Progressive die with scrap strip and stampings Forming dies are typically made by and put into production after mounting into a. The die is a metal block that is used for forming materials like sheet. For the of plastic sheet only a single form is used, typically to form transparent plastic containers (called ) for merchandise.

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Vacuum forming is considered a simple process but uses the same principles as die forming. For the forming of sheet metal, such as body parts, two parts may be used: one, called the punch, performs the stretching, bending, and/or blanking operation, while another part that is 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 [ ] The main components for die tool sets are: • Die block – This is the main part that all the other parts are attached to. • Punch plate – This part holds and supports the different punches in place. • Blank punch – This part along with the blank die produces the blanked part.

• Pierce punch – This part along with the pierce die removes parts from the blanked finished part. • Stripper plate – This is used to hold the material down on the blank/pierce die and strip the material off the punches. • Pilot – This will help to place the sheet accurately for the next stage of operation. • Guide, back gauge, or finger stop – These parts are all used to make sure that the material being worked on always goes in the same position, within the die, as the last one.

• Setting (stop) block – This part is used to control the depth that the punch goes into the die. • Blanking dies – See blanking punch • Pierce die – See pierce punch.

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• Shank – used to hold in the presses. It should be aligned and situated at the center of gravity of the plate.

Processes [ ] • Blanking: A blanking die produces a flat piece of material by cutting the desired shape in one operation. The finished part is referred to as a blank. Generally a blanking die may only cut the outside contour of a part, often used for parts with no internal features. Three benefits to die blanking are: • 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 part's 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 operations. 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. •: The process of removing material through the use of multiple cutting teeth, with each tooth cutting behind the other. A broaching die is often used to remove material from parts that are too thick for shaving. • Bulging: A bulging die expands the closed end of tube through the use of two types of bulging dies.

Similar to the way a chef's hat bulges out at the top from the cylindrical band around the chef's head. • 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. •: is similar to forming with the main difference being that a may form completely different features on either face of the blank, these features being transferred from the face of the punch or die respectively.

The coining die and punch flow the metal by squeezing the blank within a confined area, instead of bending the blank. For example: an Olympic medal that was formed from a coining die may have a flat surface on the back and a raised feature on the front. If the medal was formed (or embossed), the surface on the back would be the reverse image of the front. • Compound operations: Compound dies perform multiple operations on the part.