Development of a cutting punch tool for stamping dies

In automotive and white good industries, the most products are made of metallic materials. In production of components generally in complex forms, mass production (annually hundred thousand pieces) is carried out with multiple operations - piercing, cutting, trimming, bending, and stretching - in sheet metal stamping dies under high tonnage presses. In dies, punches are utilized to create holes with different profiles on a part. The punches in dies are worn during mass production because they are subjected to repetitive high loads. Moreover, they are tools highly difficult to remove from the dies due to their current designs. To replace the deformed punch, it is always necessary to priorly remove the punch carrying plate as well as the upper or lower die need to be removed from the press, which results in high costs due to the longer lead time. To avoid the above-mentioned disadvantages, a novel punch as stamping die tool shall be developed and verified by FEA and experimental studies. The study aims at bringing out an easily replicable punch tool. The novel punch consists of two main components: head and body. To ease the punch head separation from the body, the punch has a tapped hole in two different diameters and a bolted connection. The threaded hole diameter through the head is larger than that of the body. Thus, when the punch head is required to separate from the body, a proper size bolt can be inserted to the head hole, screwed ahead until it pushes against the surface of the body then the head can be easily removed.