Punch & Dies Selection and Troubleshooting Guide

Making Metal Work

PUNCH & DIES SELECTION & TROUBLESHOOTING GUIDE

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Selmach Machinery Ltd, Unit 8 Beacon Road, Rotherwas Industrial Estate, Hereford, HR2 6JF

The Punch and Die Range We stock a large range of punch and dies so they are available for next day delivery.

Our stock range includes all rounds, squares and most popular sizes of slots for Geka 5, Geka 8, Kingsland & Morgan Rushworth machines.

All of our punch and dies are manufactured in the UK to the highest production standards and produced from hardened steel.

Punches and dies are an ideal means of piercing sheet metal with precision and high repeatability, but one which has a low set-up cost and is almost completely maintenance-free. And all this while producing scrap that is manageable rather than piles of swarf. Punching, it seems is an ideal process for low to medium volume workshops, but there still seems to be a certain mysticism about punch and die systems, what they can achieve, and when to replace them.

As well as selling a wide range of punch and dies, we often have customers call us to trouble shoot problems they’re experiencing, in the following pages we cover the vast majority of issues you may encounter when using a steelworker, and the solutions to rectify them.

WWW.SELMACH.COM | SALES@SELMACH.COM | 01432 342 580

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Punch and Die Tooling

Selmach’s punches & dies are produced to exacting standards and are suitable for all types of steelworkers and punching machines. Proven manufacturing techniques and a closely controlled heat treatment process guarantee optimum punching performance. In addition to the comprehensive range of standard stock products, we can offer oversize tooling and design solutions for virtually any application.

Punches with Shear Angle for Stainless Steel are available on request.

PUNCH & DIE SPECIFICATION

Minicrop Multicrop PP50 Geka / Puma 50

Geka / Puma 70

Die

● ● ● ● ●

● ● ● ● ● ● ● ●

●

Geka / Puma 100 Geka 110 Geka / Puma 150 Geka 165

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B Punch Length

31

61.5

35

Over 100T

40

78

45

●

C Top Diameter

DIE DIMENSIONS

D Diameter of Die

Under 100T

61.5

32

Over 100T

78

40

E Thickness Of Die

PUNCH DIMENSIONS

A Shank Diameter OD

B Punch Length

C Top Diameter

Geka 5

27

53

30.4

Geka 8

31

64

34.8

Geka 8/40

40

64

43.8

Geka 10

40

73

43.8

DIE DIMENSIONS

D Diameter of Die

E Thickness Of Die

Geka 5

50.8

25.5

Geka 8

59.8

32

Geka 8/40

59.8

32

Geka 10

72.8

32

GEKA 8

Punch

Geka / Puma 55

Geka / Puma 80

A Shank Diameter OD

Under 100T

GEKA 5

MODEL

Microcrop

PUNCH DIMENSIONS

Punch

● ● ● ●

GEKA 8/40 Die

● ● ●

Punch

Die

●

●

●

●

GEKA 10 Punch

Die

● ●

● ● ●

●

Selmach Machinery Ltd, Unit 8 Beacon Road, Rotherwas Industrial Estate, Hereford, HR2 6JF

PUNCH & DIE STOCK CODES Morgan Rushworth / Kingsland To fit machines up to 100 tonnes and above

To fit machines up to 95 tonnes

ROUND

PUNCH

DIE

OFFSET DIE

ROUND

PUNCH

DIE

Up to 31mm

12001

12501

12513

Up to 38mm

12016

12501

12513

32 - 38mm

12002

12501

12513

39-57mm

12099

12502

12514

12514

39 - 57mm

12003

12502

58 - 85mm

12004

12503

12515

86 - 110mm

12005

12504

12516

OFFSET DIE

SLOT

PUNCH

DIE

OFFSET A

OFFSET B

SLOT

PUNCH

DIE

OFFSET A

Up to 31mm

12006

12505

12517

12521

Up to 38mm

12017

12505

12517

12521

32 - 38mm

12007

12505

12517

12521

39-57mm

12100

12506

12518

12522

12522

39 - 57mm

12008

12506

12518

58 - 85mm

12009

12507

12519

12523

86 - 110mm

12010

12508

12520

12524

OFFSET B

SQUARE

PUNCH

DIE

OFFSET DIE

SQUARE

PUNCH

DIE

Up to 21mm

12011

12509

12531

Up to 26mm

12018

12509

OFFSET DIE 12531

22 - 26mm

12012

12509

12531

27-40mm

12101

12510

12532

27 - 40mm

12013

12510

12532

41 - 60mm

12014

12511

12533

61 - 77mm

12015

12512

12534

As well as these standard tooling options, we can offer a wide range of specialist tooling for specific use cases, including tooling for notching vent holes for galvanising processes, radius corner tools or counter sinking punches and much more!

Looking for a specialist solution? Speak to our team to discuss your requirements, and how a specialist punch and die could assist you.

Specialist Punch & Dies

WWW.SELMACH.COM | SALES@SELMACH.COM | 01432 342 580

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PUNCH & DIE STOCK CODES GEKA

ROUND

PUNCH

DIE

OFFSET DIE

SLOT

PUNCH

DIE

OFFSET A

G5 up to 27mm

12019

12543

12567

G5 up to 27mm

12026

12551

12575

OFFSET B 12583

G6 up to 28mm

12020

12544

12568

G6 up to 28mm

12027

12552

12576

12584

G8 up to 30mm

12105

12545

12570

G8 up to 30mm

12028

12553

12577

12585

G8/40 up to 40mm

12021

12545

12570

G8/40 up to 40mm

12029

12553

12577

12585

G10 up to 40mm

12022

12547

12571

G10 up to 40mm

12030

12555

12579

12587

G11 up to 50mm

12023

12548

12572

G11 up to 50mm

12031

12556

12580

12588

G12 up to 75mm

12024

12549

12573

G12 up to 75mm

12032

12557

12581

12589

G13 up to 100mm

12025

12550

12574

G13 up to 100mm

12033

12558

12582

12590

SQUARE

PUNCH

DIE

OFFSET DIE

G5 up to 19mm

12034

12559

12650

G6 up to 19mm

12035

12560

12651

G8 up to 22mm

12036

12561

12652

G8/40 up to 28mm

12037

12561

12652

G10 up to 28mm

12038

12563

12654

G11 up to 35mm

12039

12564

12655

G12 up to 53mm

12040

12565

12656

G13 up to 70mm

12041

12566

12657

To order, state the relevant stock code, followed by size required - eg. 14mm x 27mm slot punch for Geka 5 - 12026-14 x 27 Large stocks available for same day / next day delivery.

Any special sizes can be manufactured upon request within 3 to 5 days.

Call today quoting the stock code above to discover the vast range of punch and dies we hold in stock, or scan this QR code to visit Selmach Tooling and order directly online.

01432 346 579 6

Selmach Machinery Ltd, Unit 8 Beacon Road, Rotherwas Industrial Estate, Hereford, HR2 6JF

Punch and Dies - Problem Solving PROBLEM

PROBLEM CAUSE

SOLUTION

Stripping Failure

Failure: • A portion of the punch is broken off in the material.

Stripper

Angular Fracture Probable Cause • Too much stripper clearance.

Possible Solution • Adjust stripper closer to the material.

Material Movement

Chipping and Galling

Failure: • Punch face chipping or heavy galling on one area of the punch.

Probable Cause • Poor alignment between punch and die, causing the punch to drag.

Chipping

Heavy Galling

Possible Solution • Adjust alignment between punch and die to clearance all around.

Compressive Failure

Failure: • Occurs when the compressive strength of the punch has been exceeded and the entire working end shatters.

Probable Cause • Attempting to punch extremely hard or thick materials, or complete misalignment of the punch and die.

WWW.SELMACH.COM | SALES@SELMACH.COM | 01432 342 580

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Punch and Dies - Problem Solving PROBLEM

PROBLEM CAUSE

SOLUTION

Punch Head Failure

Failure: • Punch head fractures or breaks off.

Possible Solution • Frequently check and re-tighten the coupling nut. Verify that the face of the punch stem is smooth and flat.

Probable Cause • Using a loose or worn coupling nut or punch stem.

Ringing

Ringing Failure: • Material being punched is deformed with each stroke of the press.

Possible Solution • Adjust the stroke length to enter into the die a maximum of 1/16’’.

Probable Cause • Material is thicker than the working length of the punch, or the punch is entering into the die too far.

Correct Setup

Punch Side • When punching mild steel 1/8” or thicker, the die side of the slug will be a distance of 10% to 20% of the material thickness.

• The punch side of the slug will have a center point indentation and a slight burr.

Die Side

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Shear

Selmach Machinery Ltd, Unit 8 Beacon Road, Rotherwas Industrial Estate, Hereford, HR2 6JF

Punch and Dies - Problem Solving PROBLEM

PROBLEM CAUSE

SOLUTION

Double Shear

Failure: • Double shear indicates insufficient clearance between punch and die.

Possible Solution • Increase punch to die clearance.

Uneven Burr

Failure: • Uneven burr indicates worn tools or misalignment of punch and die.

Possible Solution • Check condition and alignment of punch and die.

Heavy Burr

Failure: • Heavy burr on die side of material indicates too much clearance between punch and die.

Possible Solution • Decrease die clearance.

Heavy Burr

Poor Hole Quality

Failure: • Uneven punches • Poor hole quality • Hydraulic lock out Problem cause • Over-worn punch causing a lock of a sharp edge

Possible Solution • Replace the punch (and die if also worn)

WWW.SELMACH.COM | SALES@SELMACH.COM | 01432 342 580

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Punch and Dies - Useful Videos We have a wide range of useful videos on our YouTube Channel to assist you with the set-up or maintenance of your Morgan Rushworth Steelworker:

Quick Start Video

Remove and Install A Punch & Die

Adjust the Material Clamping System

Adjust the Stroke Limit Switches

Setting up the Minimum Deform Stripper Assembly

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Selmach Machinery Ltd, Unit 8 Beacon Road, Rotherwas Industrial Estate, Hereford, HR2 6JF

If you need a service, or spare parts for your Steelworker, contact our service team for help, advice and parts.

We offer a wide range of Steelworker’s, so if you’re thinking about adding to your collection of machinery, be sure to contact our sales team, or browse the range of Steelworker’s on our website.

HSV

HST

HSW

HSP

Scan here to browse the full range of Steelworker’s we can offer.

To order additional Punches, Dies and Spare parts, visit our consumables website - www. selmachtooling.co.uk, or scan this QR code.

WWW.SELMACH.COM | SALES@SELMACH.COM T: 01432 346 580 Selmach Machinery Ltd, Unit 8 Beacon Road, Rotherwas Industrial Estate, Hereford, HR2 6JF