Making Mold and Die

[BrassBuilder]

I have a part that I want to try to make by stamping it out of thin copper. I was going to make a die with a corresponding piece that it would insert into (the mold). The die would be slightly smaller than my actual part and the mold opening would be slightly bigger (enough clearance for the copper).

I have my part drawn to the size that I need it. Is there any way to scale this so that I do not have to redraw it twice (once slightly smaller and once slightly larger)?

Thanks
Mike

[metalworkz]

Hi Mike,
In Partmaster CAD open your part and select View from main toolbar, then Properties, and set the scale accordingly at the bottom of the Properties popup window.
Regards,

[BrassBuilder]

Originally Posted by metalworkz Hi Mike, In Partmaster CAD open your part and select View from main toolbar, then Properties, and set the scale accordingly at the bottom of the Properties popup window. Regards,

That was easy. Now I just need to figure out the scale that I need. Guess it is time for experimentation!
Thanks!
mike

[metalworkz]

Hi Mike,
Is this going to be a blanking die for a flat piece or is going to do some forming also? For a flat part blanking of this material say up to .060 a clearance of 10 percent is good, so about a .006" clearance between the punch and the die would be good. If the material is thinner you can just use the 10 percent formula to figure the correct clearance:
(EX: .1 x .032" material = .003" clearance) You would make the punch the same as the final shape and size of the part and make the die say .006" bigger for clearance. Keep in mind if there are flanges there will be some shrinkage and the part size may need to be enlarged to compensate for it.
If forming it will it have 90 degree flanges or are the flanges curved? Straight flanges would not be hard to figure but curved flanges will take more work. I am not a tool and die maker but I was a die setter and have a lot of experience working with blank & form tooling and high production hard tooling in punch presses up to 600 tons capacity. Now I mainly s/u & operate CNC turret punches.
Regards

[BrassBuilder]

Thanks Wes!
This gives me a good start. I attached a dxf of my part. It is rather curvy. There is going to be around a 1/16" flange all the way around the part. i was hoping to take my copper, anneal it, and then place the copper between the die and mold and squish it together with some light hammering to form it. I would then trim the flange to the desired height.
This was the best idea I could come up with for now.
And if worse came to worse, I could just make the part flat and leave the flange off. It just adds that little detail that I am striving for. I attached a pic of what I am trying to duplicate. The center, raised portion will be a separate piece.
Mike

[metalworkz]

Hi Mike,
Now that I see the part it looks like you could possible do a rough cut with snips etc. for the blank size and shape leaving enough material to trim the flat flanges as you mentioned after forming it. The closer to the final correct size you can make the flat blank the better it will form as excessive material will probably wrinkle during the forming operation and prevent you from achieving a good form of the shape. I have a chart of bend allowances for various materials and I will see if I can get you a rough idea for figuring the overal size. The bend allowances are for 90 degree bends but it should provide a way to get a "ballpark" size and you could just add a little more material to be sure you have some to trim? Give me a lil time to find my chart and I will see if you have replied to this message. I have not looked at the .dxf yet but will peep it soon as I find my chart of allowances.
Regards,

[metalworkz]

How high is the raised area of the cover? Guessing from the picture is looks to be approx. .375" to .50" high? Also how thick is the material going to be? My chart only goes down to .125" copper so not much help. I have complete aluminum and steel charts down to.015" thick and from 1/64 thru 1/4 bend radiuses.
I think you can get a close estimate of the overal size from the original by measuring. Once you get the dies made you can use a piece of thin cloth between the dies to mark the outside perimeter and come up with a close blank size when it is removed. Hope I have helped in some way. I suppose you got the other parts done already? It will be cool to see this when done!!
Regards,

[BrassBuilder]

I think it was around .375 high. It does not have to be scale perfect, getting the detail in is more important.

I checked my copper stock. It is about .011 thick. Some places measure .010 and others measure .012.

I also have some brass stock that is .005. That might be even a better alternative.

I'll post pics once I get one made.
Thanks
Mike

[MIKE JEFFERS]

correct term is punch and die
or top and bottom form tools

[BrassBuilder]

Originally Posted by MIKE JEFFERS correct term is punch and die or top and bottom form tools

LOL. Thanks Mike.
I knew I wasn't using the correct term for the "mold" part, but I couldn't think of what it was called.
Mike

[BrassBuilder]

Originally Posted by metalworkz Hi Mike, In Partmaster CAD open your part and select View from main toolbar, then Properties, and set the scale accordingly at the bottom of the Properties popup window. Regards,

Wes,
I finally had a chance to try this tonite and nothing is changing. I tried inputting 1.5 and I then printed my drawing to full size. It was the same size as before. I then entered .5 and tried it again. Same size as the original.
Any idea why?
Mike

[metalworkz]

Hi Mike,
Did you save the file after changing the scale? Look at the X or Y coordinate reading( mouse over the end of the part etc) and take note of the size. Then change the scale and check it again, but you may have to save the file(give it another name) before it will print diferently. Not sure but that's my guess.
Also maybe changing the sacle is not changing the print image size, so try looking at the actual dimensions or coordinate readings on the drawing after changing the scale.
Regards,