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A die is a specialized Tool used in Manufacturing Industries to cut, shape and form a wide variety of products and components. Like Molds and Template s, dies are generally customized and uniquely matched to the product they are used to create. From a simple paper clip to complex pieces used in advanced technology, dies are involved in producing products we use in everyday life. DIE FORMING Forming dies are typically manufactured 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. Die components
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.
#''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. #''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 die cutting operations. #''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.
#Bulging fluid dies: Uses water or oil as a vehicle to expand the part. #Bulging rubber dies: Uses a rubber pad or block under pressure to move the wall of a workpiece.
Die casting For the Casting of plastic to make components (such as bottle caps or combs) or the forming of low melting point metals (such as Zinc alloy ''pot metal'', Lead , Aluminum , or Magnesium ), a multipart die is used in a process called Injection Moulding . For automotive parts such as the cases of Automatic Transmission s these dies may be quite complex, as they must be dissasembled in specific order to ensure that the workpiece is released freely from the casting die. Parts or products produced by this method are referred to as ''die cast''. Compared to Lost Wax Casting the marginal production can be quite cheap, once the substantial investment in tooling and materials handling equipment is made. Compared to Sand Casting the die casting method can reproduce fine details on complex parts and yield a smooth surface, greatly reducing machining and polishing requirements. As some small portion of metal may leak between the mating seams of the die this can result in a sharp edge of metal called ''flash'', which must be removed by grinding and buffing. For small metal toys the term ''die cast'' is generally considered a mark of quality, especially when compared to the cheaper stamping of Lithographed sheet metal, or bare stamped metal possibly later painted. Products created by forming dies
THREAD CUTTING See Also: taps and dies Another device also called a die is a Nut-like Thread Cutting Device for making Screw Thread s on rod stock. This device may also be used to restore damaged threads - a method called ''chasing''. (Other methods are generally used to produce machine screws and small bolts in quantity — they are formed by a process called rolling.) For high production a Die Head may be used, its operation is very similar but does not require "unthreading" at the end of the cut. The head's construction permits the die head to expand at the required length of thread, disengaging the Chasers (cutting tips) and permitting the tools retraction without interfering with the work pieces rotation. Die heads are available and are commonly used for both cut threads and rolled threads. A popular machine that regularly uses a die head is a Screw Machine . Products created by threading dies In contrast to forming dies, threading dies rarely produce a part from start to finish. Many operations are performed on the part in addition to the threading created by the die.
WIRE PULLING See Also: Draw plate Wire -making dies have a hole through the middle of them. A wire or rod of Steel , Copper , or 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 logically divided into a few 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 Gauge s 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. REFERENCES
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