING TIME

5. •The ribs in this pane were nibbled, increasing machine
time and tool wear
•Use a forming tool on the turret is a much better way
EXAMPLE: INCREASED TIME AND TOOL
WEAR

6. FORMING VS. PUNCHING
•Punching
–Makes a hole
–Requires stripping
–Stroke may not be critical
–High speed
•Forming
–Changes work from 2D to 3D
–Stroke length critical to achieve
correct results
–Lower ram speed
–Station ranges are usually
reduced

7. 7
Definitions
Special Assembly-
•Any tool that transforms the material to 3D
•Any tool that requires multiple holes in a single hit.
•Any tool that requires multiple forms in a single hit.
•Any tool that punches a non-standard shape or size hole.

8. FORMING BASICS
MATE SOLUTIONS
TRAINING

9. WHAT LIMITS FORM
HEIGHT?
•Machine Limitations
–Maximum forming height is about 6.0mm
–Calculation:
Maximum Form Height = (Turret gap/2) – Material Thickness – 1.0mm safety
–Forming should always be done last
•Not necessary with machines with forming cylinder
–Adjacent stations to the forming tool should not be used
•Sheet marking, bending, risk of tool breakage could occur
•Material Limitations
–Emboss stretches material
–Some forms bend material like lance and form
–Material ductility
–Form geometry

10. MATERIAL TERMINOLOGY
•Ductility
–Ability to be elongated in one dimension while becoming
thin in another dimension
•Elastic Limit
–Point at which material will not return to original shape
•Plastic Deformation
–Stretching metal enough to exceed its elastic limit and
stopping prior to fracture
•Spring back
–Amount which material tries to return to its original
shape after forming

11. MACHINE CONSIDERATIONS
FOR CORRECT SETUP
•Shut Height:
–Measurement from ram bottom dead center to top
of new die
•Amada 205 mm
•Finn Power 203 mm
•Murata Wiedemann (Variable by Model)
•Ram Operation
–Mechanical
–Hydraulic
–Electro Mechanical
–Ram stroke control

12. = Forming Tool
= Adjacent stations
without tooling
20 Station Turret
STANDARD PUNCH PRESS
TYPICAL TURRET LAYOUT

13. FORMING IN A TURRET
PUNCH PRESS
•Because the forming die is higher than a standard die, the forming die
must protrude above the material pass line on the conventional turret
•When the sheet is moved or the surrounding stations are used, then the
forming tool may mark or scratch the sheet
CONVENTIONAL TURRET

14. CONVENTIONAL STATION
VS.
UPFORMING STATION
This lance and form could
never be achieved in a
conventional machine.
Machine with forming station
makes it possible!
Forming die operated
by forming cylinder
Die Line

15. 15
Standard vs.
Upforming
•Standard
–Shorter form height
capabilities due to
forming die height
–Form can be up or
down.
•Upforming
–Higher form height
capabilities: Use the entire
feedgap
–Conventional forming dies
sit at or below die line
–Special forming
dies(Amada P&F)
–Form can be up or down.

16. DISADVANTAGES WITH CONVENTIONAL FORMING IN TURRET PUNCH
PRESSES
Conventional Turret Finn-Power Upforming System
B D B D
Example: 3mm material, 8mm forming
Example: 3mm material, 12mm forming
To perform any forming operation on a
conventional turret:
•Forming die must be higher than a regular die
•If a formed part’s height is more than ~12mm
(including material thickness), it will crash into the
upper turret when it goes over the forming die
•A higher die also scratches the lower side of the
sheet and may cause problems during sheet
movement
NOTE: These conditions limit the forming height in a
conventional turret solution to a maximum 5.9mm
Finn-Power upforming system:
•Allows formed heights equal to the
feed clearance between turret plates
•Eliminates scratches and other
problems

17. 17
Finn-Power
Upforming
•Optional in Series 10 and newer Finn-Power F, SG and LP
model
•Consists of an upper and lower hydraulic cylinder
(250 kN, e-machines only 200 kN)
•Forms as high as .590"(15mm) (higher with foot tool)
•Lower ram travel .472"(12mm) max
•Form tools manufactured for conventional stations will
produce forms in the upforming station without any
modifications, shims or spacers.
•To achieve maximum form heights, the die assemblies
must be manufactured to these forming requirements.
•These tools should not be used in conventional stations.
•Travel is limited by a mechanical stop at the bottom of the
stroke.
•Forming is typically done at mechanical bottom.

18. •Forms up to 13.0mm high.
•No contact with sheet by
forming tool
•Form stroke controlled
within 0.001mm
FINN-POWER UPWARD
ACTING FORMING
STATION

19. 19
Amada P&F
Only for EM machines with Z-turret

20. 20
Amada P&F
Amada P&F

21. 21
‘Retractable’ Forming
Station
Wiedemann and Euromac
Forming Station
•Forming bar slides to
activate forming
•The sheet is lifted since the
lower activates first.
•Max form height same as
standard
•Eurom ac = 6m m travel
•Wiedem ann = …

22. 22
Calculating Maximum
Form Height?
•Conventional Machines: (typical form 3mm above die line)
–Standard maximum form height is about 6.0mm
–Standard maximum form height is calculated:
TURRET GAP /2 - material thickness - (safety) 1mm = MAX
FORM HEIGHT
•Upforming Machines: (typical form at or below die line)
–Upform maximum form height is about 14.0mm (dependent upon
material thickness and gap between upper and lower turret, and
machine type)
–Upform maximum forming height is calculated:
(TURRET GAP + UPFORM STROKE) /2 - material thickness
– (safety) 1mm = MAX FORM HEIGHT

23. MINIMUM SPACING
BETWEEN FORMS
Minimum = 3 x material thickness to sheet edge or form on sheet
Minimum = 6 x material thickness to like forms
3 x T
Minimum
Material
Thickness (T)
6 x T
Minimum
3 x T + R
Minimum
Radius
(R)
Radius
= 1/2 x T

24. SPRING LOADED VS. NON-
SPRING LOADED
Non-Spring Loaded
Die
Line
Spring Loaded
Die
Line

25. ULTRAFORM™ LENGTH
ADJUSTMENT
Adjustments up or
down in easy
steps of 0.05mm

26. 26
ULTRAFORM FX AND XT
•Ultraform FX and XT
–Objectives:
•Incorporate interchangeability of
Ultraform without all the features
•Improve price positioning over
Ultraform
•Reduce holder complexity to
leverage new press technology

27. 27
Ultraform XT
•Low Cost
•Adjustable Length
•For bottom stroke
machines
•B-E Station
•Same inserts as Ultraform
today
•OAL= 203 – Material (FP)
•OAL= 205 – Material (Others)

28. 28
Ultraform FX
•Low Cost
•Fixed Length
•B-E Stations
•For Precision controlled
Ram Machines
•Same inserts as
Ultraform today
•OAL=208mm !! (longer
than normal)

29. AIR/LUBRICATION
DELIVERY
Air/lubrication mist
enters here
Upper shedder
Upper Insert
AFKB2
(Ultraform Upper)
Vent to Outside
Escaping Air/
Lubrication
Lower Insert
Stripper Plate
Die
Note:
* Not avbailable for
UltraForm XT
* Option on
UltraForm FX

30. 30
Forming Tool Recommendations
•Always form as far from the clamps as possible.
•Forming should be the last process on the sheet whenever
possible.
•Additional Dwell Time may be necessary to allow tools to strip
properly (Programming command)
•Forming tools should be run at a slower punching speed to
allow material to flow/form.
•Stations next to the forming tool should not be used. It is
recommended to have a die in the die holder in these stations.
Roller or brush dies are recommended for both sides of a
forming station.
•Lubricate the sheet and use machines lube system if available.

31. 31
Forming Tool Recommendations
•Periodically remove the tool from the turret and check the
sharpness of any cutting edges.
•Form down operations should be avoided because formed
material can drop into dies, get caught and pull the work piece
out of the work holders, or distort the form. If a form down
operation is the only solution for a particular part, make it the
last operation on the sheet.
•Machine stroke lengths are different from machine to
machine.
•A tool that works in one machine may not work in another.
•Set up using the tools minimum length and adjust in 0.15mm
steps to achieve a sharp form where the tool is properly
bottomed. Keep a setup record sheet for all special tools to
minimize setup time for each subsequent use of that tool.

32. SOME FORMING
TOOLS IN DETAIL
MATE SOLUTIONS
TRAINING

33. 33
Most Common
Special Assemblies
•Top 10 Special
Assemblies
explained in detail.
Rank Description
% of SA
Items
Sold
1 Clusters 43.9%
2 Extrusion: Round 8.9%
3 Undefined 8.5%
4 Lance and Form 5.4%
5 Knockout 4.2%
6 Countersink 3.6%
7 Emboss 3.3%
8 Louver 3.0%
9 Engrave Stencil Down 1.6%
10 ShearButton 1.3%
11 EasySnap 0.7%
84.3%

34. 34
•USE: To produce m ultiple holes with m inim al hits.
Ideal to guarantee center-to-center tolerances.
•TYPICAL APPLICATION:
–Material thickness from 0.020(0.50) to 0.1 57(4.00).
–Other constraints dependent upon station size,
punch size and shape, press tonnage capacity,
distance between the border of the holes (web).
•For greater hole uniform ity and flatter sheets, spread the
punches to avoid punching adjacent holes in the sam e
hit.
•Com plete the desired pattern with the technique known
as bridge hitting.
•Do not re-punch through previously punched holes to
com plete a pattern, single hit tool m ay be necessary.
Clusters
2 to 100+ holes round or shaped
Limited to press tonnage and station parameters

35. 35
•TYPICAL APPLICATION:
–Material thickness from 0.020(0.50) to 0.1 57(4.00).
–Other constraints dependent upon station size,
punch size and shape, press tonnage capacity,
distance between the border of the holes (web).
Clusters
2 to 100+ holes round or shaped –
Limited to press tonnage and station
parameters

36. ULTRA AND ORIGINAL STYLE THICK
TURRET CLUSTERS: GUIDED & NON-
GUIDED WITH INSERTS
Minimum/Maximum
•0.5mm minimum,
4.0mm maximum
thickness
•Other restraints
dependent upon
station size, punch
size and shape and
machine tonnage
Punch head must be within pattern
øS = cluster punch retainer

37. 37
CLUSTERS
Replaceable Inserts
Fully Guided
Replaceable Inserts
Non-Guided
(shape cluster)
Note: Round cluster uses
backing disc, shape cluster
uses punch screws.
Solid Standard
or Solid Fully Guided
Cluster
punch
burned from
solid blank
BENEFITS OF FULLY GUIDED
•Guiding at punch point
•Increases hole accuracy
•Improves stripping
•Point Size closer to material thickness

38. 38
Insert Style
Clusters: Solid or
Insert
Features Solid Insert
Fully Guided Available Yes Yes
Initial Cost Lower Higher
Replacement Costs HigherLower
Punch Point Spacing CloserFarther
Pattern Size LargerSmaller
Punch Point Size Recommended LargerSmaller
Sharpening EasierHarder
Solid Style

39. Cluster Pitch Rounds
•The minimum cluster pitch is determined by the die
in most cases
•Minimum is 3.0mm STEEL between holes in the die.
Example; 5.0mm hole in 1.0 mild steel with die
clearance of 0.2mm will have a center to center
spacing of 8.2mm
•Cluster pitch with many holes is determined on a
case by case basis based upon spacing and
material thickness.
•In most cases double spacing recommended as this
produces a stronger die and less sheet distortion.
39

40. Cluster Pitch Shapes
•12.0mm is the minimum pitch between punch points on a
shape cluster. This limit is imposed by the upper assembly
screws used to hold the inserts in place.
•For some special applications the pitch spacing can be
reduced to 10.0mm but will require a full Mate engineering
review based upon complete cluster pattern and material
being processed.
40

41. 41
Clusters: Tips
for Success
Tips for Success: (addressed in upcoming slides)
2.Slug Pulling
3.Sheet Flatness
4.Tonnage or Noise
5.Tool Life
6.Tool Maintenance
7.Press Maintenance

42. 42
Clusters: Slug
Pulling
1.Sharpen tools
2.Correct die clearance
3.Proper die penetration
4.Accurate station alignment-
•Furthest punch point distance from
center is multiplied.

43. 43
Cluster
s:
Sheet
Flatnes
s
1.Bridge Hitting improves
part flatness.
2.Sharpen Tools
3.Proper die clearance
4.Move in one direction
each sequence
5.Increase Station Size
or Stripping force

44. 44
•Start punching pattern away from
clamps and work toward clamps
Clamps

45. 45
Shorten half of the cluster
punches by 50 – 60% of the
sheet thickness in order to
reduce noise, vibrations and
required punch tonnage.
Example:
16 punch cluster of 10mm square punches
Perforating in 1mm mild steel
Insert Punch length 37mm
Shorten 8 Punches to length 36,5mm ( Balanced
Shortening)
Clusters: Tonnage
or Noise
For safety, plan on all inserts
hitting at the same time for
tonnage. Do not exceed 75%
press tonnage.
Lowers the force on a die and
could extend die life
Increases slug pulling,
decreases insert grind life.

46. 46
CALCULATING CLUSTER
TONNAGE
PUNCHING FORCE FORMULA = linear length of cut x material thickness x shear strength = punching
force in kilonewtons (kN). PUNCHING FORCE SHOULD NOT EXCEED 75% PRESS CAPACITY.
EXAMPLE: Grid of .250(6.35) diameter holes. Area of punch covers 48 holes; punch every 4th
hole (12 holes). Mild steel .060 (1.52) thick. (Linear length of cut = 3.14 x diameter x number of
punches).
Spring pressure of the spring-loaded cluster assembly runs under a ton (9 kN) and can be
ignored in calculations for machine capacity.
SHEAR STRENGTH IN US tons/in
2
(kN/mm
2
):
Aluminum 5052 H32 = 15.0(0.2068) Brass = 17.5(0.2413)
Mild Steel = 25.0(0.3447) Stainless 304 = 50.0(0.6894)
Clusters: Tonnage

47. 47
Clusters: Tool Life
•More tolerances with insert style. Try Fully Guided
•Machine alignment critical
•Turret bore wear
•Guide wear
•Sharpen Tools
•Consider punch stagger if tonnage is high or die failure.
•No Double Hitting
DO NOT DOUBLE HIT HOLES. Because
of tolerances built into the punch press,
using the cluster punch to finish missed
holes in patterns will cause punches to
shave sides of previously punched holes.
The great lateral thrust from this shaving
shortens punch life. Use a single -hole
punch to complete the pattern.

48. 4848
Using cluster tools reduces
the number of hits…and
machine and tool wear
Cluster tooling will produce
patterns with just 172 hits vs.
current 2,064 hits
Clusters: Tool Life

49. 49
Clusters: Tool
Maintenance
•Sharpen before the tool requires it
•Lubricate guide assembly
•Remove galling from points in
direction of punching. Find root
cause and eliminate!
Sheet lube, maxima, alignment, clearance, guide,
bore wear, double hitting,

50. 50
Clusters: Press
Maintenance
•Station Alignment
•Good condition bore. Select the best
one you have.
•Turret bore key in good condition
•Work Holder Condition
•Die holder and shim condition.

51. 51
Alignmen
t
0.1 degree is too much

52. 52
Clusters: Review
•Several Types of Tools:
–Fully Guided 1 PC & Inserts, Standard 1 PC & Inserts
•Tips for Success:
–Slug Pulling: Sharpen Tools, Proper Die Penetration, Alignment
–Sheet Flatness: Bridge Hit, Move in 1 direction, Spring Force
–Tonnage or Noise Limits: Stagger punch points
–Tool Life: Use FG, Sharpen Tools, Align Station, No double
hitting.
–Tool Maintenance: Sharpen Often, Lubricate, Eliminate Galling
–Press Maintenance: Bores, Alignment, Workholders, Bore Keys

53. Piercing and
Forming Clusters

54. Piercing and Forming
Clusters

55. 55
Extrusion
•USE: Threading for screws and increased
bearing area for tubes, etc.
•TYPICAL SCREW APPLICATION:
–Material thickness from 0.031(0.80) to
0.106(2.70).
–Overall Height 2x to 2.5x material
thickness.
–Diameter 0.374 (9.50) (M-10)
50mm diameter
•Maximum diameter can
be increased by using an
alternative design.

56. Extrusion - Tapping
•Buy additional inverted dies to accommodate
different material thicknesses.
•Maximum diameter can be increased
by using an alternative design.
•Pre-pierce determines height.

57. Extrusion - Tapping
•Lubrication:
- Ultra-Form can provide lubrication.
- Lube the sheet (bottom if forming up).
• Problems:
- Galling : use optional Maxima coating
- Stripping : use PowerMax design
- Smaller size die inserts can break :
order spares

58. 58
Extrusion

59. Most Common
(95%)
59
Extrusions: Different
Styles
One of 4 lower assemblies is used based upon the applicationMore
Common
Less
Common
•Standard design
•Max diam eter
9.5m m
•D isc springs =
Strong
•Replaceable
insert
•ID is 9.5-1 5m m
•D isc springs =
Strong
•Replaceable
inserts
•ID up to 25mm
•For low form
extrusions due to
shoulder
•Coil springs =
weaker
•Solid lower, no
replaceable insert
•ID up to 16mm
•Coil springs =
weaker
•Replaceable insert
•Most applications
that can fit the
maximum diameter
have stripper
requirements that
requires a C station.

60. 60
Extrusion
General Limitations:
–Overall Height 1.5x to 2.5x material thickness. Beyond
2.5 the material will likely fracture
–Effective Range=Extrusion Height – thickness – radius
•Largest Range under 1.5 x thickness
–Consider “PUNCH and SHAVE” vs Extrude!
Extrusion Height
1.5 – 2.5 x thickness
Radius
.015” (0.4mm)
Effective
Range

61. 61
Extrude, OR …
Punch and Shave
Finished hole size is the starting point.
Punch #1 = finished hole size – clearance (20%)
Die #1 = finished hole size + 0.1 mm
Punch #2 = finished hole size (full mat’l contact : Maxima !)
Die #2 = die #1
.

62. 62
Extrusion: Extrude or
Punch
•When is a tapping extrusion not the best choice for
achieving the highest number of tapped threads and
punching and shaving is a better option?
–Small diameter extrusions in thicker material would require an
extremely small pre-pierce diameter to achieve a significant
form height.
–Using a pre-pierce that is appropriate for the material thickness
may not leave enough material to achieve a significant form
height.
–For this reason, the largest number of useable threads may be
available from punching and shaving the hole. This is more
likely when the material thickness exceeds .078” (2,00mm) and
the extrusion ID is less than .315” (8,00mm).

63. 63
Extrusion: Tips for
Success
Tips for Success
2.Use Pre-Pierce Calculator
3.Sharpen tools for pre-pierce hole (to avoid inside burr)
4.Form Height no more than 2.5 X Thickness
5.Tonnage= Slightly more than punching same size hole
6.Material thickness not practical to exceed 2.7mm
7.Buy additional inverted dies (Upper Insert) to accommodate
different material thicknesses.
8.Pre-pierce controls form height.
9.Lubrication:
- Ultra-Form can provide lubrication.
- Lube the sheet (bottom if forming up).
10.Galling : Consider Maxima coating
11.Smaller size die inserts can break : order spares
12.Stripping Problems: Consider PowerMax design, larger station
size, or down forming

64. 64
Lance & Form
•USE: For air flow, decoration, card guides, location
markers, shear tabs, wire harnesses or clip attachments.
•TYPICAL APPLICATION:
–Material thickness from 0.020(0.50) thick to
0.118(3.00).
–Maximum recommended top-to-top height is
0.250(6.50).
–Other limitations include material type, thickness,
station size and press tonnage capacity.
•The inclusion of a 5° draft angle is recommended to
assure reliable operation.
Ultraform B
Upper Insert

65. 65
Lance and Form
The ‘form’ part of the
operation takes place as the
work piece is squeezed
between the lower unit and
an inverted die in the upper
unit.
The ‘lance’ is normally
performed by the lower unit
using an inverted punch.

66. 66
Lance and Form Design
Considerations
•Draft Angle: An important consideration for
trouble free production.
•Made for a single material thickness,
sometimes lighter material can be used.
TOP VIEW:
Without Draft angle...
DRAFT ANGLE
5º Minimum
TOP VIEW:
With draft angle, showing effect
as front edge of tab moves
back in die...
SIDE VIEW:
Front edge of tab moves back
in die as it is formed.

67. 67
Lance and Form: Design
Considerations
SHEET METAL
PARAMETERS
Maximum
Height
.250(6.4mm)
R = .060(1.5mm)
Minimum
85º Maximum
Maximum
Thickness
.120(3.0mm)
OPEN END
85º Maximum
45º Maximum
OPEN END
CLOSED SHAPE
Lower tool
travel is what
typically limits
the form
height.
Spring Back
Thicker materials
may break before
completing form
and cause too
much abuse on
lower insert.
Angle is
typical, may
be increased
if form height
decreased.

68. 68
Lance & Form
Snaplock™
•Self-locking spring loaded tab
- fits into hole
•Eliminates spot welding, riveting
or fastening with threaded
hardware

69. 69
Lance & Form
Snaplock™

70. 70
Lance & Form
Snaplock™

71. 71
Triple Lance & Form
HexLock™
Positive retention
Common size bolts
Robust easy to use tooling

72. 72
Lance and Form:
Tips for Success
Tips for Success:
•Use forming lubricant on the sheet
•Replace the cutting components when they become dull
•Confirm the tool was designed for the material type and
thickness being formed
•Increasing the form radii
•Decrease the form height
•Sometimes requires pre-piercing around form, then
using an emboss.
•Use a more ductile material for forms with sharp angles
or curves
•Form up whenever possible
•Avoid plastic coatings if possible
Avoid forms sticking, creating a
burr, or becoming
damaged in processing

73. 73
Knockout
•USE: Allows optional pathway for electrical cable.
•TYPICAL APPLICATION:
–Material thickness from 0.024(0.60) to 0.118(3.00).
–Maximum size dependent upon material type, thickness
and press tonnage capacity.
•The tool can be used with other material thickness
within a range of + or - 0.016(0.40) from design
thickness.
•Maintain minimum of 0.236(6.00) difference between
diameters used for knockout.

74. 74
Knockout: Sample
50 Ton
Application
100 mm

75. 75
Knockout

76. 76
Knockout: Process
•The knockout process uses a single tool to create a slug
and the tabs.
•The tabs are stretched and weakened when the slug is
displaced.
•Small tabs in thicker material may not be able to stretch
enough to keep the slug attached to the sheet
•Precise, consistent stroke control in the press is very
important for producing high quality, consistent knockouts.
•It is common for knockouts to be pressed back into the
sheet (planished) to create a closed feature. Although this
flattening process will not press a knockout completely flat
back into the sheet it does prevent dust intrusion into the
enclosure.
•Planishing knockouts introduces stresses into the sheet
that may result in a slight bowing of the knockout and/or the
surrounding sheet.

77. 77
ELECTRICAL
KNOCKOUTS
SPLITTING PUNCHING FORCE WITH TWO HITS
DOUBLES…If punching force is
over capacity, make first hit
single K.O. down, second hit
single K.O. up with relief.
1.1 x material
thickness
1st Hit
2nd Hit
TRIPLES…Make first hit
single K.O. up, second hit
double K.O. up with relief.
1st Hit
2nd Hit
Thickness Variation:
•Knockout tool assembly accommodates a + .016(0.4mm) range in material thickness
•Beyond + .016(0.4mm), penetration is affected and knockout performance deteriorates
Planishing:
•Planishing punch pushes knockout back to 75% material thickness, leaving 25% still
raised
•Planishing the knockout further makes it difficult to remove and distorts the sheet
•Knockouts can be produced without planishing
1st Hit
2nd Hit
QUADS…Make first hit
double K.O. up, second hit
double K.O. up with relief.
If diameter is closer than 6mm, this process helps too

78. 78
Knockout: Beat Out or
Fall Out
•Consistency is the key factor.
–Machine repeatability
–Good tool condition (sharpened)
–Tool Length and Programmed depth
•The depth of planishing impacts force to remove.
•The number, size and location of tabs are
important.
•Material type impacts force required
•The force is subjective. To you it was easy, for me
it was hard….

79. 79
Knockout: Tips for
Success
•Be aware of tonnage limits
•Beat out or fall out
•Use lubricant on the sheet
•Confirm the tool was designed for the material
thickness range being formed
•Sharpen or replace the cutting components when
they become dull. Note: Sharpening can change form
height and tab strength.
•Review tab sizes, locations, and quantities
•Confirm the form height is correct (1 to 1.1 times
the material thickness)
•Form up whenever possible

80. 80
Countersink
•USE: Allows screw head to reside flush or below
the surface of the material.
•TYPICAL APPLICATION: Material thickness
from 0.048(1.22) to 0.250(6.35), dependent
upon press tonnage capacity.
•2 styles:
•Universal style: Prototype work
•Shoulder style (dedicated), generally ordered
for one material thickness and screw size

81. 81
Countersink
Countersink
Up
Countersink
D own
Solid body die
available for up.

82. 82
Countersink:
Dedicated
Shoulder (dedicated) Style
•Designed for one material thickness
and screw size
•May be used with thicker material
but not thinner
•Coins the surrounding area
producing a clean, flat countersink
with minimum burring
•Maximum 85% of material thickness
•Very repeatable and accurate forms
Blank Die
Upper Insert

83. 83
Countersink:
Universal
Note:
Use UltraTec instead of Ultra
Form holder for pilot-nose
Countersink down (universal).
UltraTec Fully Guided B station is
recommended as slight stripper
movement may cause breakage.
Universal style
•Used for various material
thicknesses
•Maximum 60% of material
thickness
•Where precision and repeatability
is not as important

84. 84
Countersink:
Material
Deformation
–The plastic deformation of the
material is generally opposite to the
direction of the applied force, moving
material back into the sheet and
down into a pre-pierced hole,
typically causing the final hole size to
be smaller than the pre-pierce hole
size.
–This form can be done either to the
top or the bottom of the sheet.
The area in yellow must be
displaced to areas in red.
Only the angle can be
controlled reliably.
Notice the finished hole is
smaller than pre-pierce

85. 85
Cuntersink: Dedicated
vs Universal
Universal Style
Dedicated
Style
Dedicated countersinks are preferred:
•Less material moving to the top of the sheet
•More material into hole (control via pre-pierce)
•One Die fits all

86. 86
Countersink
Material Considerations and Maximum Depths
A=Major diameter
B=Minor diameter
C=Form angle
D=Form depth
E=Approximate pre-pierce
T=Material thickness
Typical: Metric= 90, Inch=82, Rivets=120

87. 87
Countersinks: Tips for
Success
Tips for Success:
•Confirm the material thickness is correct for the tool design
•Check that the form is being sufficiently coined (witness mark
around shoulder diameter)
•Adjusting pre-pierce size changes depth
–(smaller = deeper, larger = shallower)
•Final hole size is less than pre-pierce (use calculator supplied)
•Use dedicated vs. universal when possible
•If using Universal
–understand limitations of repeatability and capable tolerances
–Use a new die with no shims always. Ground dies will not produce the
same result unless you modify length of upper or adjust program.

88. 88
Emboss - Formed
•USE:
–Provides a recess or a protrusion
–Mounting locations and stand offs on electrical
cabinets
–As a sump to collect condensation inside of
refrigeration units
•TYPICAL APPLICATION: Material thickness
from 0.027(0.70) to 0.250(6.35), dependent
upon press tonnage capacity.
•Best results are attained when the side wall
angle is 45° or less.
•Optimum form height is 3 times the material
thickness or less.

89. 89
Emboss - Formed

90. 90
Emboss - Formed

91. 91
Emboss - Formed
Example of emboss down
UltraTEC punch
holder
with special punch
Special form-down die

92. 92
Emboss – Tips For
Success
Tips for Success
•Lubricant will help reduce punching force and produce
a better emboss.
•Decreasing the form angle
•Decreasing the form height
•Increasing the form radii
•Pre-piercing a hole in the center of the emboss
•Use material that is more ductile

93. 93
LOUVERS
Use:
•To provide air flow or ventilation.
Recommended:
•2.7mm material maximum
•Maximum top height is 6.5mm
•Length is unlimited if continuous
•If non-continuous:
•Usually 12.7mm shorter than the
station size used
General:
•One tool cuts the sheet and produces the
form.
•The tool is limited to one material
thickness.
•Generally require tonnage equivalent to
punching a hole equal to the cut length of
the louver.
Open End Louver Closed End Louver

94. 94
Louvers

95. 95
Louvers
•Closed End
–Stronger design
–Smooth ends
–No exposed corners
–For exterior panels or outdoors
•Open End
–Maximum air flow
–Closer spacing
–For interior panels or indoors
–Shorter front edge and longer
back design allows sides to strip
easily
Draft Angle -- 10º standard, 5º minimum. During
forming, the shorter front edge rises and the longer
back edge bends to allow the sides to strip easily.

96. 96
Continuous:
•Prototypes.
•Short production
runs.
•Extra long louvers.
Continuous louvers are made by forming a closed
end louver and then gradually advancing the tool
along one axis to expand the opening.
LOUVERS
•Continuous louver tools are designed to produce
smooth-edged, level-topped louvers
•Start in the center and form to one side and then the
other in .030(0.8mm) increments
•If needed, complete the process by re-hitting the
center for ultimate flatness

97. 97
Louver Spacing

98. LOUVER
CONSIDERATIONS
Open End Louver Closed End Louver
•Direction that the louvers are made on
the sheet and their spacing
•Stainless steel can sometimes be a
problem as a burr is left on the edge of
the louver
•Lubrication through the tool and of the
sheet is beneficial
•Tools can be lightly sharpened if
necessary (0.1mm)
•Low to medium tonnage application
•If stripping is a problem add a post
dwell to the program

99. 99
Louvers – Tips For
Success
Tips For Success.
•Use forming lubricant on the sheet
•Move material in opposite direction of openings
•Continuous Louvers: Start in the middle (Hit A) and work toward
one end, go back to the middle (repeat Hit A) and continue to
opposite end. Then repeat Hit A for the third and final time.
•Replace the cutting components when they become dull
•Confirm the tool was designed for the material type and thickness
being formed
•Decrease the form height
•Use a more ductile material
•Form up whenever possible
If problems are experienced with a closed end louver sticking,
creating a burr, or becoming damaged in processing, improved
results can be achieved by:

100. 100
V-Line Emboss
•USE: To produce a logo / design /
messages on a part.
•TYPICAL APPLICATION:
–A thin sharp line is produced outlining
the shape required and produces an
etched appearance.
–Minimum 0.8mm thick, maximum can
be up to machine capacity. Maximum
size is dependent on station size and
size of symbols or characters.
–Low punching force; complex shapes
are possible; usually trouble free.
–Depth 0.3mm; does not disappear
with painting.
•An exact drawing, CAD file or sample of
logo is required in order to produce this
type of assembly.

101. 101
V-Line Emboss

102. 102
V-Line
Emboss

103. 103
V-Line Emboss – Tips For
Success
Tips For Success
•Relatively trouble free application
•Proximity of adjacent lines (not too close)
•Closed end features fill with material (tool
stops moving down)
•Use enough punching force to get
designed depth without leaving “witness”
marks
•Required: good artwork with clean lines
–At least two times larger image than required

104. 104
Shear
Button
•USE: To position sheet metal parts
for welding or as stops as for
shear stops.
•TYPICAL APPLICATION:
–Minimum material 0.9mm
–Maximum material 5.0mm
–A diameter of 5.0mm is
standard, but up to a diameter
of 9.5mm is possible.
•Maximum height is 65% of the
material thickness

105. 105
Shear
Button

106. 106
Shear Button
One tool produces the form in each mating part.
Using shear buttons to square large sheets...
Conventional use of shear buttons...
Shear buttons in lower plate fit into
matching holes in upper plate...
Shear buttons used as weld projections for precision
placement of plates to be welded together...

107. 107
Shear Button
Use slotted for
small diameter and
thin materials
Multiple Material Thickness Tool:
•Use slotted insert for up to 2.3mm
material and non-slotted for material up to
5.0mm thick
•Slotted insert leaves a tab (like a knock
out)

108. 108
Shear
Button
•Traditional wire style micro-
joint.
–Sharp point needs to be
removed, creating a
secondary operation
–Material left may cause
inaccurately formed parts
•Square Shear Button style m icro-joint
–Adjustable in length when strength is
required
–It can be snapped off easily, leaving a
clean edge
–Square shape allows it to be used at
both 0 and 90 without the need of an
° °
auto-index station

109. 109
Shear Button – Tips
For Success
Tips For Success
•Low tonnage operation that’s relatively trouble
free
•When using in Stainless Steel, the diameter
should be twice the material thickness
•In thin material, a slotted tip insert may be used to
help buttons stay in place
•Tools can and should be sharpened

110. 110
EasySnap™
•V-line stencil from both sides
creates snap-line
•USE: Like a m icro-joint – but better!
•Can be snapped-off with no burr
•Reducing waste of skeleton
•TYPICAL APPLICATION:
–Material thickness from 1 .0m m thick
to 1 .5m m MS and SS, and 2.0m m ALU
–Tool dedicated for 1 thickness only
–Max. recom m ended length 300m m

111. 111
EasySnap™
–Using tool for proper (designed)
material thickness allows easy
breakage of parts in two
–Using tool on material too thin for
design could shear through
material
–Using tool on material too thick
for design won’t allow easy
breakage of parts

112. 112
EasySnap
™
Use for easy part removal and skeleton breakdown
Use when a formed flange needs extra material for
gauging and forming. Snap off extra after form is made

114. 114
EasySnap™ - Tips For
Success
Tips For Success
•Designed for one thickness
–Punch depth should be about 33% into
material, both top and bottom
•Run at a slower machine speed
•Use as last operation if possible

115. 115
•Complex bending made easy
•V-line stencil creates line of
weakness
•Allows subsequent bending by
hand
•Suitable for MS or SS < 1.50mm
and Al < 2.00mm
•Maximum recommended length
300mm
•Available for all tooling styles
Before punching.
After punching with EasyBendT.
Hand bend along bend line created with EasyBend™
Component after hand
bending.
Mate EasyBendMate EasyBend
™™

116. LIT 00002

117. LIT 00002

118. JOHN ALPHA NUMERIC
MARKING
•Use standard,
replaceable, economical
inserts.
•Message or letter
changed easily

119. CARD GUIDE
Use:
•As a retainer for
printed circuit boards
Minimum/Maximum
•1.0mm thick minimum
2.0mm thick maximum

120. CARD GUIDE
•Length of the card
guide is dependent
upon station size and
machine tonnage
•Maximum height
recommended is
3.2mm
Pre-pierce ends can
be rectangular or
rectangular with
radiused corners

121. CARD GUIDE
•Two tools are required
–Pre-pierce
–One that forms the card guide
•Each tool is made for a specific
material thickness
•Galling can be a problem
–lubrication through the tool and
on the sheet is beneficial
•Mild steel give the best form
–Aluminum is fair
–Stainless can be a problem
due to spring back of the
material
•A post dwell should be used to
allow stripping

122. COLD FORGED EMBOSS
Use:
•To produce a logo or design on a part.
Minimum/Maximum:
•Minimum 0.3mm thick, Maximum 3.0mm thick,
depending on the tooling style, station size
and the machines tonnage
•Can be used on varying material thickness
(within a range)
•Best if made in 1.0-2.0mm thick material
General:
•Exact drawing or sample of logo required to
produce
•Tonnage can be high dependent on design
and material
•Usually simple trouble free operation

123. •Width of characters should
be minimum of one material
thickness, more is better
•Space between characters
or lines should also be one
material thickness minimum
•Tools are not designed to
be sharpened
•Can be dusted to
sharpen the emboss
after the tool is older
UPPER INSERT
MATERIAL
LOWER INSERT
.016(4.0mm)
to
.020(0.5mm)
For clear definition and
readability, raise characters
at least .016(0.4mm) to .
020(0.5mm) above the
surface.
This cut-away of the MATE logo shows how
a complex form is rendered by the cold
forged embossing process.
MAXIMUM
STATION PERIMETERS
B Ø .787(20.0mm)
C Ø 1.575(40.0mm)
D Ø 2.362(60.0mm)
E Ø3.346(85.0mm)
COLD FORGED EMBOSS

124. HINGE TOOLS
Tool 1 makes 2 hits: Pre bending and rising the pre-bended tap with axis
movement in between
Tool 2 makes one hit and finishes the hinge

Tool 1 Tool 2

125. HINGE TOOLS
Tool 1
Tool 2

126. Use:
•Logos, messages or symbols
•Produces an etched appearance
Minimum/Maximum:
•Minimum 0.8mm thick, maximum
can be up to machine capacity
•Maximum size is dependent on
station size and size of symbols
or characters
General:
•Thin, sharp line produced,
outlining the shape required and
•Low to high tonnage, usually
trouble free
V-LINE CUSTOM
INSCRIPTION

127. V-Line Stamping -- renders the image with a thin, sharp line
stamped into the surface. It requires relatively small force.
Large complicated images are possible.
V-Line Stamping:
•Thin, sharp line
reproduces the outline of
the shape for an etched
appearance. Low
punching force.
•Within press capability, figures may be any size up to
station maximum
•When ordering, an accurate indication of each figure’s
size, shape and depth below surface (0.30mm maximum)
are required
•Typefaces may be specified or artwork may be furnished,
depending on the requirements of the subject matter.

128. RAM CONTROL TOOLS
Press must be capable of holding the ram down while
the sheet is moved in the X and or Y direction.

129. MATE ROLLERBALL™
•Rollerball™ provides the benefit of
making forms not possible with single
hit forming tools
•Takes advantage of punch press
extended programming capabilities
•Machine must be capable of
operating in the x and y axis with the
ram down
Rollerball™ Capabilities:
•Make stiffening ribs in light gauge sheet
metal
•Cross-break operations on the punch
press
•No secondary press brake operations
•Form ribs, flanges and raised areas
across the entire work surface
•Offsets and embosses not limited to
station range

130. •Max. thickness 2.7mm
•Rib width ~22 mm (fix)
•Max. height 3.7mm incl. thickness
Ribs
Offsets
MATE ROLLERBALL™

131. Rollerball Examples

132. Rollerball
®
Beading in 1mm mild steel
Detail inside corner
Roller Ball Beading

133. Mate RollerBall DeburrMate RollerBall Deburr
Takes away the burrs on every hole – even small diameters
and in corners, also slitting lines on both sides
Machine must be capable of holding down he ram while
moving the sheet
Can be used in combination with EasySnap to get a burr-
free product
Up to 4.0mm
thickness

134. SHEETMARKER
™
Three springs, two points
(120 & 150) allow control of
depth and width of the line
scribed
Flexible, programmable marking

135. Score Plastic Protection for
removal before laser cutting or
fabrication ( bending lines etc.)
Cuts trough the protective plastic film without leaving any
marks on the metal surface .

136. Mate EasyMarkMate EasyMark
Springs: 3 Types to be
used for diamond or
Brass Inserts
Spacer: Use for
dead weight on top
of InkMarker
Punch: for installing
and removing
inserts
Ink Marker pen Insert Holder 3 Inserts (2 diamond, 1 brass)
Allen Wrench:
for installing and
removing inserts
Die: Used for
SheetMarker
and InkMarker
Spacer: Use with
SheetMarker
A-station Holder

137. Mate EasyMarkMate EasyMark
Applications with Inkmarker Pen

138. MATE SOLUTIONS
TRAINING
PROBLEM-SOLVING
CHECKLIST

139. PROBLEM-SOLVING
CHECKLIST
•Is the material correct for the tool that was
ordered?
•Is the tool length set correctly?
•Is the forming being done close to the clamps?
•Does the tool require sharpening?
•Is galling present on the tool?
•Was the correct pre-pierce used?
•Is there a delay in the program to allow stripping?
•Is the turret aligned properly?
•Is there any damage to the tool?
•Was lubrication used on the tool and sheet?

140. MATE SOLUTIONS
TRAINING
SUMMARY

141. SUMMARY
•Using forming in your operations will help you…
–Increase efficiency
–Expand your capabilities
–Eliminate of secondary operations
–Increase machine time
–Reduce tool wear

142. THANK YOU!
MATE SOLUTIONS
TRAINING