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A die is a specialized tool used in manufacturing industries to cut or shape material using
a press. Like molds, dies are generally customized to the item they are used to create.
Products made with dies range from simple paper clips to complex pieces used in
advanced technology.

Contents
[hide]

• 1 Die forming
o 1.1 Die components
o 1.2 Die operations and types
o 1.3 Steel-rule die
o 1.4 Rotary die
• 2 Wire pulling
• 3 References
o 3.1 Bibliography

• 4 Further reading

[edit] Die forming

Progressive die with scrap strip and stampings

Forming dies are typically made by tool and die makers and put into production after
mounting into a press. The die is a metal block that is used for forming materials like
sheet metal and plastic. For the vacuum forming of plastic sheet only a single form is
used, typically to form transparent plastic containers (called blister packs) for
merchandise. Vacuum forming is considered a simple molding thermoforming process
but uses the same principles as die forming. For the forming of sheet metal, such as
automobile body parts, two parts may be used, one, called the punch, performs the
stretching, bending, and/or blanking operation, while another part, called the die block,
securely clamps the workpiece and provides similar, stretching, bending, and/or blanking
operation. The workpiece may pass through several stages using different tools or
operations to obtain the final form. In the case of an automotive component there will
usually be a shearing operation after the main forming is done and then additional
crimping or rolling operations to ensure that all sharp edges are hidden and to add rigidity
to the panel.

[edit] Die components

• Die block
• Punch plate
• Blank punch
• Pierce punch
• Stripper plate
• Pilot
• Dowel Pin
• Back gage
• Finger stop
• Setting Block

[edit] Die operations and types

Die operations are often named after the specific type of die that performs the operation.
For example a bending operation is performed by a bending die. Operations are not
limited to one specific die as some dies may incorporate multiple operation types:

Press with bending die.

• Bending: The bending operation is the act of bending blanks at a predetermined

angle. An example would be an "L" bracket which is a straight piece of metal bent
 at a 90° angle. The main difference between a forming operation and a bending
operation is the bending operation creates a straight line bend (such as a corner in
a box) as where a form operation may create a curved bend (such as the bottom of
a drinks can).
• Blanking: A blanking die produces a flat piece of material by cutting the desired
shape in one operation. The finish part is referred to as a blank. Generally a
blanking die may only cut the outside contour of a part, often used for parts with
no internal features.
Three benefits to die blanking are:

1. Accuracy. A properly sharpened die, with the correct amount of clearance

between the punch and die, will produce a part that holds close dimensional
tolerances in relationship to the parts edges.
2. Appearance. Since the part is blanked in one operation, the finish edges of the
part produces a uniform appearance as opposed to varying degrees of burnishing
from multiple operations.
3. Flatness. Due to the even compression of the blanking process, the end result is a
flat part that may retain a specific level of flatness for additional manufacturing
operations.

• Broaching: The process of removing material through the use of multiple cutting
teeth, with each tooth cutting behind the other. A broaching die is often used to
remove material from parts that are too thick for shaving.
• Bulging: A bulging die expands the closed end of tube through the use of two
types of bulging dies. Similar to the way a chefs hat bulges out at the top from the
cylindrical band around the chefs head.

1. Bulging fluid dies: Uses water or oil as a vehicle to expand the part.
2. Bulging rubber dies: Uses a rubber pad or block under pressure to move the wall
of a workpiece.

• Coining: is similar to forming with the main difference being that a coining die
may form completely different features on either face of the blank, these features
being transferred from the face of the punch or die respectively. The coining die
and punch flow the metal by squeezing the blank within a confined area, instead
of bending the blank. For example: an Olympic medal that was formed from a
coining die may have a flat surface on the back and a raised feature on the front. If
the medal was formed (or embossed), the surface on the back would be the
reverse image of the front.
• Compound operations: Compound dies perform multiple operations on the part.
The compound operation is the act of implementing more than one operation
during the press cycle.
• Compound die: A type of die that has the die block (matrix) mounted on a punch
plate with perforators in the upper die with the inner punch mounted in the lower
die set. An inverted type of blanking die that punches upwards, leaving the part
sitting on the lower punch (after being shed from the upper matrix on the press
 return stroke) instead of blanking the part through. A compound die allows the
cutting of internal and external part features on a single press stroke.
• Curling: The curling operation is used to roll the material into a curved shape. A
door hinge is an example of a part created by a curling die.
• Cut off: Cut off dies are used to cut off excess material from a finished end of a
part or to cut off a predetermined length of material strip for additional operations.
• Drawing: The drawing operation is very similar to the forming operation except
that the drawing operation undergoes severe plastic deformation and the material
of the part extends around the sides. A metal cup with a detailed feature at the
bottom is an example of the difference between formed and drawn. The bottom of
the cup was formed while the sides were drawn.
• Extruding: Extruding is the act of severely deforming blanks of metal called
slugs into finished parts such as an aluminum I-beam. Extrusion dies use
extremely high pressure from the punch to squeeze the metal out into the desired
form. The difference between cold forming and extrusion is extruded parts do not
take shape of the punch.
• Forming: Forming dies bend the blank along a curved surface. An example of a
part that has been formed would be the positive end(+) of a AA battery.
• Cold forming (cold heading): Cold forming is similar to extruding in that it
squeezes the blank material but cold forming uses the punch and the die to create
the desired form, extruding does not.

Roll Forming Stand

• Roll forming: a continuous bending operation in which sheet or strip metal is

gradually formed in tandem sets of rollers until the desired cross-sectional
configuration is obtained. Roll forming is ideal for producing parts with long
lengths or in large quantities.
• Horning: A horning die provides an arbor or horn which the parts are place for
secondary operations.
• Hydroforming: Forming of tubular part from simpler tubes with high water
pressure.
• Pancake die: A Pancake die is a simple type of manufacturing die that performs
blanking and/or piercing. While many dies perform complex procedures
 simultaneously, a pancake die may only perform one simple procedure with the
finished product being removed by hand.
• Piercing: The piercing operation is used to pierce holes in stampings.
• Progressive die: Progressive dies provide different stations for operations to be
performed. A common practice is to move the material through the die so it is
progressively modified at each station until the final operation ejects a finished
part.
• Shaving: The shaving operation removes a small amount of material from the
edges of the part to improve the edges finish or part accuracy. (Compare to
Trimming).
• Side cam die: Side cams transform vertical motion from the press ram into
horizontal or angular motion.
• Sub press operation: Sub-press dies blank and/or form small watch, clock, and
instrument parts.
• Swaging: Swaging (necking) is the process of "necking down" a feature on a part.
Swaging is the opposite of bulging as it reduces the size of the part. The end of a
shell casing that captures the bullet is an example of swaging.
• Trimming: Trimming dies cut away excess or unwanted irregular features from a
part, they are usually the last operation performed.

[edit] Steel-rule die

Steel-rule dies, also known as cookie-cutter dies, are used to cut sheet metal and softer
webs, such as plastics, wood, cork, felt, fabrics, and cardboard. The cutting surface of the
die is the edge of hardened steel strips, known as steel rule. These steel rules are usually
located using saw-cut grooves in plywood. The mating die can be a flat pieces of
hardwood or steel, a male shape that matches the workpiece profile, or it can have a
matching groove that allows the rule to nest into. Rubber strips are wedged in with the
steel rule to act as the stripper plate; the rubber compresses on the down-stroke and on the
up-stroke it pushes the workpiece out of the die. The main advantage of steel-rule dies is
the low cost to make them, as compared to solid dies; however, they are not as robust as
solid dies, so they usually only used for short production runs.[1]

A steel-rule die
A steel-rule die
Steel-rule die in a press

[edit] Rotary die

In the broadest sense, a rotary die is a circular shaped die that may be used in any
manufacturing field. However, it most commonly refers to circular shaped dies used to
process soft webs, such as paper and cardboard. Two dies are used, one has cutting and
creasing rules, while the other acts as the anvil. Rotary dies are faster than flat dies, but
not as accurate.[2][3]

The term also refers to dies used in the roll forming process.[4]

[edit] Wire pulling

Main article: Draw plate

Wire-making dies have a hole through the middle of them. A wire or rod of steel, copper,
other metals, or alloy enters into one side and is lubricated and reduced in size. The
leading tip of the wire is usually pointed in the process. The tip of the wire is then guided
into the die and rolled onto a block on the opposite side. The block provides the power to
pull the wire through the die.

The die is divided into several different sections. First is an entrance angle that guides the
wire into the die. Next is the approach angle, which brings the wire to the nib, which
facilitates the reduction. Next is the bearing and the back relief. Lubrication is added at
the entrance angle. The lube can be in powdered soap form. If the lubricant is soap, the
friction of the drawing of wire heats the soap to liquid form and coats the wire. The wire
should never actually come in contact with the die. A thin coat of lubricant should
prevent the metal to metal contact.

For pulling a substantial rod down to a fine wire a series of several dies is used to obtain
progressive reduction of diameter in stages.

Standard wire gauges used to refer to the number of dies through which the wire had been
pulled. Thus, a higher-numbered wire gauge meant a thinner wire. Typical telephone
wires were 22-gauge, while main power cables might be 3- or 4-gauge.

[edit] References