General Motors Die Design Standards

GENERAL MOTORS
DIE DESIGN STANDARDS
Title Valid for No. Page

PROGRESSIVE DIES 80.00.aa 01 of 02
Sub-title Link to
INDEX
80.00 PICTORIAL INDEX

80.00.00 Pictorial Index
80.05 SAFETY
80.05.00 Safety Items
80.10 BILL OF PROCESS

80.10.00 Bill of Process
80.15 GENERAL INFORMATION

80.15.00 Definition of Progressive Die
80.15.05 Basic Design
80.15.10 General Die Space Information
80.15.15 Strip Layout and Processing
80.15.20 Typical Die Shoe Construction
80.15.25 Die Shoe Start Model
80.15.30 Die Storage Cylinders
80.15.40 Guide Pin and Heel Design
80.15.45 Pilot Pin Gaging
80.15.55 Non-pilot Gaging
80.15.60 Carriers and Stretch Webs
80.15.65 Forming Stiffening Beads
80.15.70 Stretch Web Flattening
80.15.75 Forming Offset for Blank Rigidity
80.15.80 Cast Die Shoe Construction
80.15.85 Cast Die Insert Construction z
80.20 TECHNICAL INFORMATION

80.20.00 Socket Head Cap Screw Retention Applications
80.20.05 Under Die Storage Blocks
80.25 LOWER DIE ASSEMBLY

80.25.00 General Information
80.25.05 Die Locator Hole Construction
80.25.10 Part Removal and Conveyor Setup
80.25.15 Scrap Removal
80.30 UPPER DIE ASSEMBLY

80.30.00 Mounting Irregular Shaped Punches
80.30.05 Ejector Pins for Non-standard Punches
80.35 PADS AND STRIPPERS

80.35.05 Guiding and Retaining Pressure Pads
80.35.06 Retaining Upper Pressure Pads
80.35.10 Shedder Pins in Pads
80.35.15 Pad Windows
80.35.20 Balance Blocks
80.35.25 Nitrogen Pads
Page: Implementation Timing: File Path:

1 gbl2edr17\80prog\80_00_aap1.cvx 10 JAN 11
GENERAL MOTORS

PROGRESSIVE DIES 80.00.aa 02 of 02
Sub-title Link to
INDEX
80.40 PRODUCTION REQUIREMENTS

80.40.00 Part Markers
80.40.10 Cut-off Station Supports (Option #1) - Preferred Method
80.40.15 Cut-off Station Supports (Option #2)
80.45 STOCK LIFTERS

80.45.05 Stock Guides
80.45.10 Pilot Support
80.45.15 Lift Rack Set-up Height
80.45.20 Coil Start/Feed Guide Assembly
80.45.25 Dies with Lifter Extending Over Lower Form Pads
80.45.30 Dies without Center Carrier
80.45.40 Lifter Rack Design for Progressive Dies ¨
80.45.45 Carrier Ribbon Support at Rear End of Lifter Rack
80.45.50 Dies Utilizing a Center Carrier
80.45.55 Set-up for Shock Absorber on Lifter Rack
80.45.60 Guidance, Air and Nitrogen Requirements for Lift Rack
80.45.65 Lifter Guide Shaft Assembly
80.45.70 Lift Rail Lock-up Pins
80.45.75 Blank Support - (Cam Slide)
80.45.80 Lift Rail Cross Bar Vibration Isolator Installation
80.50 PANEL ACCUMULATION

80.50.10 Category #1 Panel Accumulators
80.50.40 Panel Diverters
80.50.50 Electric and Pneumatic Schematics

2 gbl2edr14\80prog\80_00_aap2.cvx 23 DEC 09
GENERAL MOTORS

PROGRESSIVE DIES 80.00.00 01 of 01
Sub-title Link to
PICTORIAL INDEX
UPPER PRESSURE UPPER PAD

SHOE SYSTEM (UPD ##)
(USH)
LIFTER
PAD
STOCK
RETAINER
GUIDE
BAR
STOCK
STEEL
INSERTS
LIFT
RAIL
LOWER PAD
DIE SHOE WINDOW
(LSH)

3 gbl2edr14\80prog\80_00_00p1.cvx 23 DEC 09
GENERAL MOTORS

Sub-title Link to
SAFETY ITEMS
• The following listed 'SAFETY ITEMS' are found in this section:
Page Item Bullet Subject

01 80.15.20 All Maximum Die Weight
01,02 80.15.20 All Typical Die Shoe Construction !
02 80.15.30 All Die Storage Cylinder - Hot Surface Decal !
01,02 80.45.70 All Lift Rail Lockup Pins

4 gbl2edr15\80prog\80_05_00p1.cvx 24 MAY 10
GENERAL MOTORS

Sub-title Link to
BILL OF PROCESS
Normal Duty Heavy Duty Ultra Heavy

Item Condition Die Die Duty Die
Construction Construction Construction
Die Alignment
Guide Pins and Heels with
Double Wear Plates Yes Yes Yes
Lower Die Assembly
Cast Shoe with
Removable Lift Pins Yes Yes Yes
(4)-Gas Spring EQ and
Storage Cylinders Yes Yes Yes
(4)-Safety Pad Areas Yes Yes Yes
(4)-Stop Blocks Yes Yes Yes
Upper Die Assembly
Cast Shoe with
Removable Lift Pins Yes Yes Yes
(4)-Safety Pad Areas Yes Yes Yes
Pads and Strippers
HRS with Windows Yes Yes Yes
Draw Stations - Independent
Pad Yes Yes Yes
Elastomer Springs for
Cutting Stations 1st Choice Yes Yes
Nitrogen Springs for
Cutting Stations 2nd Choice Yes Yes
Gas Springs for Forming
Stations Yes Yes Yes
Guide Pins and Keeper Blocks Yes Yes Yes
Cutting Steel Inserts
Wire EDM Bar Stock Yes Yes Yes
Back-up for Unbalanced
Thrust Yes Yes Yes
Forming Steel Inserts
Bar Stock Yes Yes Yes
Cast Steels for Large Sections Yes Yes Yes
Back-up for Unbalanced
Thrust (Keys or Casting) Yes Yes Yes
Engineered Scrap
Drop-through 1st Choice 1st Choice 1st Choice
Chutes 2nd Choice 2nd Choice 2nd Choice
Panel Accumulation
In-die Panel Accumulation Yes Yes Yes
Maximum Pierce Material Thickness < 1.4 mm No No Yes z
Angle 10° Material Thickness > 1.4 mm No No No z

5 gbl2edr17\80prog\80_10_00p1.cvx 10 JAN 11
GENERAL MOTORS

Sub-title GENERAL INFORMATION Link to
DEFINITION OF PROGRESSIVE DIE
• A Progressive Die performs a series of sheet metal operations in a number of individual working stations
constructed as a single die. Each working station performs one or more distinct die operations such as
cutting, piercing, forming and flanging. The different die operations are performed as the coil fed sheet
steel progresses or moves from the first station through each succeeding station and produces a
completed part at the outgoing end of the die. As the sheet metal is fed through the die, it becomes a
continuous operation, producing parts at a rate of 20 - 40 sheet metal parts per minute depending on the
speed of the stamping press housing the die and the complexity of the part.
PROGRESSIVE DIE OPERATION
FLOW
STEEL COIL
PART AND
STRIP
PLAN VIEW
STAMPING PRESS
PULL ROLLS
FEED ROLLS
PROGRESSIVE DIE
COIL REEL FEEDER
PRESS ELEVATION

6 gbl2ed\80prog\80_15_00p1.cvx 18 AUG 05
GENERAL MOTORS

BASIC DESIGN
• Eliminate unnecessary use of:

Pocketed fitted steels
Keys to absorb thrust
Punch heeling
• Cast pressure pads are to be designed with window plates for ball-lock punches and developed trim in z
blanking station to provide die tryout and die maintenance accessibility.
• Only mount stamps and markers to pads if the pad bottoms. Otherwise, all stamps and markers will be
mounted on to a solid die member.
• Bottoming markers are to be installed on the 1st form cavity only, if part shape does not allow this the z
restrike cavity may be used.
• A partial mark is acceptable with management approval only. z
• Locate all identification markers in lower die assembly as close to the edge of coil as possible. If located
in the upper die, engineering approval required.
• Standardized die sensing has been incorporated.
• Stamp “R” & “L” identification on all parts running R & L hand parts together.
• Locate R & L identification markers in the lower shoe assembly.
• Design cutting steels for wireburn - EDM construction.
• Design dies for “slit coil” stock usage.
• Dies with cams to adhere to applicable provisions of cam die standards (section 75).
• Rotary benders for flanging:
- Rotary benders may be used for some specific progressive die flanging operations.
- Determination will be made during strip layout processing.
- Rotary benders will be treated as a deviation and will require engineering approval.
- The deviation must be recorded on page 3 of the die operational line up (DOL), in the “Deviations
Records” section.
• Serial number, die number and detail number must be engraved on all benders by the bender supplier.
• When ordering, the die construction source will provide the die number and detail number to the bender
supplier. The serial number will be issued by the bender supplier.
• Detail number and serial number must be recorded in the redbook/die buyoff book, in the punch and button
inventory section.
• To order replacement rockers or benders, the production facility must provide the die number, detail number
and serial number to the bender supplier.

GENERAL MOTORS

BASIC DESIGN
DO NOT BOTTOM OUT PRESSURE PADS FOR

PIERCING OPERATIONS PROVIDE WINDOW PLATES FOR PIERCE,
FLANGING AND FORMING PUNCHES.
USE RUBBER WINDOW PLATES WILL NOT BE WELDED TO
DIE SPRINGS PRESSURE PADS.
¨
BURN THROUGH BOILER

PLATE PRESSURE PAD.
AVOID PROGRAMMING
AND MACHINING AS SHOWN.
AVOID USING LONG PUNCHES AND

PILOTS (USE SPACERS AS SHOWN)
NOTCH STEELS TO AVOID

WEAKENING LIFT RAIL.
• For progressive die material requirement information refer to 85.00.40 page 02.

GENERAL MOTORS

PROGRESSIVE DIES 80.15.05 03 of 04 £
BASIC DESIGN
0.25
TRIM STEEL
FOR ALL STEELS WITH UNBALANCED THRUST CONDITION.
ADAPTER
TRIM STEEL
STOCK THICKNESS OVER 1.5
MACHINE KEYWAY TO STANDARD SIZE

1.2. - - - 25.4 OR 20 mm ETC.
OFFSET KEYWAY 0.25 mm
FIT KEY TO SUIT ASSEMBLY
USE STANDARD KEYS £

9 gbl2edr10\80prog\80_15_05p3.cvx 27 AUG 08
GENERAL MOTORS

£
BASIC DESIGN
• Pierce holes after forming stations to minimize developed hole locations.

• All holes that are related with a close position tolerance shall be pierced in the same station.
• Urethane strippers must not be used in progressive dies.
• All lower trim and pierce steels have 10 mm land and relief steel entrance.
• When punch steels blank through finished part or cutoff the part from the coil stock and are locked in the
die steels, enter the steels 20.0 mm to extend below the relief (ensures the part positively drops through).
• When the part is cutoff but not locked in the die steels, enter the cutoff steel 8.0 mm.
• The above entrances do not include shear. Shear must be added to all punch steels. See pierce die section
for information on shear requirements.
DIE BUTTON INSTALLATIONS

• Button retainer blocks are not to exceed 200.0 mm square for ease of removal from die to “knock out
buttons”.
• Die buttons must be used in all progressive die operations.
• If inadequate space restricts die button installation, add pierce plate inserts.
• A hardened spacer or backing plate may be added under die buttons and pierce plate inserts with
management approval.
PIERCE PLATE INSERTS

• Pierce plate insert thickness to be 30 mm minimum.
• Use 10 mm socket head cap screws and dowels.
• Provide minimum 10 mm part contact bearing area around the pierced profile geometry.
• Clear away any non-essential part to insert surfaces . Allow 3 mm clearance to part for maintenance
adjustment.
10 CONTACT AREA ALL AROUND
10.0 LAND
3 mm CLEARANCE
FOR ADJUSTMENT
HARDENED BACKING PLATE £

GENERAL MOTORS

GENERAL DIE SPACE INFORMATION
• For P-4000 & P-5500 progressive dies

• This sketch is meant to give the die designer a starting point for creating a die space envelope.
PAD 75 mm THICK FOR

BLANKING STATIONS ¨
WINDOW PLATE 110 mm DIE SPACE REQUIRED

25 mm THICK FOR PUNCH SETTING
10 mm GAP FOR REGRIND

OF DIE STEELS
BLANKING STEELS
50 mm THICK

GENERAL MOTORS

STRIP LAYOUT & PROCESSING
• Processing all strip developments are subject to General Motors approval prior to the start of die design. †
• The die and press timing to prove function with no stock movement shall be included on the strip layout and
the die operation lineup.
• Consideration must be given to minimize “No Stock Movement.”
• All strip layouts shall also include the plan view, elevation view, direction of feed, and any other view to
clarify the process and die conditions.
• Feed direction is from left to right, in CAD model.
• Identify each station with sequential numbers, e.g. Station 1, Station 2, Station 3.
• Show start line of strip avoiding loose scrap or part left on die.
• Dimension coil width and progression on strip layout.
• Design the strip layout in Unigraphics solids.
• Design math data will not reflect any die clearance.
• Strip layout with math data tipped to die position for all stations.
• For trimming and piercing:
Part shape shown on all dies will be punch shape.
Punch shape will be shown on all die steels with note stating, “Die clearance to be added”.
Don‘t construct additional geometry for die clearance and pressure pad to punch clearance. †

12 gbl2edr6\80prog\80_15_15p01.cvx 14 APR 07
GENERAL MOTORS

• (3) categories of accumulators †
CATEGORY #1
(1) AT A TIME
CATEGORY #2
(2) AT A TIME
END TO END
CATEGORY #3
(2) AT A TIME
ONE PART BEHIND THE OTHER †

GENERAL MOTORS

• All mismatch trim conditions must be shown on strip layout.

• For match cut information see GMDLS (Layout Standards) page 200.30.35. !

14 gbl2edr15\80prog\80_15_15p03.cvx 03 FEB 10
GENERAL MOTORS

• All notches shall be 6.0 mm wide minimum. ¨

• Carrier webs along coil edge for all progressive dies shall be 20 mm wide for material less than or equal to
1.0 mm thick.
• Carrier webs along coil edge for all progressive dies shall be 13 mm wide for material 1.1 mm thick and
above. ¨
• Consider punch and die geometry when splitting up notching. Machining, strength, punch fastening /
retaining, pressure pad integrity, and engineered scrap size and removal are primary factors to consider
when notching a progressive strip.
• DO NOT use pitch notches to size the coil.
• 3 mm minimum scrap on all retrimed panels.

GENERAL MOTORS

STRETCH WEBS
• Provide stretch webs between part and carriers when forming operations could cause distortion of
carrier web.
• Stretch webs except Dual Phase material to be 10 mm wide minimum. z
• Dual Phase material stretch webs to be 8 mm wide. z
• If stretch webs required - use (4) stretch webs per part (2 per side).
• All stretch webs must be verified during processing and must be able to support the part during the strip
feed cycle.
• Stretch web length must not be excessive and should always be in tension or stretch for stiffness.
• If possible design stretch webs to trail, ensuring the attachment area to carrier enters the pull-roll system
first.
• Stretch webs must not double over or create multiple metal thickness conditions within the pull-roll system.
• Stretch web control steels must be added to control stretch web geometry.
• When tipping panels less than 70° add beads to attachment webs in tip station.
• Consider adding beads to attachment stretch webs to improve panel to carrier stability during the strip
progression cycle.
PART
EXIT
OF DIE, PRESS
AND STRIP
DIRECTION
OF COIL FEED
• Strip showing stretch webs between part and outside carrier.

GENERAL MOTORS

• Strip showing stretch webs between center carrier and part and outside carrier. †

GENERAL MOTORS

TYPICAL SETUP FOR OUTSIDE AND †

CENTER CARRIER TIE
TO PROVIDE PART DROP THROUGH AT CUT-OFF AND CONTINUOUS LIFTER BAR
SENSE PART
OUT
DIRECTION OF COIL FEED PART EXIT
1) TYPICAL SETUP FOR

P4000 & 5500
2) IF COIL WIDTH
EXCEEDS 1000 mm,
CENTER CARRIER
PILOTS MUST BE
CONSIDERED IN
7.0 CONJUNCTION WITH
TYP. OUTSIDE CARRIER
PILOTS
34.0

GENERAL MOTORS

CATEGORY #2 PARTS WITH CENTER FLANGE GUIDE †

• When using a center flange guide, flare leading edge to facilitate pull roll entry and eliminate flange cut-off
station.
DIRECTION OF FLOW
A B
A B
10°
SECTION A - A SECTION B - B †

GENERAL MOTORS

• Provide cutoff steel for carrier webs in all dies for tryout.
• Upper scrap cutters will be removed after die buyoff and attached to lower die shoe for storage.
• Consideration must be given to distorted stretch webs to ensure transfer through the exit rolls and scrap
chopper.
• For material thickness less than 1.1 mm provide stiffening beads in side carrier ribbon or center z
carrier if applicable (see sketch).
• All carrier webs are required. 7.0 mm minimum dimensions must be maintained from edge of hole to inside
edge of carrier.
• Processing pilot and shedder locations must not be altered. Provide adequate material.
• For strips processed without beads, provide adequate material to accommodate shedders.
5.0
7.0 ALL CARRIER WEBS OPTIONAL CONSTRUCTION
CUTOFF FOR FEED CONTROL
UNIT BOTH SIDES OF STRIP 4.0
PROXIMITY SWITCH ON SIDE
OF OPERATOR ONLY
8.0 MINIMUM CENTERLINE OF

MICRO GAS SPRING NITRO SHEDDER
SHEDDERS MUST NOT 25°
CONTACT CARRIER NOTE:
STIFFENING BEADS IF SPACE IS NOT RESTRICTED VIEW A
DO NOT SUB-OPTIMIZE MATERIAL
IN THIS AREA
22.0 16.0 MINIMUM

TYP.
FLOW
EDGE OF COIL
3.0
10.0 mm PILOT HOLE

9.3 mm PILOT
VIEW A BEADS MUST EXTEND

PAST NOTCHING AREAS TYPICAL BEAD FOR SOLID
TO STIFFEN CARRIER ATTACHED CARRIERS
BEADS INTERRUPTED AT PILOT HOLE
(APPLIES ONLY IF BEAD IS NEXT TO
CONTINUOUS PART CUT-OFF TRIM LINE)
CARRIER BEAD
20.0 WEB FOR STOCK LESS THAN OR EQUAL TO 1.0 THICK.
13.0 WEB FOR STOCK 1.1 THICK AND ABOVE
15.0
1.0 R. FOR MATERIAL THICKNESS
LESS THAN 1.1 mm
1) PROVIDE STIFFENING BEADS IN

1.0 R. 2.0 SIDE CARRIER RIBBON OR
TO INSIDE CENTER CARRIER IF APPLICABLE
TYPICAL BEAD FOR RADIUS 2) PROVIDE STIFFENING BEADS IN
STRETCH WEBS WHEN APPLICABLE.
SIDE OR CENTER CARRIERS 3) FOR ALL DUAL PHASE MATERIAL
REDUCE BEAD HEIGHT TO 1.0 mm.

GENERAL MOTORS

• Processing to avoid aerial cams if possible. †

• Consider the following example or providing a bend ribbon in order to rotate part to pierce or forming
positions. This method does not always require larger stockwidth requirements.
FLOW
AERIAL CAM PIERCING SHOULD BE USED WHEN NO

OTHER PIERCE SOLUTION IS POSSIBLE
BELOW IS AN EXAMPLE OF HOW AERIAL CAM PIERCE

CAN BE AVOIDED. - - - - RESULTING IN LOWER DIE
COST AND MAINTENANCE.
PROVIDE ATTACHING RIBBON TO

ENABLE PARTS TO BE ROTATED TO
VERTICAL PIERCE POSITION.
THIS TYPE OF RIBBON CAN ALSO BE

FLOW USED FOR ROTATING PART FOR
BETTER FORMING CONDITION.
Y Z
TIP TO PIERCE DESIGN FOR MANUFACTURABILITY

POSITION REQUEST PRODUCT DEVIATION TO
SAVE MATERIAL COST

GENERAL MOTORS

REQUEST PRODUCT
CHANGE TO FINISHED
PART DURING STRIP
PROCESSING AND PRIOR
TO START OF DIE DESIGN
SOLUTION REQUIRES LARGER STOCKWIDTH ALTERNATIVE DOES NOT REQUIRE

ADDITIONAL MATERIAL
CIRCLE Y CIRCLE Z
32.0
WHEN USING HOLE FOR A PILOT ALLOW

32 mm CLEARANCE FROM CENTER OF
HOLE TO EDGE OF TRIM †

GENERAL MOTORS

• Longest downward flange to be on trailing end of part for minimum interference with lower die steels †
during part progression.
DIRECTION OF COIL FEED
A A
PART EXIT
IF POSSIBLE LONGEST FLANGE

SHOULD FOLLOW IN DIRECTION
OF PROGRESSION AS SHOWN
SECTION A - A
THIS ELIMINATES POSSIBLE PART

INTERFERENCE WITH LOWER DIE MEMBER
DURING THE STRIP PROGRESSION †

GENERAL MOTORS

• Scrap to overhang centerline of press bolster 25 mm maximum. †
BOLSTER
OPENINGS
25 MAXIMUM
SCRAP OVERHANG
FROM CENTERLINE
OF PRESS BOLSTER

GENERAL MOTORS

TYPICAL DIE SHOE CONSTRUCTION
• P-4000 Maximum die weight: Maximum upper tool weight 22,500 kg.
Maximum total tool weight 45,000 kg.
• Minimum length for large progressive dies is to be 3050 mm.
• Dies at minimum length must not exceed 907,000 kg (1000 US Tons) total slide tonnage due to slide balance !
considerations, when running in a P-5500 press.
• P-5500 Maximum die weight: Maximum upper tool weight 33,000 kg.
Maximum total tool weight 53,400 kg. !
• To initiate die shoe design - use latest GM supplied start model.
• All progressive dies to utilize lift pin handling. Refer to 15.30.00 and 15.30.05 for detailed information. !
• Lower die shoes shall be cast iron construction (G2500). Refer to section 85. !
• Upper die shoes shall be cast iron construction (G3500). Refer to section 85. !
• The minimum upper shoe thickness shall be 250 mm (engineering approval required for deviation).
• Use 4 Ø100 guide pins with double wear plates.
• Provide (4) stop blocks with 5 wide x 1 deep check groove for t-event verification, (4) safety pad areas, press
fastening, die locating, and storage devices for progressive die shoes as shown in start model.
• Die shoe corner configuration must not be altered without approval by GM engineering.
• Lower die shoe must be designed to cover all ribbing in the press bolster to avoid scrap laying on the
bolster.
• Additional gussets must be added directly behind each upper clamping slot.
• Additional ribbing must be added to the start model to comply with GM casting standards. These additional
ribs are to be relieved 50 mm from bolster level.
• Provide (3) keyways in base of upper die shoe per for alignment in turn-over device.
• Left rear guide pin and heel must be offset 20 mm for error-proofing, as shown in GM supplied die shoe
start model.
• All upper and lower die shoe walls and inner ribs to be 45 mm thick.
• Steels and adapters with unbalanced thrust must be backed with keys or casting. In conditions where
back-up is not required design 50 mm behind the steels and adapters for key provisions.
• Trimming, forming, piercing, and cutoff stations should be mounted on separate adapters for ease of
handling, construction, and tryout. Use M12 screws for fastening all trim, form, and flange steels, except
where thrust is encountered, then M16 screws are required.
• Provide (4) M24 tapped handling holes, 60 mm deep minimum, in all pressure pads. Maintain 75 mm radius
minimum clearance around center of tapped handling holes for hoist rings.
• The standardized shut height for all progressive dies shall be 1100.0 ±0.3 mm.
• Provide a 75 mm wide rib cast down to bolster (no relief) under 1st forming station, and restrike station.

GENERAL MOTORS

PROGRESSIVE DIES 80.15.20 02 of 02 ¨
TYPICAL DIE SHOE CONSTRUCTION
LIFT PIN LUGS TO BE TIED TO

OUTSIDE WALLS AND FLOORS

GENERAL MOTORS

PROGRESSIVE DIES 80.15.25 01 of 04 *
DIE SHOE START MODEL
TYPICAL PROGRESSIVE DIE SHOE START MODEL
D B C
A A
D B C
SECTION A - A
SECTION D - D SECTION B - B SECTION C - C

GENERAL MOTORS

PROGRESSIVE DIES 80.15.25 02 of 04 *
TYPICAL SECTION - DIE SHOE START MODEL
ADD ADDITIONAL RIBS PER

GM CASTING CONSTRUCTION
STANDARDS
RELIEF ADDED
PRESS BOLSTER RIBS 50 mm FROM
BOLSTER LEVEL
ADD ADDITIONAL RIBS PER

GM CASTING CONSTRUCTION
STANDARDS
LOWER DIE SHOE TO COVER
PRESS BOLSTER RIBS AS SHOWN
(DO NOT ALTER)

GENERAL MOTORS

PROGRESSIVE DIES DIE SHOE LENGTHS 80.15.25 03 of 04
Sub-title GENERAL INFORMATION 3.7 m TO 5.5 m Link to
• For die shoe lengths from 3.7 m to 5.5 m.

*
TYPICAL PLAN VIEW OF UPPER DIE SHOE FOR 3.7 m TO 5.5 m MODEL
TYPICAL ISO VIEW OF UPPER DIE SHOE FOR 3.7 m TO 5.5 m MODEL

GENERAL MOTORS

PROGRESSIVE DIES DIE SHOE LENGTHS 80.15.25 04 of 04 *
Sub-title GENERAL INFORMATION 3.7 m TO 5.5 m Link to
TYPICAL PLAN VIEW OF LOWER DIE SHOE FOR 3.7 m TO 5.5 m MODEL
TYPICAL ISO VIEW OF LOWER DIE SHOE FOR 3.7 m TO 5.5 m MODEL

GENERAL MOTORS

DIE STORAGE CYLINDERS
• To avoid damage to the die while in storage, balance the upper die shoe with nitrogen gas springs that
are large enough to support the weight of the upper die.
• Provide (4) areas for storage blocks in both P-4000 and P-5500 dies.
• Nitrogen cylinders to be sized to support the upper half of the die and stroke should be 5.0 mm longer
than the combined upper and lower pad travel that could cause an imbalance in the die.
• Nitrogen cylinders used for die storage blocks do not need to be hosed together.
• Do not use style base mount for storage applications.
• Use only 100 mm or 160 mm stroke cylinders. z
• Use 80% or less of available stroke. z
D
EA PA
+0
160.0
AR TY
-5
FE
SA
FOR ALL PAD TRAVELS

GENERAL MOTORS

DIE STORAGE CYLINDERS
• When nitrogen cylinders are utilized for die storage, a “Hot Surface” decal must be applied to the cylinder
body in a visible location as shown.
HOT SURFACE
DECAL

GENERAL MOTORS

GUIDE PIN & HEEL DESIGN
• Use standard straight guide pins.

• Engage heels 50 mm before start of work.
• Engage pin and bushing 70 mm from bottom of stroke.
• A minimum of 50 mm clearance between the upper and lower die components at the top of press stroke
must be maintained. (To facilitate carriage roll out with upper die mounted in press)
• Guide pin must bypass bushing by 5 mm minimum.
• See section 20 for guide pin and bushing fit.
0.05 MAX.
CLEARANCE
BETWEEN
PLATES
7.0
BYPASS
(REF.)
50.0 (REF.)
250
(REF.)
Ø 100
(REF.)
GUIDE PINS AND ALL WEAR PLATE

SURFACES MUST BE PARALLEL
AND PERPENDICULAR TO THE DIE
SHOE WITHIN 0.05 mm

33 gbl2ed\80prog\80_15_40p1.cvx 15 NOV 05
GENERAL MOTORS

PILOT PIN GAGING
• Pierce pilot holes in first station. Station 2 & 3 shall have pilots to establish progression.
• The number of pilots per station shall be determined on a strip by strip basis, at processing. Also, pilot use
in web and/or die is at engineering discression.
• Provide pilots in all form stations.
• Provide pilots in last station before cutoff.
• Progressive dies that have Ø9.30 mm pilots (pierce pilot holes at Ø10.0).
• Progressive dies that have Ø15.80 mm pilots (pierce pilot holes at Ø16.50 mm).
• Pilot holes should only be located in side carriers and/or center carriers.
• Pilot holes may be located in scrap areas of the blanking station if necessary.
• The strip area around each pilot hole must be supported by the lifter.
• Use standard pad mounted shoulder pilots 45 mm long or 70 mm long.
• Pilots mounted to the lower die are 1st choice from end of blanking station to end of die.
• Piloting of part is 1st choice from end of blanking station to end of die. !
• Pilot holes in finished part must be distortion free. Pilot holes must be re-pierced or blanked out to eliminate
distortion.

GENERAL MOTORS

PILOT PIN GAGING
• A mis-feed of the strip during set-up will cause a flanged hole. Therefore, the dimension of the clearance
hole should equal the sum of the pilot diameter plus twice the stock thickness to prevent die breakage.
• In some applications where above will weaken die steel, provide die clearance so that pilot will pierce slug.
This is more practical for thick stock thicknesses.
¨
25 DEEP
DIA. “A” = PILOT DIAMETER

+ 2 TIMES METAL THICKNESS

GENERAL MOTORS

PILOT PIN GAGING
STANDARD PILOT BLOCK (45 mm LONG PILOT) - INSTALLATION
• Location & relationship of shedders & pilots must not be altered.

• Micro-gas spring shedders must not contact carrier stiffening beads.
FORCE - 100N
(22 LBS) REF
Ø 20.0 TYP. DRILL THRU

CYLINDER CLEARANCE
IN PAD
10.0 WORK TRAVEL
5.0
REF.

GENERAL MOTORS

PILOT PIN GAGING
STANDARD PILOT BLOCK (45 mm LONG PILOT) - INSTALLATION (CONTINUED)
• All side guides at pilots must be machined as shown on sketch below.

• Side guides must be continuous through entire length of lifter excepts as shown below.
R10.0 FOR 10.0 mm PILOTS

R16.0 FOR 16.0 mm PILOTS
FROM CENTER OF PILOT
3.0
CLEAR.
REF. TYP.
R10.0
45.0° 1.0 TO CENTER !

OF PILOT
5.0
28.0
56.0
R6.0
15.0
REF.

GENERAL MOTORS

PILOT PIN GAGING
REVERSE MOUNT PILOT BLOCK (70 mm LONG PILOT) - INSTALLATION
• Typical pad mounted pilot for form station.

• Use this style pilot block when fastening area of block cannot extend inboard of carrier strip.
PAD
25.0
50.0
STOCK GUIDE
22.0 REF.

38 gbl2ed\80prog\80_15_45p05.cvx 27 OCT 05
GENERAL MOTORS

PILOT PIN GAGING
REVERSE MOUNT PILOT BLOCK (70 mm LONG PILOT) - INSTALLATION (CONTINUED)

• Typical pad mounted pilot in form station.
• Use spacer on this style pilot block when window exceeds 50 mm in height.
PAD
Ø 20.0 TYP.
SHIM PLATE CLEARANCE HOLE IN PAD
(DRILL THROUGH)
25.0
50.0
STOCK GUIDE
22.0 REFERENCE

GENERAL MOTORS

PILOT PIN GAGING
CENTER CARRIER - FLAT PILOT BLOCK INSTALLATION

• Pilot block for strips with center carrier pilot mounted to pad (option #1)
PAD
MOUNT BLOCK TO
UPPER PAD

GENERAL MOTORS

PILOT PIN GAGING
CENTER CARRIER - EXTENDED PILOT BLOCK INSTALLATION

• Pilot block for strips with center carrier pilot pocketed in upper pad (option #2)
PAD
MOUNT IN UPPER PAD

IF SPACE IS RESTRICTED
SHIM IF WINDOW EXCEEDS

FOR 70 mm LONG PILOTS 50 mm IN HEIGHT

GENERAL MOTORS

PILOT PIN GAGING
PILOTS & SHEDDERS MOUNTED IN PAD WINDOW PLATE

• Window plate clearance to side guide must be identical to pilot block & side guide set-up.
WINDOW PLATE
CONFIGURATION MUST
BE THE SAME AS PILOT
BLOCK AT SIDE GUIDE

GENERAL MOTORS

PILOT PIN GAGING
• Provide a machined ‘V’ groove for a strip start line on top of side guides. Stamp “STRIP START” and paint
red start lines on rack both sides, and on right hand side of all internal rack members. ¨
• Locate strip start line to prevent leaving loose scrap on the die steels or unsupported partial panels when
starting or finishing the coil.
• Deviations are to be approved by a General Motors representative and must be identified and painted red
on each die.
AVOID LOOSE PIECE OF SCRAP

PROGRESSION
INCORRECT
FLOW STARTING
POINT
SIGHT STOP FOR FIRST HIT

VIEW "A"
Z Z
PAINT RED 3
SEC Z - Z
VIEW A
ENLARGED VIEW

GENERAL MOTORS

NON-PILOT PIN GAGING
FOR PARTS WITH STRETCH WEBS

GAGE PART ON BOTH ENDS TO
LOCATE PART ACCURATELY GAGES
MUST BE MOUNTED TO UPPER PAD
A ONLY
10
CUTOFF STATION 0.35 CLEARANCE BETWEEN

15° MAX.
GAGE AND PART
SECTION A - A
CUT-OFF PUNCH TO ENTER

LOWER TRIM STEELS BY 15 mm
ALL PARTS WITH STRETCH WEBS
OF SOLID CARRIER
GAGE STRIP ON BOTH

ENDS TO LOCATE PART
ACCURATELY
GAGES MUST BE MOUNTED
TO UPPER PAD
FOR PARTS WITH SOLID CARRIER

WHERE PILOT CANNOT BE USED
IN CUT-OFF STATION
PART EXIT UPPER PAD

ON SOLID CARRIERS LOCATE
EDGE OF PILOT 1.5 TIMES
METAL THICKNESS FROM
PART CUTOFF - 3.0 mm MIN.
B
10
SOLID LOWER
0.35 CLEARANCE
BETWEEN GAGE AND 15°
CARRIER RIBBON MAX.
B
PILOT HOLE TOO CLOSE TO
EDGE OF CUT-OFF STEEL SECTION B - B

GENERAL MOTORS

PROGRESSIVE DIES 80.15.60 01 of 10 z
CARRIERS & STRETCH WEBS
DRAW OR FORM OPERATIONS USING LOWER & UPPER

PADS FOR HOLDING CARRIERS AT STRETCH WEBS
FLOW
SHAPE
OF UPPER
& LOWER
PAD
A A
STOCK
GUIDE
EDGE OF LIFTER RAIL
UPPER
ADAPTER
UPPER
PAD
LOWER
FORM
CLEAR LIFTER STEEL
RAIL IN LOCALIZED HOLDING
AREAS ONLY
5 mm SUPPORT MUST
BE MAINTAINED
LOWER PAD
LOWER ADAPTER
3.0 CLEAR REF.
5.0 MUST BE
MAINTAINED REF.
SECTION A - A

GENERAL MOTORS

HOLDING CARRIER STRETCH WEBS DURING DRAW OR FORM OPERATIONS

(CONDITION #1 & #2)
CUTOUT IN
LIFTER RAIL
16.5 FROM EDGE OF COIL (REFERENCE)
TO CENTER OF PIN
15.5 RADIUS
IN STOCK
GUIDE
Ø 25.0
20.0 (REFERENCE)
(REFERENCE)
3.0 CLEARANCE
REFERENCE
DETAIL VIEW
NOTE:
THIS SETUP MUST
STOCK NOT BE ALTERED
GUIDE SIDE GUIDE & LIFTER
(REFERENCE) MUST BE MAINTAINED
AS SHOWN
FLOW
B B
10.0
REFERENCE
EDGE OF LIFTER RAIL CUTOUT
PILOT CLEARANCE HOLE MAINTAIN 3.0 mm MINIMUM LIFTER SUPPORT FROM

IN LIFTER RAIL EDGE OF PILOT CLEARANCE HOLE TO INSIDE EDGE
OF ANY CUTOUT IN LIFTER RAIL
“DO NOT SLOT PILOT CLEARANCE HOLES”

GENERAL MOTORS

BOTTOMING LIFTER RACK AND HOLDING CARRIER

DURING DRAW OR FORM OPERATIONS WHEN FLEXING
STRETCH WEBS DOWN BELOW DIE LEVEL
(CONDITION #1)
• Length of holding pin to be determined in design.

• Pin retainer key must be mounted on back face of guide block or pad.
NOTE: HOLDING PAD PIN

ASSEMBLY CAN BE
MOUNTED IN UPPER
PAD OR SEPARATE
GUIDING BLOCK 30 kN NITRO CYLINDER
(MINIMUM)
VIEW “X”
UPPER Ø 35.0 HEAD

ADAPTER Ø 25.0 d8 VIEW “X”
BRONZE BUSHING
SANKYO OILLESS #
SOB-25-35-40
3 MIN. 2 - BUSHINGS STACKED
80
GUIDING BLOCK MATERIAL: 4140 Ø35.0 H7 UPPER
PRE-HARDENED (25-35 HARDNESS FORM
ROCKWELL “C” SCALE) STEEL
3.0 CHAMFER
HOLDING PIN
MATERIAL: 02
(57-62 HARDNESS
ROCKWELL ‘C’ SCALE)
CLEAR BEAD
IF NECESSARY
RADIUS
TO SUIT 16.5
(REFERENCE)
LOWER
FORM
STEEL
LOWER ADAPTER
3.0 OVERHANG
NOTE TO PIN CHAMFER
BOTTOM LIFTER RAIL 6.0 FROM EDGE OF
BELOW HOLDING PAD PIN PIN TO EDGE OF
(UNDERSIDE OF LIFTER MUST BEND (REFERENCE)
BE MACHINED)
SECTION B - B

GENERAL MOTORS

DRAW OR FORM OPERATIONS REQUIRING UPPER & LOWER

HOLDING PADS WHEN FLEXING THE STRETCH WEB ABOVE DIE LEVEL
(CONDITION #2)
• Pin retention key must be mounted on back face of guide block or pad.
• The lower holding pad must not contact the lifter rack when the lifter cylinders are exhausted and the lower
pad is still charged (typ. all pads).
NOTE
HOLDING PAD PIN ASSEMBLY CAN
BE MOUNTED IN UPPER PAD OR
SEPARATE GUIDING BLOCK
VIEW “Z”
VIEW “Z”
UPPER Ø 35.0 HEAD

ADAPTER Ø 25 d8 HOLDING PIN
MATERIAL: 02
(57-62 HARDNESS
BRONZE BUSHING
SANKYO OILLESS #
SOB-25-35-40
3 MIN. 2 - BUSHINGS STACKED
80 CLEAR PIN & RETAINER BLOCK
GUIDING BLOCK MATERIAL: 4140 FOR STRETCH WEB IF STRETCH
PRE-HARDENED (25-35 HARDNESS Ø35.0 H7
WEB EXTENDS UPWARD
ROCKWELL “C” SCALE) UPPER
FORM
3.0 CHAMFER STEEL
LOWER
FORM
STEEL
CLEAR
BEAD IF
4.0 MIN. NECESSARY
PAD UP
PIN
TRAVEL SEPARATE
16.5
+10 mm LOWER HOLDING
REFERENCE
PAD (MUST BOTTOM)
(TYPICAL) ALL
LOWER PADS
11.0
5.0 MUST BE
LOWER ADAPTER MAINTAINED
3.0 CLEAR
TRANSFER PIN TO
TYPICAL NITROGEN CYLINDER
HOLDING PIN SECTION B - B UPPER PRESSURE MUST BE
GREATER THAN LOWER PAD
(LENGTH TO SUIT) PRESSURE - 30 kN MINIMUM NITRO
PRESSURE ON LOWER PAD

GENERAL MOTORS

HOLDING CARRIER STRETCH WEBS DURING DRAW OR FORM OPERATIONS

(CONDITION #3)
CUTOUT IN
LIFTER RAIL
16.5 FROM EDGE OF COIL (REFERENCE)
TO CENTER OF PIN
15.5 RADIUS IN STOCK GUIDE
Ø 25.0
(REFERENCE)
3.0 CLEAR (REFERENCE)

C
EDGE OF LIFTER RAIL
Ø 20.0 PILOT
HOLE (REFERENCE)
DETAIL VIEW
20.0 NOTE
(REFERENCE) THIS SET UP MUST
NOT BE ALTERED
SIDE GUIDE & LIFTER RAIL
MUST BE MAINTAINED
STOCK AS SHOWN
GUIDE
(REFERENCE)
CUT RAIL TO 3.0

INBOARD OF CARRIER
FLOW
B B
10.0 EDGE OF LIFTER RAIL CUTOUT

(REFERENCE)
PILOT CLEARANCE HOLE MAINTAIN 3.0 mm MINIMUM LIFTER SUPPORT FROM

IN LIFTER RAIL EDGE OF PILOT CLEARANCE HOLE TO INSIDE EDGE
OF ANY CUTOUT IN LIFTER RAIL
“DO NOT SLOT PILOT CLEARANCE HOLES”

GENERAL MOTORS

BOTTOMING LIFTER RACK AND HOLDING CARRIER

DURING DRAW OR FORM OPERATIONS
(CONDITION #3)
• Pin retention key must be mounted on backface of guide block or pad.

• Where pins are too close together and two cylinders is not an option use a common plate to utilize one
cylinder.
NOTE
HOLDING PAD PIN
COMMON
ASSEMBLY CAN BE
PLATE
MOUNTED IN UPPER 30 kN NITRO CYLINDER
PAD OR SEPARATE (MINIMUM)
GUIDING BLOCK VIEW “Y”
UPPER
VIEW “Z”
ADAPTER
BRONZE BUSHING
3 MIN. SANKYO OILLESS #
SOB-25-35-40
2 - BUSHINGS STACKED
80
HOLDING PIN MATERIAL: 02
GUIDING BLOCK MATERIAL: 4140
(57-62 HARDNESS Ø35.0 H7 PRE-HARDENED (25-35 HARDNESS
ROCKWELL “C” SCALE)
LIFTER RAIL
Ø 25 d8 TYPICAL
MACHINE
LIFTER BOTTOMING
UNDERSIDE
BLOCK
OF RAIL
LOWER ADAPTER
SECTION C - C

GENERAL MOTORS

HOLDING CARRIER DURING DRAW OR FORM OPERATIONS

(CONDITION #3)
• If holding pads other than round pads are used, clearances in side guides and lifter rack must be
maintained as shown.
• Holding pad to side guide clearance must be identical to pilot block and side guide set up.
EDGE OF
LIFTER RACK
LOCAL PAD
SECTION A - A

GENERAL MOTORS

STRETCH WEB CONTROL STEELS
TO CONTROL STRETCH WEB GEOMETRY

AND TO AVOID MULTIPLE METAL
CONDITIONS WITHIN THE PULL ROLL
SYSTEM, DESIGN UPPER & LOWER
WEB CONTROL STEELS IN ALL
FORMING OPERATIONS WHERE WEB
DISTORTION MAY OCCUR
CONTOUR THE CONTROL STEELS

AS REQUIRED TO ATTAIN
UNIFORM & CONTROLLED
STRETCH WEB SHAPE 1.0 + METAL THICKNESS
GAP (SHOW IN DESIGN)
ACTUAL GAP DETERMINED
IN TRYOUT
SECTION A - A

GENERAL MOTORS

EXAMPLES OF TYPICAL ATTACHMENT WEB DESIGNS
BOW TIE FLEX WEB PART ROTATION WEB
DIRECTION OF COIL FEED
DOUBLE STRETCH WEB SOLID WEB

GENERAL MOTORS

CARRIERS AND STRETCH WEBS
BOW TIE FLEX WEB ATTACHMENT DESIGN REQUIREMENTS
f
e
h
VIEW X
VIEW X
a = 17 mm MINIMUM
b = 71 mm MINMIMUM WITH PILOT
OR
b = 17 mm MINIMUM WITHOUT PILOT
c = 2t + (GREATER a OR b)
e = 10 mm MINIMUM
f = 6 mm MINIMUM
g = 6 mm MINIMUM
h = 6 mm MINIMUM

GENERAL MOTORS

FORMING STIFFENING BEADS
• See 80.15.15 page 9 for additional information. !

8.0 TYP.
MUST BE MAINTAINED
ALL BEAD FORMING STATIONS
3.0
A A
OVERLAP
PROGRESSION
8.0
3.0
3.0 CLEAR CLEARANCE
NOT TO BE
ALTERED
ADAPTER
BOTTOMING
BLOCK
BOTTOM PAD DIRECTLY ABOVE
PAD BEAD (PROVIDE ADEQUATE
AMOUNT OF BOTTOMING BLOCKS
TO EQUALLY BALANCE PAD)
4.0 B
DETAIL B
LOWER
ADAPTER
SECTION A - A

GENERAL MOTORS

STRETCH WEB FLATTENING
STRETCH WEBS FLATTENING STANDARDS
DIE SHOE OR
MOUNTING BLOCK
¨
FLATTEN ANY STRETCH WEBS

EXCEEDING 50 mm IN HEIGHT 40 MINIMUM 5.0 GAP ¨
FOR TRAILING WEBS AND
25 mm FOR LEADING WEBS
EXTENDING EITHER UPWARD
OR DOWNWARD.
DEVIATION WITH APPROVAL
OF GENERAL MOTORS
REPRESENTATIVE ONLY.
SECTION A - A
STRETCH WEB
FLATTENING
BLOCKS
IF NECESSARY
REMOVE FLATTENING
STEELS TO MOUNT
TEMPORARY CARRIER
RIBBON CUTTING STEELS
A

GENERAL MOTORS

FORMING OFFSET FOR BLANK RIGIDITY
• If unable to provide continuous lifter support through the draw or form station, form offset to reduce blank
sag.
OPTION #1 OPTION #2
FORMING OFFSET WITH FORMING OFFSET WITH PAD
SOLID FORM STEELS
SOLID BOTT. BLOCK
PAD PAD PAD
WINDOW WINDOW
1.0
SOLID 1.0 SOLID OFFSET
OFFSET
IF POSSIBLE
LOCATE OFFSET
ON FEATURE LINE
IF POSSIBLE OF PART
LOCATE OFFSET
ON FEATURE LINE
OF PART

GENERAL MOTORS

- CAST DIE SHOE CONSTRUCTION
• Lower die shoe thickness 65 mm rough must be maintained.

• 100 mm finish where steels are fastened to shoe.
• 75 mm finish where backing plates are needed under steels.
A A
TRIM STEEL
LOWER SHOE
ADAPTOR
75 FINISH 100 FINISH 65 ROUGH
SECTION A - A

GENERAL MOTORS

• Upper die shoe thickness 65 mm rough must be maintained.

• 100 mm finish where steels are fastened to shoe.
• 75 mm finish where backing plates are needed under steels.
• Upper pads are to be retained with standard GM pad retainers.
• Upper shoe thickness to be minimum 37 mm in retention area.
UPPER SHOE
65 ROUGH 75 FINISH
37 MINIMUM
UPPER PAD

GENERAL MOTORS

• When large adaptors are not used in trim and pierce areas, trim and pierce steels to be backed up with local
adaptors (fragile sections only). Adaptors to be 25 mm thick.
TRIM STEEL
ADAPTOR
25
75 FINISH
65 ROUGH
LOWER SHOE
SECTION A - A

GENERAL MOTORS

• All thin punches and blade steels that cannot be fastened down toward shoe (80.30.00 page 3), must have
local adaptor plate 25 mm thick for backing steels to casting.
25

GENERAL MOTORS

• Form steel sections to be mounted in local cast adaptors for ease of machining and die repair.
• All adaptors to be backed up in direction of thrust as shown.

GENERAL MOTORS

• When trimming or piercing on one side of steel (retrim and pierce areas), deck area to be 87 mm thick with
75 mm finish to accommodate backing up of steels for thrust.
TRIM STEEL
87 ROUGH MINIMUM
75 FINISH
LOWER SHOE
SECTION A - A

GENERAL MOTORS

- CAST DIE INSERT CONSTRUCTION
• Cast die insert socket head screws and dowels must be 20 mm minimum from edge of machined pocket,
and on 20 mm grid pattern where possible.
• Do not increase steel size to accommodate 20 mm grid pattern for screws and dowels.
• See sections 15.25.60, 55.25.00 and 55.30.05 for additional information.
• See section 55.25.10 for additional information on wire EDM constructed die inserts.

GENERAL MOTORS

Sub-title TECHNICAL INFORMATION - SOCKET HEAD Link to
CAP SCREW RETENTION APPLICATIONS
• Progressive die stamping requires thread locker application to all socket head cap screws for all items listed
below:
1.) Attachment of all upper die members.
2.) Attachment of all accumulator components.
3.) Attachment of all plate type keepers. ¨
• Use loctite (blue) 243 thread locker - medium strength, oil tolerant, or equivalent.

GENERAL MOTORS

Sub-title TECHNICAL INFORMATION Link to
UNDER DIE STORAGE BLOCKS
• For use under progressive dies.

• Use Jolico J-20158 or equivalent.
• Provide 6 die storage block areas for progressive dies 4000 mm long or less. z
• Provide 8 die storage block areas for progressive dies over 4000 mm and up to 5500 mm long. z
• Areas to be provided for die storage block storage on die when not in use is required (see illustrations that
follow).
• Do not order storage blocks with die. z
DIE STORAGE BLOCKS
TYPICAL ON-DIE STORAGE FOR UNDER DIE STORAGE BLOCKS

GENERAL MOTORS

PROGRESSIVE DIES DIE SHOES 3.7 M 80.20.05 02 of 03
Sub-title TECHNICAL INFORMATION TO 4.0 M LONG Link to
UNDER DIE STORAGE BLOCKS
• Minimum six storage blocks required per die set (3 per side).
• Locate as shown below, with one block as close as possible to each lift lug area and one block in the clamp
slot next to the centerline of die.
BOTTOM VIEW
JOLICO #20158
OR EQUIVALENT

GENERAL MOTORS

PROGRESSIVE DIES DIE SHOES 80.20.05 03 of 03
Sub-title TECHNICAL INFORMATION OVER 4 M TO Link to
UNDER DIE STORAGE BLOCKS 5.5 M LONG
• Minimum eight storage blocks required per die set (4 per side).
• Locate as shown below, with one block on each side of the lift lug areas.
• All upper die shoes over 4000 mm long must have an “x” rib configuration as shown below.
BOTTOM VIEW
JOLICO #J-20158
OR EQUIVALENT

GENERAL MOTORS

Sub-title LOWER DIE ASSEMBLY Link to
GENERAL INFORMATION
• Do not use diagonal dowels.

• Inline dowels apply to all cutting and forming steels.
• When shape is symmetrical, offset one dowel 6.0 mm minimum - inline but offset to setup points for
foolproofing.
• Second choice is shown shaded.
• Keep dowels as far apart as possible.
• Use pull dowels on all progressive die details. Use jack screws for all details, pocketed on (3) sides or more.
• For ultra heavy duty die construction (GMW3399 AHSS material): Tapered relief is not permitted for all die
steels cutting contoured or shaped scrap in a closed section, subject to springback as created by a z
locked-in scrap condition within the die steel. Provide 1.5 mm straight relief.
15 MINIMUM ALL AROUND

FOR SCREWS AND DOWELS
WHERE POSSIBLE MAINTAIN 30 mm

MINIMUM WALL THICKNESS FROM
TRIM PROFILE TO EDGE OF TRIM STEEL
A A
6.0 OFFSET FOR

ERROR PROOFING
12
12
10 mm TO FOLLOW
CONTOUR OF PANEL
1.5 mm 1.5° OPTIONAL TAPERED RELIEF (NOT

RELIEF PERMITTED FOR ULTRA HEAVY DUTY
SECTION A - A DIE CONSTRUCTION.)

GENERAL MOTORS

PROGRESSIVE DIES 80.25.00 02 of 03 £

GENERAL INFORMATION
• Wall thickness requirements for screw and dowel locations
“X” “X”
FOR TRIMMING AND PIERCING
“X” = 15 mm
FOR FLANGING
“X” = 15 mm

GENERAL MOTORS

GENERAL INFORMATION
• Ball seat punches used for notching or forming should be self-heeled.

• The punches can be heeled against the lower die steel when it is not practical to split the lower steel in
order to add an aluminum bronze plate or block.
• Add a step on the punch steel in preference to raising the die steel level.
BURN THRU BOILER PLATE

PRESSURE PAD.
AVOID USING LONG PUNCHES

(USE SPACERS AS SHOWN)
NOTCH STEELS TO AVOID WEAKENING

LIFT RAIL.
AVOID POCKETING STEELS.

DESIGN PUNCH TRIM STEELS KEEPING
THEIR THICKNESS TO A MAX. OF 80 mm
IF POSSIBLE
• Pierce punch entrances to be staggered between 10 mm and 13 mm, in all ball lock pierce equipment.
• Ejector pins must be provided for all pierce punches, deviation with management approval.
• Cutting steel shear to be 1 mm per 100 mm of trim line - not to exceed 3 mm total - shear points to be !
determined at construction.
• Shear is acceptable on cutting steels for ultra high strength steel (dual phase and TRIP) only if there is
secondary trim. Developed trims will be staggered with no shear, due to work hardening.
• Break all cutting edge corners on all upper and lower cutting and piercing steels. Light stoning is required
after hardening.
• For dies running AHSS - cutting edge corners must be stoned to attain approximately 0.1 Radius.
• For all new dies - welding of trim, pierce, form or draw steels is not permitted.
!

GENERAL MOTORS

PROGRESSIVE DIES GME 80.25.05 01 of 02
DIE LOCATOR HOLE CONSTRUCTION
• For use with “Bullet” type pin locators.

• For new construction in all GME progressive dies. ß
Ø 56.00 H12
5
125
(MINIMUM)
10 x 45°
CHAMFER
10 x 45°
10 CHAMFER
10
155.0
(MINIMUM)
100 100
+0.300
H12 FOR 56.00 NOMINAL DIAMETER = 56.000 - 0.000

GENERAL MOTORS
Title Valid for No. Page ß

STANDARD COMPONENTS GMNA - NEW & 80.25.05 02 of 02
Sub-title PROGRESSIVE DIES
REPAIR Link to
GME - REPAIR ONLY
DIE LOCATOR HOLE CONSTRUCTION
• For repair of “Bullet” type pin locator holes for GMNA and GME progressive dies.
• For new construction in GMNA progressive dies only.
+0.10
Ø100 -0.00 90.80.500
DIE LOCATOR
Ø 56.00 H12 HOLE REPAIR FLANGE
5
125
(MINIMUM)
10 x 45°
10 CHAMFER
10
162
155.0
(MINIMUM)
100 100
+0.300
H12 FOR 56.00 NOMINAL DIAMETER = 56.000 - 0.000

73 gbl2edr9\90std\80_25_05p2.cvx 04 APR 08
GENERAL MOTORS

PART REMOVAL & CONVEYOR SETUP
• Part out - Telescoping conveyor through press column, and over bolster is part of press system.
No auxiliary in die conveyors are to be utilized.
• Conveyor recess - At part exit end, across width of die, cast a continuous relief, 225 mm high, 100 mm deep.
No other surfaces, devices or part chutes to extend into this area.
• Conveyor stops - Provide 3 finished bosses 200 mm high x 150 mm wide x 15 mm thick. Outer most bosses
to be no more than 2200 mm apart.
• Controlled part exit is critical for consistent placement onto the telescoping exit conveyor.
• Each die must be evaluated at tryout and buyoff for proper part exit and part-out chutes revised if necessary.
• Part-out chutes must end 225 mm above the bolster minimum, and may not extend beyond the end of the
lower die shoe.
• Refer to regional press standards.
RIBBON
SUPPORT
TABLE
25°
MIN.
865 MAX.
630 MIN.
225
100
BOLSTER / DIE CART
SCRAP CHUTE
25° MIN.
ANGLE
100
25 mm
225
EXIT CONVEYOR
FINISHED BOSSES
ENLARGED VIEW

GENERAL MOTORS

PART REMOVAL & CONVEYOR SETUP
• For progressive dies running in P4000 and P5500 presses.
• Stainless steel half round stock 12 mm diameter.
• Locate as Required.
• Tack weld to chute.
• Tack welds to be 150 apart maximum.
• GM approval required for part exit chute angles less than 25°.
• Add hardened plates to high wear areas of part exit chutes.
• Cast depression with sheet metal cover is 1st choice for sensor wire routing. ¨
• Raised sheet metal cover only is 2nd choice for sensor wire routing. ¨
PART EXIT CHUTE
PART CHUTE ALLOWABLE

ANGLE - 25° MINIMUM
CHUTE TO BE MADE FROM 3.0 mm THICK STEEL STAINLESS STEEL

SHEET METAL. RIGIDTEX MAY BE USED WHEN HALF ROUND STOCK
CHUTE IS LESS THAN 25° BUT AT LEAST 20°. 12 mm DIAMETER ¨
(SEE 55.40.10 PAGE 13)
SECTION A - A

GENERAL MOTORS

SCRAP REMOVAL
• Drop through methods are first choice.

• Cast scrap chute angle to be 60° minimum.
• Sheet metal scrap chutes to be last choice.
• Sheet metal chutes must be removable.
• No open cores allowed in scrap areas.
• Scrap shedding is critical, no scrap hang-ups are permissible.
• Scrap shedding must be verified at tryout and buyoff by a General Motors Representative.
• Whenever possible lower shoe scrap openings must accommodate a 360° plan view scrap rotation.
60° MIN.
10
MIN.

GENERAL MOTORS

Sub-title UPPER DIE ASSEMBLY Link to
MOUNTING IRREGULAR SHAPED PUNCHES
STANDARD BALL LOCK CHOICE 1 & 2 CHOICE 3 & 4

38
25
RETAINER 50 (REFERENCE) (REFERENCE)
32
85 110
90
60 70
44 40
25
WINDOW
PLATE
11 10 13
APPROXIMATE APPROXIMATE APPROXIMATE
FASTEN TO SUBPLATE 20 (REFERENCE) 38 (REFERENCE) z
70
50
120
75 110
100
40 40 40
10 10
APPROXIMATE APPROXIMATE
CHOICE 6 CHOICE 7 & 8 CHOICE 9 z
SET-UP FOR BLANKING STATIONS

DENOTES CLEARANCE TO SET PUNCHES

GENERAL MOTORS

PUNCH RETAINER
SPACER
DO NOT USE COMMON SCREW AND DOWELS

THRU STANDARD RETAINERS AND SPACERS
SCREW AND DOWEL PUNCH

HOLDER TO BACKING PLATE
Ø 12
USE 10 mm SCREWS AND
DOWELS ALL APPLICATIONS
DOWEL THRU TO ENABLE

WIRE EDM OF PUNCH
SHAPE & DOWELS.
NOTE: DOWELS ARE 80 mm LONG

GENERAL MOTORS

• Below are seven examples of how to mount irregular shaped punches in order of preference.
1ST CHOICE 2ND CHOICE
PREFERRED METHOD OF MOUNTING

IRREGULAR SHAPED PUNCH
DOWEL THRU TO ENABLE
SCREW & DOWEL TO WIRE EDM OF PUNCH
BASE OR SPACER SHAPE & DOWELS
SET UP
SET UP POINT
POINT
70 70
DO NOT BURY DO NOT BURY
UNDERNEATH PUNCH UNDERNEATH PUNCH
SUFFICIENT WALL THICKNESS FOR HEAD OF INSUFFICIENT WALL THICKNESS FOR HEAD OF SCREWS
SCREW S & DOWELS TO THE EDGE OF THE STEEL BUT SUFFICIENT FOR SCREW THREAD AND DOWELS
3RD CHOICE 4TH CHOICE
WIRE CUT BOTH THE WIRE CUT BOTH THE

PUNCH AND RETAINER PUNCH AND RETAINER
SET UP
POINT
SET UP
POINT
ALWAYS SCREW AND DOWEL

ALWAYS SCREW AND DOWEL 85
FROM BACK AS SHOWN
FROM BACK AS SHOWN
32.0 PUNCH HOLDER RING TYPICAL
85
INSUFFICIENT WALL THICKNESS FOR SCREW AND INSUFFICIENT WALL THICKNESS FOR HEAD OF SCREW
DOWELS BUT SUFFICIENT FOR HEADS OF SCREWS BUT SUFFICIENT FOR SCREW THREAD AND DOWELS

GENERAL MOTORS

5TH CHOICE 6TH CHOICE
PREFERRED CONSTRUCTION
WIRE CUT BOTH THE
PUNCH AND RETAINER ALTERNATIVE CONSTRUCTION
SET UP
POINT 70
120
SET UP
POINT
RADIUS
50
M16 FLAT POINT
SET SCREW 100
INSUFFICIENT WALL THICKNESS FOR SCREW THREAD
HOLE IN PUNCH TO
USE THIS STYLE OF BLADE PUNCH HOLDER
BE DOWEL SIZE
WHEN PUNCH SHAPE IS SIMPLE TO MACJINE
USE A DOWEL TO RETAIN PUNCH
12.0 mm MINIMUM DOWEL SIZE
7TH CHOICE
WIRE CUT BOTH THE

PUNCH AND RETAINER
M16 x 2 - 12 mm LONG HOLE IN PUNCH TO
FLAT POINT SET SCREW BE DOWEL SIZE
2- REQUIRED 12.0 mm MINIMUM DOWEL
SIZE REQUIRED
LOCK IN USING A M16
FLAT POINT SET SCREW
SET UP POINT FROM BOTH SIDES OF
25 RETAINER
FOR DOWEL APPLICATION

THIS DIMENSION TO BE
50 mm MINIMUM 100
• If blade punch exceeds 150 mm in length, 2 dowels are required.

GENERAL MOTORS

Sub-title UPPER DIE ASSEMBLY - EJECTOR Link to
PINS FOR NON STANDARD PUNCHES
• Deviation with management approval.

• Ejector pins must be added to all trimming and piercing operations - and all standard and GMSP direct ¨
pierce punches.
• 2 ejector pins minimum required for punches over 100 mm in length.
TYPICAL EJECTOR PIN APPLICATIONS
NARROW COMMON HEELED CLOSELY SPACED

BLADE PUNCH SHOULDER PUNCH NOTCHING PUNCHES BLADE PUNCHES

GENERAL MOTORS

Sub-title PADS AND STRIPPERS Link to
GENERAL INFORMATION
• The travel for each pressure pad is independent from the other pads in the die. The lifter system is
depressed by upper nitrogen cylinders making it unnecessary to travel all pads the same distance.
• Blanking pad travel must be equal to longest vertical pad travel in die. ¨
• Each draw station shall have independent pressure pads for binders.
• Pressure pads shall be 75.0 mm minimum thickness.
• Flame-cut clearances for plate pressure pads and cast clearances for cast pads is first choice. Provide
10.0 mm minimum clearance around all details.
• Machine clearances in pressure pads is second choice. Provide 3.0 mm minimum clearance around all
details.
• Do not create weak pad conditions or safety concerns by adding pad retaining screws and dowels to thin
wall sections.
• No local bottoming of pressure pads and strippers (including stamp markers).
• If pad bottoming is required - bottom entire pad equally.
• Individual GMSP stripper assemblies (Moeller or equivalent) may be used for certain cam and aerial cam
applications. Usage for any special direct pierced holes must be approved by General Motors.
(For technical information refer to section 90.60.40p1)
10.0 mm MIN. FLAME-CUT OR CAST

CLEARANCE - FIRST CHOICE.
3.0 mm MIN. MACHINED CLEARANCE.
SECOND CHOICE.
75.0
MIN. 2 mm SHEETMETAL
GUARD

GENERAL MOTORS

GUIDING & RETAINING PRESSURE PADS
• Use guide pin bushings for all upper progressive die pressure pads with upper pilots - do not use pressure ¨
pad bushings.
• All other pads to use standard pressure pad bushings.
• Guide and retain pressure pads with guide pins and 90.80.105 pad retainers, first choice.
• Use flat plate keepers and guide blocks with 3 screws minimum, as second choice. ¨
• Pressurize pressure pads for cutting stations with fiber-belted rubber die springs.
• Pressurize pads for forming and flanging stations with nitrogen gas springs.
• Use a maximum of 25% compression for fiber-belted rubber die springs.
• Use of any other type of a guiding or retaining must be approved by a General Motors representative.
• Use guide blocks for thrust not heeled internally only.
• All guide blocks must be backed by casting or keys. ¨
• Plate keeper design for lower pads and upper pads with very long travels.
• Apply thread locker to all keeper plate screws. (See 80.20.00) ¨
FOR KEEPER & GUIDE BLOCK

APPLICATIONS - PROVIDE TWO
¨
DOWELS IN PAD AND SUB PLATE
TO ENABLE SETTING OF BLOCKS
B
USE GUIDE BLOCKS
FOR THRUST NOT
HEELED INTERNALLY.
BACKUP OR KEY. ¨
¨
0
13.5 +.25/-.0 TYP
0
B (SEE SHT. #2)
PLAN VIEW OF TYPICAL STRIPPER
WITH FLAT PLATE RETAINERS ¨

GENERAL MOTORS

• Press fit guide pins, - 50 mm diameter minimum. Use guide pin bushings. ¨
• 4 pins per pad required. (Deviations must be approved by a General Motors representative.)
• Use optional construction only when die conditions will not permit use of preferred construction.
SECTION B - B
PREFERRED CONSTRUCTION
GUIDE PIN PRESSED INTO ADAPTER PLATE
SECTION B - B
OPTIONAL CONSTRUCTION
GUIDE PIN PRESSED INTO PAD

GENERAL MOTORS

• 2nd choice flat plate keepers on a cast boss. ¨
A A
5 MINIMUM
KEEPER PLATE ¨
MIN. 10
KEEPER PLATE
OVERLAP
SEE 90.80.225
2.0 MAX. CLEARANCE

M16 SCREWS ¨
SECTION A - A

GENERAL MOTORS

PROGRESSIVE DIES UPPER PRESSURE 80.35.06 01 of 02
Sub-title PADS AND STRIPPERS PADS Link to
RETAINING UPPER PRESSURE PADS
• Preferred retaining method for retaining upper pressure pads only. ¨

• Use M12 x 50 long screws if attached to steel and M12 x 60 long screws if attached to casting.
• For pressure pads up to and including 1200 mm in length or width - use a minimum of 4 pad retainers.
• For pressure pads over 1200 mm in length or width - use a minimum of 6 pad retainers.
• Placement of keepers to be determined at design. ¨
X = PRESSURE SYSTEM
TRAVEL + 5
+5
15 -0 2.5 x 45° CHAMFER
13 A
M12 SOCKET
HEAD SCREW
UPPER
ADAPTER
37
MIN.
UPPER
PRESSURE
PAD +1 25 MIN. STEEL
3 -0 37 MIN. CAST
¨
5
5
R5
ALL X
3 REF. 2.5 x 45°
AROUND
CHAMFER
5
SANKYO
PD-16
+1
3 -0
SECTION A - A A

GENERAL MOTORS

PROGRESSIVE DIES UPPER PRESSURE 80.35.06 02 of 02
Sub-title PADS AND STRIPPERS PADS WITH LONG Link to
RETAINING UPPER PRESSURE PADS TRAVELS
• For alternate retaining of upper pressure pads with long travels only.
• Use M12 x 50 long screws if attached to steel and M12 x 60 long screws if attached to casting.
• For pressure pads up to and including 1200 mm in length or width - use a minimum of 4 pad retainers.
• For pressure pads over 1200 mm in length or width - use a minimum of 6 pad retainers.
• Placement of keeper to be determined at design. ¨
UPPER SHOE
X = PRESSURE SYSTEM
TRAVEL + 5
CAST RELIEF
IN SHOE
5
+1
35 3 -0
MIN.
SANKYO
PD-16
R5
5
2.5 x 45° X 3 REF.
ALL
CHAMFER AROUND
5
+1
25 MIN. STEEL
5
37 MIN. CAST
3 -0 ¨
UPPER
37 ADAPTER
MIN.
UPPER
PRESSURE
PAD
M12 SOCKET
HEAD SCREW 13
A
2.5 x 45° CHAMFER +5
15 -0
SECTION A - A

GENERAL MOTORS

SHEDDER PINS IN PADS
INTERNAL PART SHEDDERS
• Shedder must be added to all internal die stations (2) per part per station.
• Use micro-gas spring for internal shedder applications.
• Usage of longer stroke shedders will be determined at die buyoff or at plant tryout events (with management
approval only).
• Additional clearance holes will be provided for all die internal front blanking station shedders only, excluding ß
pilot block locations.
ADDITIONAL DEPTH
CLEARANCE HOLE
REQUIREMENT
DRILL AND TAP

UPPER M16 x 1.5 THREAD
NITRO PAD 45 mm DEEP
10.0 DEEP
LOWER
FORM STEEL

GENERAL MOTORS

PADS WINDOWS
• Provide windows in cast pads only for ball-lock punches and developed trim at all working stations. z
Windows shall be 25 mm thick minimum. Windows that contact the coil at die line shall be 25.00 ±0.25 mm
thick. Fasten all windows with M12 socket head cap screws.
• Use M12 tapped dowels on all windows.
• Pressure pad window clearance to punch to be 70% of metal thickness, constant. z
• Pad construction will be G3500 cast, with 40 mm thick and 75 mm tall outer wall. All inner ribs and deck will z
be 30 mm thick.
• Pads will be cast without windows where practical. z
DO NOT BOTTOM PRESSURE PAD

STRIPPER ON PUNCH
RETAINER
OVER 5.0 mm WINDOW
Ø M12
25.0
SCREW
MINIMUM
DIE BUTTON
5 MINIMUM
HARDENED
SPACER

GENERAL MOTORS

BALANCE BLOCKS
• Provide (4) Ø 40 mm balance blocks between each pressure pad and lower adapter. ß
• Material for blocks - ISO 683/1 - 43CrMo54 (pre hardened 25-35 HRC) ß
PRESSURE PAD
Ø 40 BALANCE ß
BLOCK
ADAPTER
PAD BALANCE BLOCK ß

CLEARANCE = 0.2 mm
WITH STRIP IN DIE

GENERAL MOTORS

NITROGEN PADS
• All pad extensions are to be mounted to the pad directly with 2 - M16 x 50 long socket head cap screws. ¨
• Riser base to be 125 x 125 minimum, and base to height ratio of 2 to 1 maximum. ¨
• Risers to be fastened with 4 - M16 x 50 screws and tack welded. ¨
Ø 95.0
Ø 76.0 REFERENCE
LOWER PAD
LOWER ADAPTOR
LOWER SHOE
LOCTITE
GMGDS 90.80.100-XX SCREWS AT
LENGTH NOT TO ASSEMBLY
EXCEED 100 mm
RISER REQUIRED TO
KEEP PAD EXTENSIONS
AS SHORT AS POSSIBLE
TACK WELD ¨
THESE SCREW
HEADS ONLY
WELD ALL
AROUND
FOR ADDITIONAL
INSTALLATION ¨
INFORMATION
(SEE 25.40.20 PAGE 01) M16 x 50 SCREWS
(TYPICAL LOWER PAD EXAMPLE SHOWN) REQUIRED - LOCTITE
SCREWS AT ASSEMBLY

GENERAL MOTORS

Sub-title PRODUCTION REQUIREMENTS Link to
PART MARKERS
• Locate identification markers on the right side in the lower shoe assembly as close to the edge of coil as
practical.
• If marker must be placed in upper shoe assembly, engineering approval is required.
• See local supplement for ordering information.
• Stamp removal is to be done with the lifter in the up position.
BEND AND SHORTEN

HANDLE TO SUIT AT
ASSEMBLY
LIFTER UP POSITION
DO NOT CLEAR AWAY VERTICAL

FLANGE OF LIFTER RAIL WITHOUT
ENGINEERING APPROVAL

GENERAL MOTORS

PART MARKERS
“R & “L” Part Markers

• Stamp “R” & “L” identification on all parts running R & L hand parts together
• Locate identification marker in the lower shoe assembly.

GENERAL MOTORS

CUT-OFF STATION SUPPORTS - (OPTIONAL)
• Preferred Method
• Addition of air slides to support panel into cut-off station (option #1). - Preferred method
A A
* IF POSSIBLE MOUNT SLIDE AT THIS LOCATION TO WORK IN DIRECTION OF FLOW
ADD EXTENSION SUPPORT

TO END OF SLIDE
(LENGTH TO SUIT)
AIR ACTUATED
LAST STATION
SUPPORT
SECTION A - A

GENERAL MOTORS

CUT-OFF STATION SUPPORTS - (OPTION #2)
• Addition of air slides to support panel into cut-off station (option #2).
A A
ADD EXTENSION SUPPORT

TO END OF SLIDE
(LENGTH TO SUIT)
AIR ACTUATED
LAST STATION WELD TO LIFTER RAIL
SUPPORT
SECTION A - A

GENERAL MOTORS

Sub-title STOCK LIFTERS Link to
GENERAL INFORMATION
• Lifter rack design is subject to General Motors approval.

• Lifter rack design is to be used for all progressive dies.
• All racks will be welded construction.
150 x 150 x 12 continuous side rails
150 x 200 x 12 continuous side rails may be used for panels with extreme part depths ¨
75 x 75 x 12 end rails (80 x 80 x 10 - optional construction)
Internal structural angle iron or cold rolled steel bars as required
Round bars to be Ø 16 minimum.
Maximum weight of P4000 lifter rack assembly is 650 kg
Maximum weight of P5500 lifter rack assembly is 950 kg
• Hose all lifter cylinders together to a surge tank. Use standard 16 mm O.D. hosing of equal length for each
cylinder. See section 40.20.25 for installation information. ¨
• Upper nitrogen cylinders for depressing lifters are hosed together to one control panel.
• Support the blank and/or part in each station to avoid transfer problems due to sagging.
• Lifter assembly must be stress relieved after welding.
• All welds must be continuous - to ensure integrity.
• Lifter rack must be painted yellow.
• Lifter rack must allow strip to auto thread and auto feed without any assistance. The following information
must be stenciled on both sides of the lifter rack. Use 25 mm high figures, 20 mm spacing, paint black. ¨
- Tool Number
- Lifter travel
- Shock absorber setting (Lifter travel - 45 mm)
- Progression ¨
- Shut height ¨
- Rack weight ¨
• Lifter travel should be designed to ensure that part to lower die steel clearance is 25 mm to the highest
interference point.
• Lifter travel to be 50 mm minimum.

GENERAL MOTORS

GENERAL INFORMATION
• Provide angle iron welded supports at the feed side of the die to support the coil, with adequate lead in.
• The lifter rack shall have air cylinder pressure system, guiding, retaining and handling provisions at all four
corners. Refer to the following sketch for design specifications.
• All dies with center web are to have a continuous center carrier on lifter.
• The lifter in each station and between stations must support the blank and part to avoid sagging and part
transfer problems.
• Integrity of the main (side) angle iron rails must be maintained, clear lower steels to avoid rail cutouts.
• All welded lifter bar supports should be bridged whenever possible (not cantilevered).
• For lifter strip support bars subject to wear due to abrasion caused by part geometry during the strip transfer, £
use ISO 683/1 - 42CrMo4, induction harden to 58 - 62 HRc.
FLOW
A
W
SECTION A-A

97 gbl2edr10\80prog\80_45_00p2.cnv 27 AUG 08
GENERAL MOTORS

STOCK GUIDES
• The stock guides on the left side shall be doweled at tryout with Ø8 dowels.
• All stock guides shall have adjustable slots. Adjustment will start when guides are set to nominal position
and adjusted outward from centerline of die.
• Keep lead angles all around the front and rear of all stock guides as shown.
• Stock guides must be continuous, except dies with AHSS material: Break stock guides for 100 mm at end of z
blanking station, both sides of strip.
• Add 3rd screw fastening if length is greater than 300 mm.
• Maximum length of stock guide to be 500 mm.
• Material - ISO 683/1-42 CrMo4 or 42CrMoS4 - 22 x 50 x length to suit.
Pre-hardened (HRC 25-35) 1 x 45 CHAMFER TYPICAL ON ALL
INTERNAL ADJOINING STOCK GUIDES
10
(TYPICAL) 6
15
55
12.7 (TYPICAL)
9.5 12
12.7 (TYPICAL) (TYPICAL)
22
TO SUIT
Ø8 SCREWS x 20 LONG MINIMUM
PLAN VIEW OF INTERNAL
1 mm GAP TYPICAL
ADJOINING STOCK GUIDES
30° (TYPICAL) PROVIDE LEADS BY ANY

CUTOUT IN RAIL
15° (TYPICAL)
12 (REFERENCE) 4 (TYPICAL)
LEAD THIS END ENABLES

STRIP TO BE PULLED
TYPICAL FRONT FEED SIDE BACKWARDS
STOCK GUIDES ONLY
30°
FLOW
6 30
ADD 3RD SCREW FASTENING IF LENGTH IS GREATER THAN 300 mm

MAXIMUM LENGTH OF STOCK GUIDE TO BE 500 mm
MATERIAL - ISO 683/1-42 CrMo4 OR CrMoS4 - 22 x 50 x LENGTH REQUIRED
PRE-HARDENED (HRC 25-35)

GENERAL MOTORS

STOCK GUIDES
• Notch steels to avoid weakening lift rail where possible.
50 HOLE PERMISSIBLE IN
LIFTER RACK TO CLEAR
40 BALANCE BLOCKS
(PREFERRED METHOD)
FOR AIR CYLINDER RAIL
APPLICATION 22 mm
STOCKGUIDE THICKNESS
IS USED.
THIS ELIMINATES ANY
MATCHING OF PRESSURE
PAD THAT WOULD BE
NECESSARY IF THICKER
STOCKGUIDES WERE
USED.
CLEAR STOCK GUIDES

FOR BALANCE BLOCKS
25 TO ACCOMMODATE STOCK
GUIDE ADJUSTMENT
PAD BALANCE BLOCK ß

CLEARANCE = 0.2 mm 25
(SEE 80.35.20 PAGE 01)
22
NOTE: 6
AVOID CUTOUTS IN
VERTICAL SECTION
OF LIFTER RACK.
10 mm TO ALLOW
SHARPENING OF
DIE STEELS
NOTE:
10 mm CLEARANCE MUST
BE MAINTAINED UNDER
3 mm SIDE CLEARANCE THE ENTIRE LIFTER RACK
TYPICAL FOR ENTIRE ASSEMBLY
PLAN VIEW OF LIFTER RACK

GENERAL MOTORS

PILOT SUPPORT
B A
20 mm PAST
C/L OF PILOT
SIGHT STOP FOR

FIRST HIT
B A
AVOID LOOSE PIECES OF SCRAP PILOT CLEARANCE HOLE IN KEEP CUTOUTS TO
RAIL MUST BE FULL DIAMETER A MINIMUM.
(DIA. OF CLEARANCE HOLE = USE 13 mm RADIUS IN
PILOT DIAMETER + 2 TIMES METAL CORNERS OF ALL CUTOUTS
THICKNESS)
(SIDE GUIDE NOT
SHOWN FOR CLARITY)
USE LIFTER RAIL TO SUPPORT ALL PILOTS
26
9
3
12 REFERENCE
10 RADIUS 8
5 10 (REFERENCE)
10
*
15
40 8 RADIUS 22
11 25
19 (REFERENCE)
LENGTH OF LOWER STEEL

NOT TO EXCEED 250 mm
SECTION A-A NOTCH NON-CUTTING STEELS

LIFTER RAIL MUST BE
AS SHOWN TO AVOID
WEAKENING LIFT RAIL AT DIE LINE IN
RELIEVE LIFTER RAIL AND LOWER CUTTING DOWN POSITION
STEELS AS SHOWN TO ALLOW WHERE POSSIBLE
CONTINUOUS LIFT RAIL SUPPORT TO STRIP
WITH TRIM AND PIERCE OPERATIONS SECTION B-B
CLOSE TO EDGE OF STRIP

GENERAL MOTORS

LIFT RACK SET-UP HEIGHT
• Design the die so the strip is one-half of the lifter travel below the standardized coil feed level in the die
closed position.
FEED
DIE LIFT
1/2 DIE LIFT
1/2 DIE LIFT

DIE LEVEL
700
FEED
LEVEL
BOLSTER

GENERAL MOTORS

COIL START/FEED GUIDE ASSEMBLY
• For lifter rack guide assembly set-up, refer to the global progressive die start model file ß
#801525P1-main.prt)
10 CLEARANCE
EDGE OF COIL
30
A A
PARTIAL UPPER FEED IN
GUIDES ARE TO EXTEND
30 mm FROM EDGE OF COIL.
TYP. (2) PLACES
DO NOT EXTEND PAST

FRONT OF DIE
EDGE OF DIE
6 TYP.
30
EDGE OF COIL
10 CLEARANCE
40
38
REF. 1 mm GAP
10 OPENING IN 60 ß
GUIDE ASSEMBLY 25° 6 15° 6 REF.
25° 30°
6
MUST BE LOCATED
INSIDE OF DIE SHOE NOTCH FOR
4 TYP.
CONTINUOUS CROSS BAR
75
DIE SHOE
SECTION A-A
(ENLARGED)
ADD 6 mm THICK SPACER PLATE ON TOP OF ANGLE ß

IRON TO RAISE THE LOWER FEEDING GUIDE TO
MATERIAL FEED LEVEL EVEN WITH SIDE RAIL.

GENERAL MOTORS

Sub-title STOCK LIFTERS - DIE WITH LIFTER Link to
EXTENDING OVER LOWER FORM PADS
A A
LIFTER RAILS
LIFTER
UP
§
PAD
10 TRAVEL
CLEARANCE
PAD UP PAD
SECTION A-A
THE LOWER PAD MUST NOT
CONTACT THE LIFTER RACK WHEN
THE LIFTER CYLINDERS ARE
EXHAUSTED AND THE LOWER
PAD IS STILL CHARGED

103 gbl2edr4\80prog\80_45_25p1.cvx 08 SEP 06
GENERAL MOTORS

DIES WITHOUT CENTER CARRIER
• Panel support at form station (typical).
SECTION B - B
MACHINE LOWER FORM

STEELS TO ACCOMMODATE
B B LIFTER RAIL SUPPORT
LIFTER RAILS

GENERAL MOTORS

PROGRESSIVE DIES DIES ABOVE 80.45.40 01 of 04 z
Sub-title STOCK LIFTERS - LIFTER RACK DESIGN 4000 mm Link to
FOR PROGRESSIVE DIES
• Use (6) lower air cylinders for lifting rack, 100 mm bore. ADD 12 X 30
• Use (6) upper nitrogen cylinders to depress rack lifter. SUPPORT RIBS
• Use (6) shock absorbers as shown. WHEN OVERHANG
OVER EXCEEDS 100
100
OPTIONAL CONSTRUCTION:
80 mm BORE AIR CYLINDERS MAY BE USED WITH
MANAGEMENT APPROVAL ONLY. VIEW “A”
“RL”
REAR LIFTER
SHAFT ABSORBER UNIT
6 PLACES
LIFTER RACK
ASSEMBLY FLOW
PROVIDE CENTER
SIDE GUIDE MUST SUPPORT WHERE VIEW “A”
BE CONTINUOUS NECESSARY
50
254 MAXIMUM
OVERHANG
LIFTER RACK
ASSEMBLY
50
“CL”
CENTER LIFTER LIFTER RACK SHOULD
SHAFT BE DESIGNED TO
TURN DOWN CENTER BALANCE AT A POINT
LIFTER SHAFTS TO WITHIN ±50 mm OF
Ø 49.50 TO MINIMIZE CENTERLINE OF RACK
BINDING OF RACK
“FL”
FRONT LIFTER
SHAFT
NOTE: LIFTER RACK MUST BE PAINTED YELLOW PRIOR TO BUYOFF.

GENERAL MOTORS

PROGRESSIVE DIES DIES 4000 mm 80.45.40 02 of 04 z
Sub-title STOCK LIFTERS - LIFTER RACK DESIGN AND UNDER WITH Link to
FOR PROGRESSIVE DIES GMNA PRODUCTION
• Use (4) lower air cylinders for lifting rack, 100 mm bore.
• Use (4) upper nitrogen cylinders to depress rack lifter.
• Use (4) shock absorbers as shown.
“RL”
REAR LIFTER
SHAFT ABSORBER UNIT
4 PLACES
LIFTER RACK
ASSEMBLY FLOW
PROVIDE CENTER
SIDE GUIDE MUST SUPPORT WHERE
254 MAXIMUM
OVERHANG
LIFTER RACK
ASSEMBLY
LIFTER RACK SHOULD

BE DESIGNED TO
BALANCE AT A POINT
WITHIN ±50 mm OF
CENTERLINE OF RACK
“FL”
FRONT LIFTER
SHAFT

GENERAL MOTORS

PROGRESSIVE DIES DIES 4000 mm 80.45.40 03 of 04 z
Sub-title STOCK LIFTERS - LIFTER RACK DESIGN AND UNDER WITH Link to
FOR PROGRESSIVE DIES GME PRODUCTION
• Use (6) lower air cylinders for lifting rack, 80 mm bore. ADD 12 X 30
• Use (6) upper nitrogen cylinders to depress rack lifter. SUPPORT RIBS
• Use (6) shock absorbers as shown. WHEN OVERHANG
OVER EXCEEDS 100
100
VIEW “A”
“RL”
REAR LIFTER
SHAFT ABSORBER UNIT
6 PLACES
LIFTER RACK
ASSEMBLY FLOW
PROVIDE CENTER
SIDE GUIDE MUST SUPPORT WHERE VIEW “A”
50
254 MAXIMUM
OVERHANG
LIFTER RACK
ASSEMBLY
50
“CL”
CENTER LIFTER LIFTER RACK SHOULD
SHAFT BE DESIGNED TO
TURN DOWN CENTER BALANCE AT A POINT
LIFTER SHAFTS TO WITHIN ±50 mm OF
Ø 49.50 TO MINIMIZE CENTERLINE OF RACK
BINDING OF RACK
“FL”
FRONT LIFTER
SHAFT

GENERAL MOTORS

PROGRESSIVE DIES DIES WITH AHSS 80.45.40 04 of 04 z
Sub-title STOCK LIFTERS - LIFTER RACK DESIGN PARTS WHERE EDGE Link to
OF PART LEADS
FOR PROGRESSIVE DIES
• Hardened lifter bars to be used on all AHSS parts with leading trim edge after 1st form station.
• Hardened lifter bars to be attached with screws as shown. (No welding)
• Use ISO 683/14-51CrV4 hardened to 50 HRc.
• M8 attach screws to be 50 mm from ends and approximately every 100 mm of length.
12 X 30 SUPPORT RIBS
LIFTER RACK
ASSEMBLY FLOW
VIEW “A”
PROVIDE CENTER VIEW “A”
SUPPORT WHERE
NECESSARY
254 MAXIMUM
OVERHANG
LIFTER RACK
ASSEMBLY
Ø16 HARDENED
DO NOT BREAK ROUND BAR
SURFACE WITH
TAPPED HOLES
VIEW “B”
CRS SUPPORT
VIEW “B”

GENERAL MOTORS

Sub-title STOCK LIFTERS - CARRIER RIBBON Link to
SUPPORT AT REAR END OF LIFTER RACK
PART EXIT
A
B B
A 80 LIFTER MUST CLEAR PANEL

40 OR WEB IF BELOW DIE LEVEL
SET-UP
¨
RELIEVE PIN AND RAIL AS REQUIRED

LEAD - IN AND IF STRETCH WEB IS ABOVE OR BELOW
GUIDE RODS TO DIE LEVEL
COVER RIBBON
ONLY IF STRETCH
WEB IS ABOVE OR SECTION B-B
BELOW DIE LEVEL Ø 16 DRILL ROD
¨
WELDED TO STOCK
GUIDE
ADD LEAD-IN
GUIDES TO ROD
¨
PART EXIT
100 MINIMUM
TO PULL ROLLS
65
150
(REFERENCE) 30°
6
75
(REFERENCE)
LEAD REQUIRED FOR DOWN

SECTION A-A STRETCH WEB ONLY

GENERAL MOTORS

DIES UTILIZING A CENTER CARRIER
• Panel support through form station (typical).
A CONTINUOUS LIFTER RAIL

SUPPORT MUST BE PROVIDED
IN ALL STATIONS
SECTION A - A

GENERAL MOTORS

Sub-title STOCK LIFTERS - SET-UP FOR SHOCK Link to
ABSORBER ON LIFTER RACK
180 89 COTTER PINS

(REFERENCE) (REFERENCE) M24 THREADS M-24
CASTLE NUTS
MOUNT CYLINDER
TO TOP OF PLATE
MOUNT PLATE TO
TACK WELD LOWER LOCK LOWER SHOE
NUTS TO CABLE STUD AFTER Ø 50
FINAL ASSEMBLY HOLE
LOWER
SHOE
Ø 25 (REFERENCE)
ROD (REFERENCE)
25 +12.0
DIAMETER 560 -0.0
(REFERENCE)
Ø 12
CABLE PROVIDE ACCESS CORE
(REFERENCE) IN DIE SHOE FOR SHOCK
SETTING
(150 x 150 MIN. SIZE)
Ø 25
ROD (REFERENCE) LIFTER TRAVEL
MINUS 45 mm
NOTE: M-24
SHOCK ABSORBER IS USED 25 CASTLE NUT
TO DECELERATE LIFTER
DURING THE LAST 45 mm
OF UPSTROKE
180
(REFERENCE) M24 THREADS
LIFTER RAIL SHOWN ß
AT BOTTOM OF PRESS
89 STROKE
(REFERENCE) CORED CLEARANCE HOLE
(FOR LONG LIFTER TRAVEL ONLY)
FOR DIES WITH LONG 10 x 104 x 180 CRS PLATE M10 x 30 SOCKET HEAD SCREW
LIFTER TRAVELS ONLY:
ADD CORED CLEARANCE HOLE AND 260
SHOCK ASSEMBLY RETENTION PLATE.
ATTACH PLATE TO CAST LUGS PROVIDED 130
IN START MODEL WITH 4-M10 x 30 LONG
SCREWS.
RETENTION PLATE WILL PREVENT
SHOCK ROD ASSEMBLY FROM FALLING 50 Ø140 TYPICAL HOLE
THROUGH BOTTOM OF SHOE WHEN FOR LIFTER
100
UPPER CASTLE NUTS ARE REMOVED. RAIL SHOCK
ABSORBERS
ß
GENERAL MOTORS

Sub-title STOCK LIFTERS - GUIDANCE, AIR AND Link to
NITROGEN REQUIREMENTS FOR LIFT RACK
• Use 15 kN nitrogen gas spring for rack-style lifter delay. A lifter delay gas spring shall be located directly
above each lifter rack air cylinder.
• Lifter delay gas spring travel shall equal longest upper pad travel plus 3.0 mm.
• Lifter delay gas springs to be hosed together to a separate 345 bar control panel.
• Use 100 mm bore air cylinders for all lower lifter pressure systems.
• Optional construction - use 80 mm bore air cylinders for lower lifter pressure systems.
CYLINDER MUST BE MOUNTED TO

AND BACKED UP BY UPPER DIE.
MOUNTING FACE HEIGHT TO BE
DETERMINED AND APPROVED
DURING DESIGN.
ANGLE IRON ASSEMBLY

LIFTER RACK
LIFTER SHAFT MUST BE 0.3 MIN.

BELOW CLAMP PLATE
SHOULDER SCREWS
ENERGY ABSORBING PADS M10 X 25 LONG
8mm THICK
SHORE HARDNESS: 65
NOTE: 100 mm MIN. ENGAGEMENT

WITH LIFTER RACK IN UP
POSITION.
SANKYO OILLESS BUSHING

#SOB-5065100 OR EQUIV.
(2) REQ’D
MATERIAL 1144
FATIGUE PROOF
50.0 DIA. (NOMIMAL) JAM NUT
(SEE 90.80.aa) (INCLUDED WITH CYLINDER) !
AIR CYLINDER HEIGHT ADJUSTER USE AIR CYLINDERS
(SEE 90,80.120) FOR ALL LIFTER
PRESSURE SYSTEMS
AIR CYLINDER MOUNTING
PLATE FASTENED TO
BOTTOM OF DIE

GENERAL MOTORS

PROGRESSIVE DIES GMNA 80.45.65 01 of 01
Sub-title STOCK LIFTERS - GME Link to
LIFTER GUIDE SHAFT ASSEMBLY
• See section 90 for detail information.
Ø 10 x 25 SHOULDER SCREW
SEE 90.41.05-1025
STRIKER BLOCK
SEE 90.80.165
STRIKER ISOLATOR PAD

SEE 90.80.185
BASIC BLOCK !
SEE 90.80.175
CLAMP BLOCK
SEE 90.80.170
M12 x 80 SOCKET
SHAFT (CENTER SHOWN)
HEAD SCREW
SEE 90.80 INDEX !
Ø 10 x 25 SHOULDER SCREW
SEE 90.41.05-1025
Ø 12 x 80
DOWEL
BOTTOM BLOCK
SEE 90.80.180
Ø 16 x 70
SHOULDER SCREW
SEE 90.41.05-1670 BOTTOM ISOLATOR PAD
SEE 90.80.190
BUSHING (2 REQUIRED)
SEE 90.80.195

GENERAL MOTORS

PROGRESSIVE DIES ALL PROGRESSIVE 80.45.70 01 of 02
Sub-title STOCK LIFTERS DIES Link to
LIFT RAIL LOCK-UP PINS
• For use when servicing die.

• Keeps lift rail up when air is removed.
• Use (4) pins for dies 4 M long and less.
• Use (6) pins for dies over 4 M long.
DESIGN FOR RAIL TRAVELS DESIGN FOR RAIL TRAVELS

UP TO AND INCLUDING 95 mm OVER 95 mm
A A B B
VIEW “X” VIEW “Y”

(SEE PAGE 02) (SEE PAGE 02)
CHAMFER EDGE
AS REQUIRED LARGE PROG. DIE
95 LIFT RAIL (SHOWN
MAX. IN LIFTER UP
LIFT RAIL IN POSITION)
150 DOWN POSITION LIFT RAIL
TYP. TRAVEL + 10 mm
WELD LOCAL
EXTENSION TO
10 MIN. LIFT RAIL
GRIND WELD FLUSH
GMGDS 90.80.65 TO SURFACE !
17.5 SAFETY PIN THIS SIDE ONLY
27 5
MIN. 75
34 10 MIN.
2.5 27
17.5 MIN.
2.5
SECTION A - A
SECTION B - B

GENERAL MOTORS

Sub-title STOCK LIFTERS DIES Link to
LIFT RAIL LOCK-UP PINS
LANYARD
STORAGE CLIP
ISO VIEW
(PIN SHOWN IN STORAGE POSITION)
R6
TYP.
W W 17.5
17.5
R 17.5
R 16 R 17.5
MIN.
TYP.
PARTIAL
VIEW “Y”
VIEW “X”

GENERAL MOTORS
Title Valid for No. Page §

BLANK SUPPORT - (CAM SLIDE)
BLANK SUPPORT LIFTER - (CAM SLIDE)

WHEN BLANK SUPPORT IS NOT AVAILABLE USE THE LIFTER CAM SLIDE
A
B
BLANK
A
B
CAM SLIDE
(MOUNTED TO
LIFTER RACK)
LOWER DRAW POST

CYLINDER
LOWER DRAW PAD

UPPER CAM
MOUNTED DRIVER LOWER ADAPTOR PLATE
SOLID CAM
DRIVER
SECTION A - A
DRAW STATION
CAM SLIDE
INCOMING BLANK
(MOUNTED TO
LIFTER RACK)
SHEET METAL BLANK SUPPORT

APPRX. 3 mm THICK
LOWER DRAW PAD
LOWER DRAW POST
MICRO GAS LOWER ADAPTOR PLATE

SPRING
SECTION A - A (SHOWN OPEN)

DRAW STATION
KEEPER WEAR PLATE
KEEPER
DRIVER
SECTION B - B

116 gbl2edr4\80prog\80_45_75p1.cvx 08 SEP 06
GENERAL MOTORS
Title Valid for No. Page ß

Sub-title STOCK LIFTERS - LIFT RAIL CROSS BAR DIES Link to
VIBRATION ISOLATOR INSTALLATION
• See section 90 for detail information.
LIFTER RAIL
M8 HEX NUT
SEE 90.41.20-8
SAFETY WASHER
SEE 90.41.37-8
CROSS BAR
THICK WASHER
SEE 90.41.38-8
VIBRATION ISOLATOR
VIBRATION ISOLATOR SEE 90.80.125
MOUNTING BRACKET
SEE 90.80.140
CROSS BAR MOUNTING BAR

SEE 90.80.145

GENERAL MOTORS

Sub-title PANEL ACCUMULATION Link to
GENERAL INFORMATION
PROCESS REQUIREMENTS FOR IN-DIE PANEL ACCUMULATION

1) Ideal candidate should nest. (Grouping of parts is an acceptable alternative to nesting.)
2) Proper support must be provided for cutoff steels.
3) Left and right hand panels must be accumulated separately and diverted on exit, to increase separation
between left and right hand panel stacks.
4) For category 3 parts - the front (closer to feed end of press) panel stack must clear the rear panel stack
by 25 mm minimum when exiting die.
5) Stacking mechanism must be contained in die.
6) See 80.20.00 for retention requirements.
7) Preferred method for accumulation of all parts will be a “dumptable” type panel accumulator. z
8) When a category 3 style accumulator is used, the part closer to the exit end of press can use the z
“paddle” style of accumulation and the panel farther from the exit end of press to use a “dumptable” style
accumulator.

GENERAL MOTORS

GENERAL INFORMATION
ACCUMULATOR PADDLE CONSTRUCTION GENERAL INFORMATION

• Construct accumulator paddles to provide proper clearance for part and part out chute.
• Gages to be constructed of Ø12 mm rod and 10 mm thick plate. ¨
• Gages that have Ø12 mm rods that extend more than 100 mm above their mounting need to be gusseted. ¨
Use 6 x 19 stock.
PART
REST
PAD
DO NOT CUT CLEARANCE IN SIDE WALL
OF CHUTE FOR ACCUMULATOR
PADDLE ASSEMBLY
15 MIN. ¨
PART
W
W
35.0 MIN. FROM PART TO CHUTE

SIDE WALL OF CHUTE
15 MIN. CLEARANCE ACCUMULATOR PADDLE

AROUND ACCUMULATOR ¨
W
PADDLES IN RETRACTED
POSITION
W
50.0 TRAVEL
PROVIDE CLEARANCE IN
DIE SHOE AS REQUIRED

GENERAL MOTORS

CATEGORY #1 PANEL ACCUMULATORS
PART GUIDES
(ATTACHED TO
SUB-PLATE)
PART REST PADS
1st CHOICE:
Ø 40 x 50 STROKE
SPECIAL AIR CYLINDER
SEE 90.80.70
2nd CHOICE:
Ø 40 x 50 STROKE
STANDARD AIR CYLINDER
WITH MANAGEMENT
WELDMENT
APPROVAL ONLY
FOOT MOUNT ¥
SEE 90.40.206
IN-LINE COUPLING
SEE 90.40.225
RECIRCULATING BALL-LINEAR BEARING CARRIAGE ¥
(SEE 90.80.110)
LINEAR GUIDE RAIL

(SEE 90.80.110) ¥
ISOMETRIC VIEW

GENERAL MOTORS

ACCUMULATOR PADDLE
IN RETRACTED
(PART DROP) POSITION
M12 SOCKET
HEAD SCREW
(TYPICAL)
A A
PLAN VIEW SIDE ELEVATION
SECTION A - A

GENERAL MOTORS

PART GUIDES
(MOUNTED TO
1st CHOICE: SUB-PLATE)
Ø 40 x 50 STROKE
SEE 90.80.70
2nd CHOICE:
Ø 40 x 50 STROKE
WITH MANAGEMENT
APPROVAL ONLY
WELDMENT
FOOT MOUNT ¥
SEE 90.40.206
IN-LINE COUPLING WELDMENT

SEE 90.40.225
RECIRCULATING BALL - LINEAR BEARING CARRIAGE ¥

(SEE 90.80.110)
LINEAR GUIDE RAIL

(SEE 90.80.110) ¥
ISOMETRIC VIEW

GENERAL MOTORS

B
A A
PLAN VIEW
B SECTION B-B
C
100.0
SUB-PLATE
25.0 MIN.
20 20
CAST 50.0 RIB

UP TO LEVEL OF
CHUTE
C
SECTION A-A SECTION C-C

GENERAL MOTORS

4140 BLOCK
25-35 HRC
Ø10 x 80 LONG
4140 PIN
25-35 HRC
ROLL PIN
4140 BLOCK
25-35 HRC
10.20 INTERNAL
DIAMETER BUSHING
CLEVIS PIN 12.20 INTERNAL

DIAMETER BUSHING
ROD END CLEVIS MOUNT
DETAIL VIEW OF CENTER DIVERTER
REFER TO MATERIAL CALLOUTS

SECTION 85

GENERAL MOTORS

PART GUIDES
(ATTACHED TO
SUBPLATE)
PART REST PADS
1st CHOICE:
Ø 40 x 50 STROKE
SEE 90.80.70
2nd CHOICE:
Ø 40 x 50 STROKE WELDMENT
WITH MANAGEMENT
APPROVAL ONLY
FOOT MOUNT
SEE 90.40.206 !
IN-LINE COUPLING
SEE 90.40.225
RECIRCULATING BALL-LINEAR BEARING CARRIAGE

(SEE 90.80.110)
LINEAR GUIDE RAIL

(SEE 90.80.110)
ISOMETRIC VIEW

GENERAL MOTORS

M12 x 50 LONG
SOCKET HEAD
SCREW
A A
B SECTION B - B
PLAN VIEW
25 MINIMUM
WHEN EXITING DIE

FRONT STACK TO CLEAR
REAR STACK BY 25 mm
MINIMUM
SECTION A - A

GENERAL MOTORS

PANEL DIVERTERS
• Locate all diverters 10 - 20% inboard of part length.
PART CATEGORY 1:
PERMANENT PIN
DIVERTER STYLE #1
(FASTEN TO CHUTE)
PART CATEGORY 2:
2 PERMANENT PINS
DIVERTER STYLE #2
(FASTEN TO CHUTE)
PART CATEGORY 3:
USE DIVERTER STYLE 3 OR STYLE 4

GENERAL MOTORS

PANEL DIVERTERS - STYLE #3
• Preferred style
POWER TOGGLE CLAMP
BASE (WELDMENT) PART CHUTE PART
25.0
MIN.
A DIVERTER ARM MUST CLEAR

THE PART EXIT CONVEYOR
SECTION A - A

GENERAL MOTORS

• To be used only when limited space will not allow style #3 diverters to be used.
• Engineering approval required for use of style #4 diverters.
AIR CYLINDER FOOT MOUNT
SEE 90.40.206 !
40 BORE x 320 STROKE

AIR CYLINDER WITH MALE ROD END
WELDMENT
IN-LINE COUPLING
RECIRCULATING BALL-LINEAR BEARING CARRIAGE

(SEE 90.80.110)
LINEAR GUIDE RAIL

(SEE 90.80.110)

GENERAL MOTORS

320.0
TRAVEL
PLAN VIEW
END ELEVATION
SIDE ELEVATION

GENERAL MOTORS

Sub-title PANEL ACCUMULATION GME Link to
ELECTRIC AND PNEUMATIC SCHEMATICS
CATEGORY #1 ACCUMULATOR SCHEMATIC
TO LIFTER RACK CYLINDERS
GMGDS 90.80.71 ¨
EXTEND MANIFOLD ASSEMBLY
CONSTANT AIR SUPPLY TO DISTRIBUTION

MANIFOLD FOR LIST RAIL SYSTEM
RETRACT
PADDLE IN PANEL RELEASE POSITION
HIGH STACK HIGH STACK

PRESS BOLSTER MOUNTED LOWER DIE
SENSOR SENSOR
MULTI-COUPLING ASSEMBLY SHOE MOUNTED
RECEIVER #1 EMITTER #1
MULTI-COUPLING
PRESS PLATE
AIR VALVE #1
PRESS EXTEND
AIR VALVE #3 SHORT FEED
SENSOR
PRESS
AIR VALVE #4
PART
PRESS FLOW
AIR VALVE #2
NOTE: ALL AIR CYLINDERS SHOWN IN

PANEL ACCUMULATE POSITION
19 CONDUCTOR CABLE HIGH STACK HIGH STACK

TO PRESS CONTROLS SENSOR SENSOR
DIE
I.D.
BOX
STD. 3-WIRE SENSOR CABLES

GENERAL MOTORS

Sub-title PANEL ACCUMULATION
GME Link to
GMGDS 90.80.71 ¨
MANIFOLD ASSEMBLY
EXTEND

MANIFOLD FOR LIFT RAIL SYSTEM
RETRACT PADDLE IN PANEL
RELEASE POSITION
PRESS BOLSTER MOUNTED LOWER DIE HIGH STACK HIGH STACK

MULTI-COUPLING ASSEMBLY SHOE MOUNTED SENSOR SENSOR
MULTI-COUPLING RECEIVER #1 EMITTER #1
PRESS PLATE
AIR VALVE #1
PRESS EXTEND
LEFT SIDE PART

AIR VALVE #3
PRESS
AIR VALVE #4
PRESS
AIR VALVE #2
FLOW
HIGH STACK HIGH STACK
RIGHT SIDE PART
SENSOR SENSOR
19 CONDUCTOR CABLE
TO PRESS CONTROLS
SHORT FEED
SENSOR
DIE
I.D.
BOX
STD. 3-WIRE SENSOR CABLES

GENERAL MOTORS

Sub-title PANEL ACCUMULATION
GME Link to

(WITH STYLE #3 DIVERTER)
DIVERTER VALVE
EXTEND
ADD FITTING FOR
DIVERTER VALVE PILOT GMGDS 90.80.71 ¨
EXTEND MANIFOLD ASSEMBLY
EXHAUST
MANIFOLD FOR LIFT RAIL SYSTEM PADDLE IN PANEL
RETRACT
RELEASE POSITION PRESS
PRESS BOLSTER
AIR
MOUNTED HIGH STACK HIGH STACK
LOWER DIE
MULTI-COUPLING SENSOR SENSOR EXHAUST
SHOE MOUNTED
ASSEMBLY RECEIVER #1 EMITTER #1
MULTI-COUPLING
PRESS PLATE
AIR VALVE #1
EXTEND
PRESS
AIR VALVE #3 SHORT FEED
FRONT PART
REAR PART
SENSOR
PRESS
AIR VALVE #4 FLOW
PRESS HIGH STACK
HIGH STACK
AIR VALVE #2 SENSOR SENSOR
DIVERTER
(STYLE #3)
19 CONDUCTOR ADD FITTING FOR

CABLE - TO PRESS EXTEND DIVERTER VALVE PILOT
CONTROLS
STD. 3-WIRE RETRACT
SENSOR CABLE
DIE DIVERTER
I.D. (STYLE #4)
BOX


General Motors Die Design Standards

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General Motors Die Design Standards

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What are progressive dies and what are they used for?

What are progressive dies and what are they used for?

What are the main components of a progressive die?

What are the main components of a progressive die?

GENERAL MOTORS

DIE DESIGN STANDARDS

Title Valid for No. Page

80.00 PICTORIAL INDEX

80.10 BILL OF PROCESS

80.15 GENERAL INFORMATION

80.20 TECHNICAL INFORMATION

80.25 LOWER DIE ASSEMBLY

80.30 UPPER DIE ASSEMBLY

80.35 PADS AND STRIPPERS

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80.40 PRODUCTION REQUIREMENTS

80.45 STOCK LIFTERS

80.50 PANEL ACCUMULATION

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UPPER PRESSURE UPPER PAD

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• The following listed 'SAFETY ITEMS' are found in this section:

Page Item Bullet Subject

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Normal Duty Heavy Duty Ultra Heavy

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PROGRESSIVE DIE OPERATION

COIL REEL FEEDER

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• Eliminate unnecessary use of:

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DO NOT BOTTOM OUT PRESSURE PADS FOR

BURN THROUGH BOILER

AVOID USING LONG PUNCHES AND

NOTCH STEELS TO AVOID

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FOR ALL STEELS WITH UNBALANCED THRUST CONDITION.

STOCK THICKNESS OVER 1.5

MACHINE KEYWAY TO STANDARD SIZE

OFFSET KEYWAY 0.25 mm

FIT KEY TO SUIT ASSEMBLY

USE STANDARD KEYS £

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• Pierce holes after forming stations to minimize developed hole locations.

DIE BUTTON INSTALLATIONS

PIERCE PLATE INSERTS

10 CONTACT AREA ALL AROUND

HARDENED BACKING PLATE £

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