Safe Reliable Die Clamping
Alex Monroe 1/18/2011
Outline
• Background and Motivation
• Clamps, Die Carriers
• Bolts, Washers, and Nuts
• Eyebolts and Lifting of Dies
• Organization
• Torque and Clamping Force
Clamping Issues
• Bolts break
• Platen T-slot break
• Die falls off platen
• Die becomes loose, and either shifts
downward or rotates during
production.
• One die half is pulled off a platen
during opening
• Clamps break
Root Causes
• Too much or too little
clamp force
• Wrong, Under, or
un-rated clamp parts
• T-Slot Bolt
Figure
3:
Fixed
height
die
clamp
kit
designed
for
die
cas8ng
die
clamping
(Advance
Products)
Clamp Parts
• T-bolts 1.5*Bolt Dia
• Nuts
• Washers
• Clamp
Figure
2:
A
high-‐strength
alloy-‐steel
T-‐slot
bolt
and
nut
permits
the
use
of
a
large
strong
fastener,
and
visual
inspec8on
for
proper
thread
engagement.
In
this
case
the
nut
has
the
correct
thickness
allowing
a
thread
engagement
of
one
and
one-‐half
8mes
the
bolt
diameter.
(Smith
&
Associates)
Physics of Clamping
• How many clamps?
– Weight of die half
– Friction
– Torque applied
– T-Bolt Diameter
– Distance of t-bolt from die edge
– Parallelism of mold clamps
– Presence of die items engaging into platen (Shot Sleeve,
T-slot Keys ,or Locating Pins, Pull Back Rods)
– Safety Factor
• Prevent Die Slipping
– Clamps and Die Carrier
• Prevent Pushing Die Off Machine
– Clamps
Tools
• Visually Inspect
Tools
– Before Using
– After Possible
Damage
• Properly Sized
– Should Fit Snug
• Cleaning Tools
• Cheater Bars
Used with Care
Clamps
• Clamps
• Use the Correct
Clamp
• Proper Size
• Proper Height
• Aligned
Clamp Types
• Die Casting Die
Clamps
• Use Die Carriers
– Large Dies
– Large Machines
– Reduce the Number
of Clamps Needed
Clamp bolt torque
Figure
15:
T-‐Bolt
installed
in
the
correct
posi8on,
close
to
Figure
14:
Example
of
t-‐bolt
installed
too
far
from
the
the
die.
This
will
result
in
a
majority
of
the
clamping
force
edge
of
the
die.
Most
of
the
force
is
in
the
heel
of
the
being
applied
to
clamping
the
die.
Also
no8ce
the
nose
of
clamp
instead
of
the
nose
of
the
clamp
onto
the
die.3
the
clamp
is
pushed
onto
the
die
clamping
surface
adequately,
but
may
be
able
to
be
pushed
even
father
in
for
beQer
results.
(Smith
&
Associates)
Clamps
• Place Bolts as Close to Die As
Possible
• Clamping Force Depends on Bolt
Location
No Clamping Force Best Clamping Force
Clamps
Clamps
Too Many Nuts Too Many Washers
Clamps
• Remove Un-used Clamps and Bolts
• Ideally Safety Wire in T-slot
T-Slots
• Provide Base for
Clamps
• Should not Be
Broken
• Should be Cleaned
• T-Slot Cleaners
– Easier Clamping
– Better Contact with
T-Bolts
Figure
12:
T-‐Slot
Scrapers
(J.W.
Winco)
Never Use T-Slot Nuts
Figure
5:
The
use
of
a
T-‐slot
nut
requires
the
use
of
a
smaller
hex-‐head
bolt,
and
does
not
permit
visual
inspec8on
of
thread
engagement.
(Smith
&
Figure
4:
T-‐Slot
Nut,
not
recommended
for
die
clamping
Associates)
Bolts, Washers, and Nuts
• Keep Clamp
Components Clean
– After Use
• Difficult To Use
• Cannot Achieve
Needed Clamping
Force
• Dirty Bolts Require
up to 50% More
Torque
Bolts, Washers, and Nuts
• One Bolt, Nut, and
Washer
• 1.5 X Diameter
Thread Engagement
(150%)
• Do Not Bottom Out
Threads
• Correct Bolt Length
Washers
Figure
10:
Die
clamp
washer
28-‐32
RC
hardness
150,00
PSI
tensile.
This
washer
is
designed
to
withstand
die
clamping
forces
(Quad
Steel
Co.)
Figure
11:
This
clamp
will
loosen
because
a
thin
washer
of
the
wrong
material
type
was
used
causing
it
to
bend
under
the
clamping
force.3
Tools and Techniques
Figure
6:
Never
use
washers,
nuts
and
slugs
to
increase
clamping
height.
Slugs,
nuts
and
washers
are
seldom
flat
and
normally
have
burrs
that
compress
and
will
cause
the
clamp
to
loosen;
also
these
parts
are
not
designed
for
clamp
spacing
applica8ons.
3
Eyebolts and Lifting
• Correct eye bolt
thread length
• Eyebolt is not
damaged or bent
• Check for cracks
• Corrosion
• Wear
• Working load limit
Eyebolts and Lifting
Correct Chain Length
• Angular loading Chain Length > Chain Spread
• Chain Length
Direction of Pull Adjusted Working Load
45 degrees 30% of rated working load
90 degrees 25% of rated working load
SPREADCHAINLENGTHDIE
HOISTEYEBOLTCHAIN
90o45oIN-LINE
Eyebolts and Lifting
• Swivel Hoist Ring
• Use Whenever
Possible
Eyebolts and Lifting
Organization
• Keep Clamps and Tools Organized
• Safer
Why
is
this
– Use Correct Item Every Time
• Clamps, Wrenches, Bolts, Etc…
– Recognize Damage Immediately
Hard
to
Do?
• Faster
– Eliminate Searching for Tools
• Easier
– Less Stress
– Less Rushing
Organization
Work Toolbox Home Toolbox
5S – A Way To Organize
• Sort: Remove Unnecessary Items
• Set in Order: Arrange Items
• Shine: Clean workplace
– Tools, Clamps, Machine, etc…
• Standardize: Simplify Job Content
• Sustain: Maintain 5S habit
• Safety: Common Sixth ‘S’
11
Presence of Shot and Ejector parts
• Do not Rely on Shot and Ejector System to Hold
the Die
• Do not Rely Solely on Die Carrier
• Shot System
– Shot Sleeve
– Allows Rotation
– Shot tries to Push
Cover Off Platen
• Ejector System
– Knockout Rods
– Pullback Rods
– Can Seize up
– Ejection Tries to Push
Ejector off Platen
Clamp Number Location
• How Many Clamps are Needed?
• Where Should They Be?
• Factors Considered
– Die Weight
– Torque
– Position and Number
– Etc…
• Typically Use as Many As Possible
Die Weight
• How Many Clamps?
• How heavy?
– Each half
• Weight Engraved on Side of Die
Clamping Friction
• Coefficient of Friction
Dry Steel on Steel ~ 0.75
• Cleanliness
– Clamp
– Die
– Platen
– T-Slots
Figure
13:
BoQom
fric8on
clamp
must
prevent
slippage
at
points
A,
B,
and
C
in
order
to
hold
the
mold
securely.
1
Figure
12:
T-‐Slot
Scrapers
(J.W.
Winco)
Torque
(Courtesy of SPS Technologies, Aerospace Fasteners Group)
Torque
• Use Feel
– Example 40 ft-lb = 20 lbs at 2’ breaker bar
– Inaccurate at Best
• Best Measure using
Torque Wrench
• Measured Torque Wrong
– Dirty Threads
– Cross Threaded
– Rusted Threads
– Etc…
• Keep Bolts Clean
– 25%-50% added Torque
• Final Tighten at Lock-up
Torque Alternative
• Turn-by-Nut Method
– No Undue Damage to Clamp System
– Snug bolts
• Full Effort using Spud Wrench
– Turn XX Angle
– Angle Depends on Bolt Size
Clean Clamps and Platen
Estimated Torque
Estimated Torque for Clamping
(May vary depending on application,
material type and grade)4
Thread Size Max Torque Bolt Force
1/2”-13 125 ft lbs 100 lbs
5/8”-11 245 ft lbs 160 lbs
3/4”-10 425 ft lbs 233 lbs
1”-8 591 ft lbs 245 lbs
1-1/4”-7 800 ft lbs 264 lbs
Estimated Torque for Clamping
(May vary depending on application,
material type and grade) 4
Thread Size Max Torque Bold Force
½”-13 17.29 m kgs 45.35kg
5/8”-11 33.8 m kgs 72.57kg
¾” - 10 58.7 m kgs 105.6kg
Clamping Force
• Calculate Bearing Load
• Steel on Steel CoF µ ~ 0.75
• X/Y ~ 0.5
Y
X
Check
• After 15-20 shots
• Check clamps
– Are they loose?
– Have the Nuts Backed off?
– Die Flopping on Platen?
– Ejector Operating Smoothly?
– Slide Operating?
Conclusions
• Safe and Reliable Clamping Requires
Consistent Practices
– One Bolt, One Washer, One Nut
– Clean Components for Reproducible
Clamp Force
– Never Use T-Slot Nuts
– Use Estimated Torque Values
• Consider Turn by Nut Method
• 5S Enables Better Clamping and
Faster Setups
