Flange Die

Press tooling. Flanging down, flanging up, calibration tools. Basics on design Importante Note :

GE24-080R

/C

________________________________________

Guide ________________________________________

Status

Enforceable

This document has been translated from the french. In the event of any dispute, only th french version is referred to as the reference text and is binding on the parties.

Object

Define the recommendations for designing flanging down, flanging up, and calibration.

Scope of application

Renault group

Issued by

Confidentiality

65307

-

Stamping Process Industrialisation

Non confidential

Approved by

Function

D.COURATIN

Head of department 65307

© RENAULT 2005

Signature

Origin: PEGI - Renault

Application date 01/2005

Page: 1 / 38

GE24-080R

/B

History of versions Version Update A C

Object of main modifications modifications

02/2004 10/2005

Creation Addition of the paragraph 3.2.8 flanging up with rocker.

Author (1) B. Nouhant C. Laizé Dept 65307

Supersedes

GE24-080R of 01/2005 version B

Availability

Inside Renault, on the Intranet: http://gdxpegi.ava.tcr.renault.fr Outside Renault, on the Internet: www.cnomo.com E.mail: [email protected]

Documents cited

Regulations International European French CNOMO Renault

: : : : : :

Other internal doc Other external doc

: :

ISO 3755, ISO 4957. EN 10083-1. E01.14.220.N, E01.33.211.N, E01.41.050.N, E01.45.030.N. EM24.01.100, EM24.15.050, EM24.15.100, GE24-017R, GE24040R, GE24-060R, GE24-120R.

Coding

ICS:

25.120.10; 03.120.20

Class

E24

Key words

emboutissage, outillage de presse, outil de presse, dessin, fondamentaux, tombage, relevage, calibrage, conception, pressing, press tooling, press tool, design, basics, bending, flanging down, restrike

Language

French

(1) Have participated in writing the document Site Dept Name Site LHA

09610

LHA

04734

FLINS

09410

Mme LEREVEREND MM. BEAUFOUR / DELAFENESTRE / DELAHAYE LECHEVALIER / LOISEL / MORVAN / TERRIER MM. BAUBE / PASQUIER ROULIER MM. CHAPPE /

© RENAULT 2005

TCR

Dept

Name

65307

MM. BRUNDU / FERRANDON / GUYOMARCH / HAMMOUDI / LEBOEUF PRESA / TRADOTTI M. GOURDET

64140


Page: 2 / 38

GE24-080R

/B

Contents Page

1

General ....................................................... ........................... ........................................................ ......................................................... ..................................................... ........................ 4

1.1

Different types of tooling....................................................................................... tooling ................................................................................................................................4 .........................................4

1.2

Different functions .............................................................................................. .........................................................................................................................................4 ...........................................4

1.3

Foundries design...........................................................................................................................................5

1.4

Frame guides ............................................................................................. ................................................................................................................................................6 ...................................................6

1.5

Storage .......................................................................................... ..........................................................................................................................................................6 ................................................................6

1.6

Calculations...................................................................................................................................................7

1.7

Aluminium parts.............................................................................................................................................7

1.8

Butt welded parts...........................................................................................................................................7

1.9

Narrow parts, thick parts, HLE, THLE panels ...................................................................................... ...............................................................................................7 .........7

2

Flanging down / flanging down-calibration tool ........................................................ ............................ ........................................ ............ 11

2.1

General on design ................................................................................................. .......................................................................................................................................11 ......................................11

2.2

Tool composition ........................................................................................ .........................................................................................................................................13 .................................................13

3

Flanging up tool............................. tool. ......................................................... ......................................................... .............................................................. .................................. 16

3.1

General on design ................................................................................................. .......................................................................................................................................16 ......................................16

3.2


4

Flanging down / Flanging up / Calibration tool................................................ tool.................... .................................................. ...................... 19

4.1

Operation.....................................................................................................................................................19

4.2


5

Working parts................................ parts............................................................ ......................................................... ................................................................ ................................... 20

5.1

Blades..........................................................................................................................................................20

5.2

Punch and presser range............................................................................................................................26

5.3

Pullers / Separators.....................................................................................................................................30

5.4

Presser .................................................................................................. ........................................................................................................................................................32 ......................................................32

5.5

Part centring ............................................................................................. ................................................................................................................................................33 ...................................................33

6

Materials ..................................................... ........................ ......................................................... ........................................................ ................................................... ....................... 35

7

Cambering........................... Cambering ........................................................ ......................................................... ........................................................ ............................................. ................. 36

8

Normative references references for metallic materials materials cited in this document.............................. document.. ................................. ..... 37

9

List of documents cited ........................................................ ........................... ......................................................... ................................................... ....................... 38

Foreword This guide is not: 

A collection of "design rules".

Exhaustive in propositions. This guide is a reminder of a few basics and examples, and must be enriched with: 



The different user projects.



All manufacturing sites by the intermediate of different DIVDs.

NOTE:

© RENAULT 2005

All the information concerning the materials are indexed by an asterisk (*): this means that the type of material is cited for information, and is defined by the EM24.01.100 standard and specific project standards.


Page: 3 / 38

GE24-080R

1

General

1.1

Different types of tooling    

/B

Flanging down tool Flanging down / calibration tool Flanging up tool Multiple tool: 

flanging down / flanging up / calibrating

or flanging up / flanging down / calibrating designated as "double pressure tool". 

1.2

Different functions •

Conformance A stamped radius is reduced to meet the value in the part drawing

•

Calibration A surface is struck, e.g. to ensure proper mating with a neighbouring part.

•

Shrinkage The part is flattened to reduce a radius. Requires the part to be mobile in the tool.

•

Fitting the aspect line An aspect line is marked with a small radius. It must be obtained from the stamped OP. To prevent the panel from being pushed back in the aspect zone, the finished part must be as vertical as possible.

•

Fold According a straight line intersecting 2 planes.

•

Flanging down According to a curved line in 3 dimensions.

•

Edge flanging up According to a curved line in 3 dimensions.

•

Edge striking According to a curved line in 3 dimensions.

•

Overfolding See paragraph 7 Along a straight line

© RENAULT 2005


Calibrated zone (Hashed in a top view of the part in the manufacturing sheet)

Page: 4 / 38

GE24-080R

1.3

/B

Foundries design See Renault standards EM24.01.100 and Renault guide GE24-040R . Guiding gap – 0.1 +-0.01 +-0.01 in GP (lower frame/upper frame) – 0.15 +-0.01 +-0.01 in TGP if frame/frame columns

guiding constant

guiding constant

(or more according to result of flexion calculations under reaction load)

Gap between presser and blade: 0.4 to 0.6 to reduce to 0.1 min in major shrinkage zones

Upper frame

Presser

Offset punch Dropping blade blade blade parting parting line: gap

© RENAULT 2005

≤

0.03


Page: 5 / 38

GE24-080R

1.4

/B

Frame guides The general guides must be located on the same level as working parts. The 2D and 3D master drawings must hence be modified to meet these conditions.

g n i e g r a o g f e n b e n n i m m u l 0 o 5 c

Range of working parts

l s o i o x T a

1.5

Storage s e t a l p e h t s x n i i a s n m s e o i p m r t r 0 d n e 4 a s l o n o I = T

Tool tip view Free tool position ( HOL )

© RENAULT 2005


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GE24-080R

1.6

/B

Calculations See Renault guide GE24-040R.

1.7

Aluminium parts The design is identical, except for materials specifications: refer to Renault guide GE24-120R.

1.8

Butt welded parts If the butt welding line is located in a zone to calibrate, include blades to ensure the time, aspect, and geometry.

1.9

Narrow parts, thick parts, HLE, THLE panels

1.9.1

Particularities of design of narrow parts    

Implement compensators between presser and lower working part. The presser, mobile base elements must be in cast steel 270-480W* or G50CrMo4 M* The blades must be in steel with specific treatment (X153 CrMoV12* T6 special) implanted in blade holders Presser guides per plate 

© RENAULT 2005

at the ends


Page: 7 / 38

GE24-080R

/B

fitting from top of presser



Rib above blade parting lines

e k o r t S

G N I L D N A H

Blades

Other frame shape

Frame

X = nominal stroke of of spring – working stroke

Rib above blade parting lines

e k o r t s g n i k r o W

G N I L D N A H

Blades

Other frame shape

Frame

© RENAULT 2005


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GE24-080R 

/B

other particularities  Extension of the internal presser by an outside zone.  Caution: 

the sizing and number of linking suspenders



space "P" between the suspenders and blades implanted in "overhang"



consider max crushing of presser dampers



positioning the suspenders according to the blades



the gaskets of blades to remove



balancing loads, retainers, and guides. Note: drawbacks of this design = maintenance penalised by removing the blades before presser access.

P

Compensation bloks

Blades

1.9.2

Design specifics for thick parts High thickness parts are panels thickness ≥ 1,2 mm. They are usually narrow parts.  The foundry thickness of cast elements must be increased  The presser, mobile base elements must be in cast steel 270-480W* or G50CrMo4*  The blades must be in steel with specific treatment, X153 CrMoV12* T6 special (56 to 58 HRC), implanted in the blade holders  The blade holders must be of a "fuse" design  Include sized reference holes to facilitate refitting.

Blade holder 270-480W

Tie-rod axis

Tie-rod axis

Holes Ø H7 for reference reference

© RENAULT 2005


Page: 9 / 38

GE24-080R

/B

Other examples:

The blades must be implanted in blade holders with a "fuse" system: e.g. tie rods, keys.

© RENAULT 2005


Page: 10 / 38

GE24-080R

2

Flanging down / flanging down-calibration down-calibration tool

2.1

General on design

2.1.1

Tool with offset punch

TOOL WITH STRIKE A

B

C

/B

TOOL WITHOUT STRIKE D

A

Cast iron

Steel

Cast iron

Steel

B

C

D

Cast iron

Steel

Cast iron

Steel

TGP

40

50

40

40

40

40

40

50

40

30

30

20

GP

40

50

40

40

40

40

40

50

40

20

30

20

MP

30

40

30

30

30

30

30

40

30

20

30

20

1)

Lower frame:

FGL 215 HB*

2)

Lower punch.:

G50CrMo4* T3 + T7 hardness ≥ 54 HRC (if rate

≥

500 p/day)

or FGS 600 3A* (if rate < 500 p/day) 3) Upper frame.: FGL 215 HB* 4) Presser: FGL 240 HB*, FGS 600 3A*, 270-480W* 5) Calibration blades: X153CrMoV12* T6 hardness 54-56 HRC or 42CrMo4* or G50CrMo4* T3+T7 hardness ≥ 54 HRC 5bis) Location of the calibration blades to be planned. X153CrMoV1*2 - T6 (54-56 HRC) + TiN or G50CrMo4* T3+T7 (≥ 54 HRC) or pre-treated steel* T4 (>52HRC) 6) Flanging down blades: X153CrMoV12* - T6 Special (56-58 HRC) HRC) + TiN or 42CrMo4* or G50CrMo4**T3+T7 (≥ 54 HRC) or pre-treated steel* T4 ( ≥ 52 HRC) 7) Gas springs in upper part (type of springs according to calculations) 8)

separators: Stroke < 80 mm, outside purchases from Renault certified suppliers

9)

Stroke ≥ outline drawing 01 016 in Renault guide GE24-017R. Retaining/locking pins (if compatibility with loads)

10) 11)

Probe (do not implant in a span zone) Span balancing of the presser (supports).

© RENAULT 2005


Page: 11 / 38

GE24-080R 2.1.2

/B

Tool with lower frame / Single book cage

TOOL WITH STRIKE A

1) 2) 3)

B

C

TOOL WITHOUT STRIKE D

A

Cast iron

Steel

Cast iron

Steel

B

C

D

Cast iron

Steel

Cast iron

Steel

TGP

40

50

40

40

40

40

40

50

40

30

30

20

GP

40

50

40

40

40

40

40

50

40

20

30

20

MP

30

40

30

30

30

30

30

40

30

20

30

20

Lower frame single block in FGL 240 HB* Upper frame: FGL 215 HB* Presser: FGL 240 HB*, FGS 600 3A*, 270-480W*

4) Calibration blades: G50CrMo4* T3 + T7 hardness ≥ 54 HRC 4bis) Location of the calibration blades to be planned: X153CrMoV12* - T6 (54-56 HRC) + TiN or G50CrMo4* or 42 CrMo4* T3 + T7 ( ≥ 54 HRC) or pre-treated steel* T4 (>52HRC) 5) Flanging down blades: X153CrMoV12* - T6 Special (56-58 HRC) + TiN or 42CrMo4* or G50CrMo4 * T3+T7 (≥ 54 HRC) or pre-treated steel* T4 ( ≥ 52 HRC) 6) Gas springs in upper part (choice of type of springs according to calculations); spring distribution ensuring proper load balance. 7) 8) 9) 10)

Separators: Stroke < 80 mm, outside purchases from Stroke ≥ outline drawing 010 16 in Renault guide GE24-017R. Retaining/locking pins (if compatibility with loads) Part presence detectors Span balancing of the presser (supports).

© RENAULT 2005


Renault

certified

suppliers.

Page: 12 / 38

GE24-080R

2.2

/B

Tool composition Functions to be provided The general functions of all tooling must be met (handling, storage, fitting under press, part loading and extraction...). In addition, beware more particularly the points in the following table: FUNCTION PART CENTRING

WORKING PARTS GUIDE

OBJECTIVE Machine ability ratio, CAM ≥ 1.3 tolerance interval CAM = dispersion

Compensate press guiding faults.

COMMENTS Within this objective, plan effective centring in the important zones of the part. This centring must be durable (paragraph 5.5).

Clearanc Clearance e see paragrap paragraph h 1.3

Calculation of clamping loads. TIGHT CLAMPING OF PART

Prevent parasite distortion and strip the part in respect of working blades.

REACTION

Compensate horizontal roller loads due to working on sloped shapes.

WORKING PARTS STURDINESS

Withstand shock, high superficial loads and intense friction.

SEPARATORS AND PULLERS

Prevent the part from adhering to the lower part or struck onto the upper part.

PART SUPPORT

Apply the geometry and prevent creating aspect faults.



The moving parts must be lockable at bottom dead centre position for unseizing  Fit the reaction plates as close as possible to the loads to compensate to reduce distortion of the tooling frames. Seizing between panel and working blades is highly detrimental, as it results in press stoppage and requires grinding the blades, hence a drift in geometry. Separators and pullers must not distort the part. In order to do this, they must not exert any flexion loads on the part, when the upper part of the tool is in contact with the part. The punch span must be sufficient next to the working lines, and prevent the part’s collapse.

Locking: it must be included provided calculations allow it for parts with rolled edges likely to cause seizing. The locking decision must be validated during drawing reviews with all players. (Project, plant, provider)

© RENAULT 2005


Page: 13 / 38

GE24-080R 2.2.1

Lower frame FGL 215 HB* or upper frame single block punch FGL 240 HB*



Carries the fasteners and centrers on production and backup press platform Pneumatic and/or electric connecting plates Handling by slings and/or clamps Storage spacers (elastic, RG, storage set over 3 heights) Safety jack plates Holes for contact tips Adjusting spacers (on ribs) Guide: Columns if collar flanging down punch Guide stop with cupro plate including cast iron inserts Reaction: if required, cupro plate with inserts on steel plate Punch fastening and keying Separators / pullers / centrers For aspect parts: presser supports (prevent marking, protection of edge lines, after contact, during press cycles without part or/and loads too high between presser and punch) For single block tools: any grains in major shrinkage zones For single block tool: part presence detectors 2 detectors per part For single block tool: part centring on shape, centrers-separators (see paragraph 5.2)



Include passage of punch support studs (see Renault guide GE24-040R)

             

2.2.2

G50CrMo4* or FGS 600 3A* punch       



2.2.3

/B

Fastening / keying on lower frame Carry the separators / centrers / pullers For aspect parts: presser supports (prevent marking, protection of edge lines, after contact, during press cycles without part or/and loads too high between presser and punch) Possible grains (e.g. collar flanging down) Part presence detectors 2 detectors per part (ex working zones) Part centring: on shape, by centrers / separators: See paragraph 5.2 Snap connection plate for detector Electric link between lower frame and connecting plate or KHEOPS socket with detector cable on punch Studs (supporting studs of free punch to protect detector and cable or/and separators) (see Renault guide GE24-040R)

Upper frame FGL 215 HB*              

Clamping under production and backup press ram (snap and manual clamping) Handling by slings and/or clamps Clearance for link with press ram pneumatic connection block Ranges for safety jacks with contact tip holes Ranges for adjustment spacer, fitted on ribs Range for storage spacer Guides – bushes (consistent with lower frame) plates (consistent with lower frame) Reaction (consistent with lower frame) Presser guides Pressure means Carry the blades Separator stands Retaining pins with or without locking (according to calculations) Pneumatic link with lower frame if start up

© RENAULT 2005


Page: 14 / 38

GE24-080R 2.2.4

/B

Presser FGL 240 H*B or FGS 600 3*A or in case of fragility cast steel 270-480W*  Pressure means stand (metal, polyurethane springs) Note: springs must be balanced RG / work loads / guiding  Housing for retaining and/or locking pins  Part clamping (see paragraph 5.2)  For aspect parts: presser supports (prevent marking, protection of edge lines, after contact, during press cycles without part or/and loads too high between presser and punch)

2.2.5

Blades 

2.2.6

See paragraph 5.1

Pressure means Metal springs  Polyurethane springs  Non linked gas springs. Choice of type of springs according to load calculation Pressure means and loads impact the choice of storage spacers 

2.2.7

Separators 

2.2.8

Detection 

2.2.9

See paragraph 5.3

2 detectors per part

Reaction 

Compensate horizontal loads due to: 

the work slope

the outline shape (beware open outline) Place the reaction place as close as possible to the loads to compensate to reduce distortion of the various tool elements. 



2.2.10

Calibration blades 

Calibration must be performed with blades fitted onto the upper frame. Exceptionally calibration of coining can be performed by the presser.

•

Calibration blades X153CrMoV12* - T6 (54-56 HRC) or G50CrMo4* or 42CrMo4* - T3 + T7 (≥ 54 HRC) or pre-treated steel* T4 + T7 ( ≥ 54 HRC) Punch: plan the foundry for possible implantation of blades.



© RENAULT 2005


Page: 15 / 38

GE24-080R

3

Flanging up tool

3.1

General on design

/B

1) Punch in G50CrMo4* T3+T7 hardness ≥ 54 HRC. 2) Lower frame FGL215 HB*. 3) Mobile base FGL240 HB* or G50CrMo4* T3+T7 (≥ 54 HRC) 4) Gas spring (no prop) Avoid using polyurethane springs (rebound effect upon press flanging up, detrimental to part extraction). 1) No shim under mobile base.

3.2

Tool composition

3.2.1

Lower frame FGL 215 HB*        

    

Carries the fasteners and centrers on production and backup press platform Pneumatic and electric connecting plate Handling by slings and/or clamps Storage spacers (elastic, RG, stop over 3 heights) Safety jack ranges Holes for contact tips Adjusting spacer (on ribs) Guide: Stops with cupro plates including inserts on foundry or male/female slider Columns if collar flanging up Reaction if required by cupro plates with inserts on steel plate Mobile base guide Carry pressure means Mobile base retainers with or without locking Flanging up and fitting blade holder

© RENAULT 2005


Page: 16 / 38

GE24-080R 3.2.2

Moving base         

3.2.3

         

 

≥

54 HRC

See paragraph 5.1

Pressure means     

3.2.7

FGL 240 HB* or FGS 600 3A* or G50CrMo4 M* T3+T7 hardness Fasteners, keying with upper frame Separator stand

Blades 

3.2.6

Clamping under production and backup press ram Snap and manual clamping Handling by slings and/or clamps Clearance for link with press ram pneumatic connection block Pneumatic link with lower frame if start up Ranges for safety jacks and contact tips Ranges for adjustment spacers fitted on ribs Ranges for storage spacer Guide with lower frame / consistent with lower frame Reactions if required Fastening, punch keying Passage or stand for separators

Punch 

3.2.5

FGL 240 HB*, FGS 600 3A*, G50CrMo4* M T3+T7 hardness ≥ 54 HRC if fragility Supports for pressure means Handling (anchor point balance) Guide with frame Passage of retainer Possible grains 2 detectors per part If steel reaction plate (cupro with inserts on frame) Location of the columns to be planned.

Upper frame FGL 215 HB* 

3.2.4

/B

Metal springs Polyurethane springs Gas springs Choice according to load calculation Pressure means and loads impact the choice of storage spacers

Separators 

See paragraph 5.3

© RENAULT 2005


Page: 17 / 38

GE24-080R 3.2.8

/B

Flanging up with rocker Note: this type of construction can avoid the realization of a mobile bottom. Principal plan

Upper frame

presser

Shim in polyamide

Control rod

spring insert

spring support grain Punch of de rising Guiding ring punch

rocker Retention pin

support

Shim of reaction Adjustment shim

Lower frame

© RENAULT 2005


Page: 18 / 38

GE24-080R

4

Flanging down / Flanging up / Calibration tool

4.1

Operation

/B

In this tooling, also called "double pressure tools", the part is mobile, and the upper part includes a presser. However, flanging down and lifting operations cannot be simultaneous. The decision to perform first a flanging down or first a flanging up depends on the working loads and also the capacities (in footprint) to receive the number of springs required. Flanging down is performed first if the load is lighter than the lifting load. We then have: Lower clamping load

>

Presser load + presser weight + flanging down load + Weight of the lower moving base.

If lifting is lower than the flanging down load, lifting is performed first. Upper clamping load>

Clamping load + Lifting load + Weight of the presser + Weight of the lower moving base.

Column to be planned, but do not launch. For possible implantation of punch or/and flanging No stroke shim Retainer-locking pin

Stroke shim, shim, superior superior size Springs (no props). Columns required if reference flange lifted

If the load to lock exceeds the load capacity of 4 pins diameter 63, do not install a locking (only use retaining).

© RENAULT 2005


Page: 19 / 38

GE24-080R

4.2

/B

Tool composition All elements cited below use the functions described in paragraphs 2 and 3.     

Lower frame Moving base Upper frame Presser Blades Flanging down  Flanging up  Calibration 

5

Working parts

5.1

Blades When working the panel, the active part of the tool is subject to friction, whereas the item supporting the part (here the punch) is less solicited, as the sheet is wound on it. Usually, the active item is made of blades which are offset, embedded, screwed into the frames. Upper frame Presser Punch

The presser cannot be used to calibrate the part. If a lower zone must be picked up, a punch will be fitted on the frame inside a recess in the presser or mobile base. Prevent the presser from "rubbing". For single block punches in G50 CrMo4 *- T3+T7 (HRC ≥ 54) the foundry must be of capacity for the implantation of the blades in the zones to be calibrated; (e.g. crimping zone). No stroke shim

Presser Punch

Upper part Blade Blade (to be planned, planned, but do not launch) 2 CHc screws screws M12 + 1 pin Ø12 (plan but do not launch) Do not source from foundry

NOTE: in the case of parts with off-centred tolerances, shims must be implanted behind the blades on the punch, and in the upper parts. These shims must be linked to the blade stand element.

© RENAULT 2005


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GE24-080R

/B

Calibration of a stringer in HLE panel AVOID In safety parts (material fibre breakage)

Angle to be determined practically

Radius stroke requested upon calibration

Calibration of a small edge and one mating face

Presser

Upper Upper frame frame

Punch Calibration blade without vertical cylindrical part

© RENAULT 2005


R accordin according g to part part drawing

Page: 21 / 38

GE24-080R

/B

Expanding edges

Outer view of blades

Work line profile The blade parting lines must be symmetrical in respect of the part’s axis of symmetry

Outline sketch of the work line outline

Penetration Penetration

Very large shrunk edges Implant a presser with balancing shims to prevent the formation of folds.

s s e n k c i h t l e n a P

© RENAULT 2005

Lower presser Offset blades if required


Page: 22 / 38

GE24-080R

/B

Blade materials Blades in X153CrMoV12* - T6 The blades are cut in commercial rolled steel X153CrMoV12* preferably pre-machined, in order to reduce machining and guarantee the working zone will not be decarbided, or rough rolled, but with sufficient descaling ( -5 mm). In case of strong lamination and after development in the plant, apply ionic nitriding or a titanium nitride coating (TiN) on blades in X153CrMoV12* Special T6 treated according to the range indicated in EM24.15.100. 

Final development of the blades.



T8.2: Ionic nitriding (thickness 0.1 to 0.2 mm),



or T9: TiN.

In case of complex shapes, it may prove interesting to cast blades in X153CrMoV12*, while ensuring the foundry overthickness is sufficient beside the working zone to ensure the blade has the hardness required.

Blades in G50CrMo4* or 42 CrMo4* T3+T7 hardness 54 HRC or pre-treated steel T4+T7 ( 54 HRC) Torch treatment (T7) must be performed on the entire working section.

f o n 7 o i t T c e e m r i a D l f

Zone impacted impacted by T7

© RENAULT 2005


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GE24-080R FLANGING DOWN BLADE

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STRIKING BLADE

Reaction Reaction indispen indispensabl sable e for stroke stroke on unbala unbalance nced d slope sloped d edges edges and flang flangin ing g > or = 1 m

Upper Upper frame frame Presser

1 GT 12 pin per per blade blade 2 Chc Chc scre screw w M12 M12

Punch

Dropping Dropping blade blade

R = panel thickness on blade before before MAP) MAP) For rising, rising, flip the flanging flanging section section

Punch blade

RESTAMPING

RADIUS CONFORMANCE

See Renault guide GE24-060R.

2 Chc Chc screw screw M12 M12 Restamping blade

G50 CrM04 * T3+T7 Hardness ≥ 54 HRC if th ≤ 0.8 mm

1 GT 12 pin per blad blade e

G50 CrM04 * T3+T7 Hardness ≥ 54 HRC

X153CrMoV12 * T6 54-56 HRC if th ≥ 0.8 mm

SHRINKAGE BLADE

Between Between panel before before calibra calibratio tion n and span span limit limit

CALIBRATION OF THE CRIMPING ZONE OR CALIBRATION WITH VARIATION OF PART DEPTH

Upper Upper frame frame

e s a b g n e i v k o o t r M s

G50 CrM04 * or 42CrMo4 * T3+T7 Hardness ≥ 54 HRC

2 Chc Chc scew scew M12 1 GT 12 pin per per blad blade e

G50 CrM04 * or 42CrMo4 * T3+T7 Hardness ≥ 54 HRC X153CrMoV12 * T6 54-56 HRC

Cast steel punch Blade location planned, but do not launch Cast iron punch Blade location planned, launch this blade in case of rework on part depth

Note: For blocks cast in G50CrMo4*, plan handling means. For blades in hot reduced steel, do not exceed 15 kg To select the materials, refer to paragraph 2.

© RENAULT 2005


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GE24-080R

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Blade design Max weight = 15 kg (machined) DETAIL OF A FLANGING DOWN BLADE AND ITS MARKING Front view (extraction) (extraction)

d ) e w a z r i s d e e b d t l a s b u n M ( o

e t a R

Example Example of markin marking g before thermal thermal treatment treatment

Top view view If pulled pulled blade blade

Nature material Mark

e t a R

Comercial Comercial rate (preference pre-machined

Mark 56

If pinned pinned blade blade Rate Markin Marking g of hardne hardness ss after thermal thermal treatment treatment

Grindi Grinding ng wheel wheel radius radius 20 to 30

Note: To facilitate the development of parts with a symmetry plane, study blades symmetrical with this plane (MANDATORY) .

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GE24-080R

5.2

Punch and presser range

5.2.1

Aspect parts

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a) The punch must be on span along the working lines over a width of 160 min. b) The punch must support the part properly, without risk of marking the edge lines: The recesses in the punch span must never be at less than 40 mm from the edge lines. Note: Recesses must never intersect an edge line. c) No hole nor blading nor probe housing must end in the punch span. d) The punch span recesses must be contained in a square dimensions 200 x200. e) The presser must never have a range contained in the punch span (5 to 100 mm recess) and must never press a panel not supported in the lower part. f) In the particular case of concave zones on the punch and convex on the spans, the presser and punch must be extended beyond the peripheral 120 mm by protruding the punch’s concave zone by 40 mm.

Convex Convex punch

Concave punch

Convex Convex punch

Presser Edge Edge line line suppo supporte rted d without without interrutio interrution n Uper Uper frame frame

Blade

Pin

Screw

Probe

Punch e n i l k r o W

No sharp edges

5.2.2

Other parts General principle for structure part a) The punch must be on span along the working lines over a width of 160 mm. b) The mating zones must be on punch and presser span. c) The punch span recesses must be contained in a square dimensions 300 x 300. d) The presser must have a span contained in the punch span (5 to 10 recess). e) Avoid screws, pins, probes at less than 40mm from the working lines.

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GE24-080R 5.2.3

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Diagrams FLANGING DOWN OF HOOD FR, RR

LAT EDGE

Punch Presser Extractor

Cross-section Cross-section A

Presser clearance

Fulley Fulley suppor supportted edge edge line line

FLANGING DOWN FOR GENERAL CALIBRATION OF FENDER Cross-sectio Cross-section nB

Full punch Presser cleared

DOOR CAISSON RESTAMPING DETAIL: Hinged panel restamping Upper Upper frame frame Deta Detail il A Separation

Punch (blade)

Presser Deta Detail il A Blank Blank holder holder

Punch Full punch Presser Presser cleared cleared locally

The "restamping" is treated in the Renault guide GE24-060R .

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GE24-080R

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CALIBRATION EDGE FLANGING DOWN FOR FR DOOR PANEL C cross-section

CALIBRATION EDGE FLANGING DOWN OF THE LATERAL PANEL D cross-section

Punch cleared presser cleared

Probe in not visible visible zone

Beware the "edge" lines CALIBRATION EDGE FLANGING DOWN FOR RR DOOR PANEL Full punch (except (except window frame Presser cleared

E cross-section

Beware the "edge" lines

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GE24-080R

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GENERAL CALIBRATION EDGE FLANGING DOWN OF THE ROOF F cross-section

Note: Note: Eliminate all these recesses on the punch if the rear gutter is restamped. In this case, the upper presser must be in span in the concave zones of the punch and over the entire periphery. Beware the "edge" lines TUNNEL: CALIBRATION EDGE FLANGING UP

G cross-section

© RENAULT 2005

Upper presser presser Upper Upper blades blades


G cross-section Presser / punch contact

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GE24-080R

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BODY SIDE

Punch cleared Presser cleared

Beware the "edge" lines

5.3

Pullers / Separators If the part is likely to remain clamped on the tool, the punch or the upper frame are fitted with pullers or separators (pullers for skin parts, separators for structure parts) Pullers are required in the following cases: 

One flanging down or flanging up line completely closed.



Edges flanged or risen in expansion (e.g. wheel entrance edges on fender or lateral panel).



Edged holes or openings.

Pullers in an edged hole

∅

Of pre-ho pre-hole le

Spring

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GE24-080R

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Outer pullers Centrer-Extractor master drawing Stroke

0 to

≤

63

Stroke

63 to

≤

80

Stroke

80 to

≤

140

External purchasing from suppliers approved by Renault

}

Outline drawing 01016 in Renault guide GE24-

017R Cent Centri ring ng of the the part part

Panel Panel holder holder at contac contactt

(Tool (To (T ool ol at top stroke stroke))

0 = r g e n s i s h e s u r r P c

Flange Flanged d edge edge (Too (Tooll at bott botton on stro strock cke) e)

e k c o r t s r e l l u P

6 + H = e k c o r t s r e l l u P

0 = = e k c o r t s r e l l u P

End End stro stroke ke of panel holder

H = height of the max flanged edge Presser stroke = H+35

0 = g n i h s u r c r e s s e r P

End End stro stroke ke of pullers

g n i h s u x r c a g m n 8 i p m a D

= EXTRACTOR STROKE = 2H+43 Y1 = height of the floating face of the puller E = cylindrical height of profile templates E≥H+9+5

0 = e k c o r t s r e l l u P

Size the punch cylindrical (edge height + 25 mm) outside pullers, represent the supporting surface of the pullers and size the cylindrical height on punch X > 2H + 43 + Y1 beside the pullers.

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GE24-080R

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In the case of very large edges leading to spring strokes > 120-160 mm or edges primed at α < 30° which fragilize pullers, it is best to separate the puller and centrer functions and actuate pullers using a double effect jack. 

the puller is actuated upwards from the bottom dead centre.



the puller must return to its low position before the arrival of the new part.

a<30°

Center

Extractor

5.4

Presser

1 1 + e k c o r t s r e s s e r P

Hold the panel using the presser with a ribbed plate. Principle forbidden for aspect parts.

If marking the part by the ribbed section is not admissible, change the process or product

High pressure

Ribbed Ribb Ribbe Ri bbed ed d plate plate

The The panel panel is swallowed by the the blade blade Simultaneous attack of the edges

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GE24-080R

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Presser stroke and load The stroke must be sufficient to ensure the presser holds the panel at 10 mm minimum before the blades touch the part, 25 mm if centrers - pullers. The clamping load must be sufficient to prevent the panel from sliding or buckling close to the working blades. The value of the load is determined preferably based on existing tools for a similar part. a) Refer to the tooling study of the reference tool. b) Determine in the plant whether pressure on the presser is considered correct and actually the one studied. In the absence of references, the load will be determined according to chapter 1. Presser recentring with lower part (see paragraph 2.2.4)

5.5

Part centring For most parts, the punch shape is sufficient to centre the part. In this case, install additional centrers: NOTE: for certain parts, it may be required to add profile templates for precentring (process individually) Fixed pilot in punching or opening 12 mm

Fixed profile template on edge already risen or trimmed "hole" type formed upon stamping the risen edge

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GE24-080R

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Mobile centrer on flanged edge Principle to be used exceptionally: prefer fixed centring on edge tip

Mobile centrer on puller (see § 5.3) Caution! Centring must be ensured until the part is clamped.

"Y" must exceed the distance travelled by pullers before presser contact.

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GE24-080R

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Centrer for part with a shape not ensuring centring: Adjustable Adjustable pilot Surface to adjust adjust

Cross-sectio Cross-section nA Cuttin Cutting g or flang flanging ing line line Have Have the the hole hole and and tab sorced sorced from from the trim trimmin ming g OP

Cuttin Cutting g rework rework profil profile e

Two tabs, with a triangular punch are created upon trimming. Part centring is performed by the pilot (adjustable) and then the tab is cut by the flanging down blade.

6

Materials NOTE: NOTE:

NOTE:

© RENAULT 2005

All the information concerning the materials is indexed by an asterisk (*): this means that the type of material is cited for information, and is defined by the EM24.01.100 standard and specific project standards. If the materials do not result from European standards, use materials with a quality exceeding that required. Beware compatibility with treatment and recharging, see Renault standard EM24.15.050 and EM24.15.100.


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GE24-080R

7

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Cambering Particular function of flanging down =

DANLY principle (Contact (Con tact the brand representative to validate particular cases)

CLAMPING Holding ensured

FOLD Lesser Lesser load load

OVERFOLDING Up to 120 120° °

Short edge Folding is required when the height of the edge is too low to be primed by the roller jaw.

Overfold

Folding has an angle between 90° and 120°. 120°. It is achieved by modifying the standard roller. The radius of the folding jaw remains constant with respect of the new angle tangent to this radius. Overfolding is ideal for spring or high hardness panels, and for preparing folds dropped at 180°.

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GE24-080R

8

Z at 90°

Folds frequent for DANLY cambering blades. blades. For Z folds, the panel’s thickness and height determine the diameter of the roller. A "pad" will sometimes be required to prevent the panel from buckling. We recommend a double-section anvil. Panel clamps or pilots can maintain the part’s stability during folding.

U

U and Omega folds are implemented with two DANLY cambering blades in a single press stroke.

Omega

Omega folds can be achieved in a single operation with two Z fold elements.

Large radius

Large radius folds, larger overfolding is required to compensate panel return. A larger roller diameter is required to roll the radius. Refer to DANLY to determine the anvil blank angle.

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Normative references for metallic materials cited in this document

© RENAULT 2005

Designation 270-480W

Reference document

42 CrMo4

standard EN 10083-1

T4 pre-treated steel

CNOMO standard E01.14.220.N

FGL 215HB


FGL 240HB


FGS 600-3A


G 50CrMo4


X 153CrMoV12

standard ISO 4957

standard ISO 3755


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GE24-080R

9

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List of documents cited NOTE

:

For non dated documents, the latest version is applicable.

ISO 3755 ISO 4957 EN 10083-1 E01.14.220.N E01.33.211.N E01.41.050.N

:

Tempered steel. Section 1: Technical delivery conditions for special steel.

:

Tool steel

:

Tempered steel. Section 1: Technical delivery conditions for special steel.

:

Bars in T4 pre-treated steel. Technical specifications.

:

Moulded steel G50CrMo4. Technical specifications.

:

Lamellar graphite cast iron. FGL 175HB. FGL 215HB. FGL 240HB. Technical specifications

E01.45.030.N :

Spheroid graphite specifications.

EM24.01.100 EM24.15.050 EM24.15.100 GE24-017R GE24-040R GE24-060R GE24-120R

:

Presentation of the basic offer and free offer in press tooling design

:

Materials used and associated surface treatment for press tooling.

:

Procedure for chrome-plating press tooling.

:

Press tooling. Miscellaneous master

:

Press tooling. General design guidelines

:

Press tooling. Stamping tools. Basics on design (Being written)

:

Design rules for press tooling for aluminium stamping

© RENAULT 2005

cast

iron

FGS


400-18A

and

FGS

600-3A.

Technical

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Flange Die

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