Form _ Cutting Calculation

25.05 SAFETY25.05.00 Safety

25.10 BILL OF PROCESS25.10.00 Bill of Process

25.15 GENERAL INFORMATION25.15.00 Combination Air Cushion and Gas Springs

25.20 TECHNICAL INFORMATION25.20.00 Stripping and Holding Force

25.25 PRESS CUSHION25.25.00 General Information25.25.05 Lower Installation Requirements25.25.10 Upper Installation Requirements25.25.15 Air Cushion Balance

25.30 MECHANICAL WIRE SPRINGS25.30.00 Light, Medium, Heavy, and Extra Heavy Wire Springs

25.35 ELASTOMER SPRINGS25.35.00 Fiber Belted Rubber Die Springs

25.40 NITROGEN GAS SPRINGS25.40.00 General Information25.40.05 Installation Options25.40.10 Installation Requirements / Draw Dies25.40.15 Installation Requirements / Pads and Strippers25.40.20 Installation Requirements / Plated Systems

25.45 NITROGEN MANIFOLD SYSTEMS25.45.00 Safety25.45.05 General Information25.45.15 Manifold Cylinder Selection25.45.20 Reservoir Hole Calculations25.45.25 Manifold Design25.45.35 Installation Criteria25.45.40 Nitrogen Cylinder Staggering

25.50 NITROGEN HOSE AND TANK SYSTEMS25.50.00 Safety25.50.05 General Information

25.55 PRESSURE MONITORING25.55.00 Digital Nitrogen Pressure Monitoring Kit

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Implementation Timing: File Path:

GENERAL MOTORSDIE DESIGN STANDARDS

PRESSURE SYSTEMSINDEX

03 APR 09

25.00.aa 01 of 01

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PRESSURE SYSTEMS

Item ConditionNormal Duty

DieConstruction

Heavy DutyDie

ConstructionDraw DiesHolding Pad Pressure

Lower Air Cushion 1st Choice 1st ChoiceNitrogen Gas Spring 2nd Choice 2nd ChoiceUpper Air Cushion *Last Choice *Last Choice

Trim DiesStripping Pad Pressure

Fiber Belted Rubber SpringUrethane Spring

1st Choice 1st Choice

Mechanical Wire Spring 2nd Choice 2nd ChoiceNitrogen Gas Spring 3rd Choice 3rd ChoiceLower Air Cushion *Last Choice *Last ChoiceUpper Air Cushion *Last Choice *Last Choice

Pierce DiesStripping Pad Pressure

Fiber Belted Rubber SpringUrethane Spring

1st Choice 1st Choice

Mechanical Wire Spring 2nd Choice 2nd ChoiceNitrogen Gas Spring 3rd Choice 3rd ChoiceLower Air Cushion *Last Choice *Last ChoiceUpper Air Cushion *Last Choice *Last Choice

Form and Flange DiesHolding Pad Pressure

Nitrogen Gas Spring 1st Choice 1st ChoiceFiber Belted Rubber SpringUrethane Spring

2nd Choice 2nd Choice

Mechanical Wire Spring 3rd Choice 3rd ChoiceLower Air Cushion *Last Choice *Last ChoiceUpper Air Cushion *Last Choice *Last Choice

NOTE:• For holding pads with multiple operations (example forming and trimming) selection hierarchy is as follows:

DrawHoldingStripping

• See section 75 for cam pressure pad systems applications.

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ONLY WITH MANAGEMENT APPROVAL.


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PRESSURE SYSTEMSBILL OF PROCESS

03 APR 09

25.10.00 01 of 01

gbl2edr12\25press\25_10_00p1.cvx

0

STATIONCL0

AIR PIN

LOWERBINDER

FIRST WORKING STATION

FLOW

GASSPRING

• When lower binder punch opening is outside air pin locations, gas springs and air pin combination can beused.

• When combined gas springs and air pins are used the lower binder must be balanced with gas springs fordie storage.

• A and B transfer press air pins and gas springs must have the same travel.• Do not use programmable air cushion delay (hold-down) feature on AA crossbar presses when combined

air pins and nitrogen gas springs are used. Air and nitrogen pressure systems must be fully activatedthrough the press stroke.

• If used on a AA Crossbar you must have binder bounce equipment.• On AA Crossbar set up gas spring with 7.0 mm less travel than air pin travel.

SECTION SHOWINGAA CROSSBAR GAS SPRINGWITH 7.0 mm LESS TRAVELTHAN AIR PIN TRAVEL.

7.0 mm LESS THAN AIRPIN TRAVEL

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PRESSURE SYSTEMSGENERAL INFORMATION - COMBINATIONAIR CUSHION AND GAS SPRINGS

03 APR 09

25.15.00 01 of 01


· Concentrate pressure system over work area.· Consider pad balance when positioning springs.· Use minimum stock thickness specified for all required calculations.

FORMULAS FOR FORCE CALCULATIONS

LEGEND Flange Break Radius FactorRadius RF

LT = Length of trim line (mm) 1/3 MT 0.133LB = Length of break line (mm) 1/2 MT 0.128MT = Metal thickness of panel (mm) 1.0 MT 0.096TS = Tensile strength of panel (MPa) - 350 MPa for mild steel 1.5 MT 0.076BM = Break line multiplier - see pages 2 and 3 of this section 2.0 MT 0.066RF = Flange break radius factor - see chart at right 3.0 MT 0.060

4.0 MT 0.0356.0 MT 0.029

- Trimming force:

LT X MT X TS = Trimming force (N)

Example: 400 X 0.8 X 350 = 112000 N = 112 kN

- Trimming stripping force:

LT X MT X TS X 0.05 = Trimming stripping force (N)

Example: 400 X 0.8 x 350 X 0.05 = 5600 N = 5.6 kN

- Flanging force:

LB X MT X TS X 0.8 = Flanging force (N)

Example: 400 X 0.8 x 350 X 0.8 = 89600 N = 89.6 kN

- Flanging holding force:

LB X BM X MT X TS X RF = Flanging holding force (N)

Example: 400 X 1.5 X 0.8 x 350 X 0.128 = 21504 N = 21.5 kN

Notes:- Break line Multiplier of 1.5 used (see pages 2 and 3 for examples)- 0.4 mm radius on flange break (½ Metal Thickness) required a Radius Factor (RF)

of 0.128 (see chart at top right)

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PRESSURE SYSTEMSTECHNICAL INFORMATIONSTRIPPING AND HOLDING FORCE

22 AUG 07

25.20.00 01 of 03


• Length of line calculations for holding pressure on flange and form dies with more than one breakline.

1

1 TIMES LENGTH OF LINE

PAD

12

1.5 TIMES LENGTH OF LINE

PAD

12


PAD

12


PAD

PAD

1

2


PAD

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07 FEB 06

25.20.00 02 of 03


• Length of line calculations for holding pressure on flange and form dies with more than one breakline.

1

2 3


PAD

1

2

3


4

PAD

1

2

3


PAD

4

PAD

1

2

3


PAD

1

2

34


PAD

PAD

1

2 3


PAD

PAD

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07 FEB 06

25.20.00 03 of 03


• All air cushions must be balanced.• When designing an air cushion die, place air pins as close to the punch line as possible. This will

concentrate the tonnage at the work area and eliminate unwanted slippage on the binder surface.• For additional information see press specifications.

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PRESSURE SYSTEMSPRESS CUSHIONGENERAL INFORMATION

03 APR 09

25.25.00 01 of 01


DIES WITHAIR PINS

PREFERRED

Ø70

*

2ND CHOICEMIN. 10 mm

RIB

90.0MIN.

30.0

10 MIN.

70 TYP.

1st CHOICE

120MIN.

120MIN.

30

50R 40.0

2nd CHOICE 3rd CHOICE

90.0MIN.

170.0MIN.

30.0

80.0

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PRESSURE SYSTEMSPRESS CUSHIONLOWER INSTALLATION REQUIREMENTS

14 APR 09

25.25.05 01 of 02


90

90 120

60CLEARANCE

SEE SECTION 90FOR STRIKER PLATEDIMENSIONAL INFORMATION

CASTING WITHATTACHED PLATE

PREFERRED CONSTRUCTION

CASTING WITHNO ATTACHED PLATE

Ø70

Ø90 MIN.CLEARANCE

• Consult Regional Press Specifications for press cushion requirements for.Cushion design and capabilitiesPin patternDie design requirements

• Design draw die to fit part. Provide clearance for unused air pins.• Provide 20 mm above air pins (cushion up) to all die items (deck, lift lugs, air and electrical equipment, etc.)• Pressure of inner and outer binders can be done independent.• Shims may be added under striker plates for adjustments, during tryout with management approval.

Ø54

20

PIN

TRAVEL

20MIN.

50MIN.

20 MIN.

ELECTRICALEQUIPMENT

OUTER BINDER

INNERBINDER

STRIKER PLATES

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Ø54

PIN

PRESS PIN DIA. <40(REQUIRES CAST

CLEARANCE)

PRESS PIN DIA. >40(REQUIRES MACHINED

CLEARANCE)

AIR ORELECTRICALEQUIPMENT


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PRESSURE SYSTEMSPRESS CUSHIONLOWER INSTALLATION REQUIREMENTS

14 APR 09

25.25.05 02 of 02


AIR DRAW DIESWITH ALL PINS INBOLSTER

Ø 40 h11

UPPERDIE SHOE

PAD TRAVEL + 2

MINIMUM SHOETHICKNESS =2 x PAD TRAVEL(MIN. 80)

PROVIDE PRESSURE PAD BUSHINGSTEEL PLATE APPLICATIONS

Ø 60

Ø 12

22

PAD

10

200

AIR PRESSURE PIN,SNAP RING

Ø 41 H11

ROLL PIN

• Requires management approval.• For presses with upper air pin hole diameter 40 mm or larger.• Refer to local press information

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PRESSURE SYSTEMSPRESS CUSHIONUPPER INSTALLATION REQUIREMENTS

03 APR 09

25.25.10 01 of 02


GME

• Requires management approval.• For presses with upper air pin hole diameter less than 40 mm.• Refer to local press information

BD...

....

20.0Ø 32.5

PAD

UPPERDIE SHOE

MAT: ISO 683/1 36CrNiMo6FLAME HARDENING

Ø 33 H11Ø 32 h11

Z - SEE LOCAL PRESS INFORMATION

20

HOUSE AIR PIN WHEN:

1 - “W” IS UP TO 125 mm;2 - “W” IS UP TO 70% AIR PIN LENGTH

Z

W

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PRESSURE SYSTEMSPRESS CUSHIONUPPER INSTALLATION REQUIREMENTS

03 APR 09

25.25.10 02 of 02


GMLAAM

C/L OF PRESS

ONE QUADRANT

C/L OF EACH CUSHION

PINS USEDPREFERRED ALTERNATE

SKETCH 'A'

CL CL CL

OUTER PINBOUNDARY

• Loads on air cushions in press bolsters and rams are to be balanced. Each air cushion centerline mustbe located inside the boundary of the outer most air pin pattern of that cushion.

• If an air pin configuration does not allow balancing of load, balance pins must be added, or considerrelocating the panel within the die.

BALANCING OF AIR CUSHIONS

• Locate a minimum of one air pin in each quadrant of the air cushion for balance. Refer to Sketch ‘A’.• When die conditions do not permit one air pin in each quadrant, locate the air pins in a triangular

array so that the centerline of each cushion will fall within connecting straight lines. Refer to Sketch ‘A’.• Each cushion in presses with multiple cushions must be balanced.

• If the pin configurations in sketch ‘A’ cannot be held, balance pins must be used. Refer to sketch ‘B’.

• Balancing pins are not required for dies having only one row of air pins on center line of air cushion,traveling less than 30 mm.

• If travel is over 30 mm, use balance pins as shown in sketch ‘C’.

SKETCH 'C'

UNDER 3000 OVER 3000

= AIR PINS

= BALANCE PINS

SKETCH 'B'

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PRESSURE SYSTEMSPRESS AIR CUSHIONBALANCING REQUIREMENTS

03 APR 09

25.25.15 01 of 05


ALL DIES WITHAIR PINS

= ACTIVE AIR PINS = BALANCE PINS

I II III IV

SLIDE BALANCE FOR PRESSES WITH MORE THAN 1 DIE, BINDER OR PAD MOUNTED TO 1 SLIDE

• For high force applications additional balance pins (up to 6) may be required. (Consult retional pressstandards.)

• If extensive load is needed in a station outside of ram center, consider adding balance pins for slidebalancing.

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03 APR 09

25.25.15 02 of 05

gbl2edR12\25press\25_25_15p2.cVX

MULTIPLE PADSON A SINGLECUSHION

FABRICATEAT CONSTRUCTIONSITE

M12 x 40DIN 912

BALANCINGPINRETAINER

BOREDHOLEØ57 H11PINØ56 h11

Ø43

X = LOWER PAD TRAVEL + 5Y = UPPER PAD TRAVEL + 5Z = UPPER PAD TRAVEL +2

WASHER SERRATEDSCHNORR SAFETY

20

20

20

20

MANUFACTUREAT CONSTRUCTIONSITE

BORED HOLEØ57 H11PINØ56 h11

Ø43

PRESS AIR PIN

LOWERPAD TRAVEL

±0.1

±0.1

NOMINALPRESS PIN TRAVEL

165 (140)

2

Z

±0.1

(120)

±0.1

X

13

8

35

40

Y

8

5

UPPER PADTRAVEL

FOR Ø OF LESS THAN40 USE ALTERNATECONSTRUCTION ONPAGE 04

40 h11

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03 APR 09

25.25.15 03 of 05


DIES WITH UPPERAND LOWER AIRPRESSURE PADS

BOREDHOLEØ57 H11PINØ56 h11

30

Ø43

Y = UPPER PAD TRAVEL + 5Z = UPPER PAD TRAVEL + 2

FABRICATE ATCONSTRUCTIONSOURCE

STANDARDAIR PRESSURE

PIN

30

FABRICATE ATCONSTRUCTION

20

20

10

Y

UPPER PAD TRAVEL2

Z5

HEIGHT ±0.1

Y13 8 TRAVEL

40 h11

PREFERRED CONSTRUCTIONFOR Ø40 AIR PIN HOLE OR LARGER

ALTERNATE CONSTRUCTIONFOR LESS THAN Ø40

AIR PIN HOLE

Ø32 h11

WASHER

HEIGHT ±0.1

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03 APR 09

25.25.15 04 of 05


DIES WITH UPPERAIR PRESSUREPADS

30

LOWERSHOE

BORED HOLEØ57 H11

PINØ56 h11

Ø43

M12 x 40

RETAININGPLATE

M10 x 40UPPERSHOE

PRESSURE PLATE

X = LOWER PAD TRAVEL + 5

X

30

SCHNORRSAFETYWASHER

20

PRESS AIR PIN

FABRICATE ATCONSTRUCTION

20

13

8

HEIGHT ±0.1

NOMINAL PRESSAIR PIN TRAVEL

LOWER PADTRAVEL

HEIGHT ±0.1

• For slide and/or cushion balancing.

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03 APR 09

25.25.15 05 of 05


LOWER PADS WITHPRESS AIRPRESSURE PADS

FREELENGTH

(PAD TRAVEL +0)

HOLEDIAMETER

ROD DIAMETER

• For mechanical wire spring specifications, see Section 90.

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PRESSURE SYSTEMSMECHANICAL WIRE SPRINGS

03 APR 09

25.30.00 01 of 01


• Use the largest diameter fiber belted rubber spring that die conditions permit.• When using fiber belted rubber springs for panel holding operations, add the total tonnage produced by the

springs to the total forming tonnage to ensure that the available press tonnage is not exceeded.• Retain fiber belted rubber springs with a mounting stud in the stationary die member. Stud body length

must not exceed 50% of spring free length. If necessary, stud to be altered to suit, and this alteration to beshown by designer.

• Provide machined bosses for fiber belted rubber springs, at least 10mm diameter larger than compresseddiameter of spring.

• Springs must not apply any force to retainer pins or keepers in the die open position.• Spring compression starts at pad contact.• In die applications where additional holding pressure is required, increase the pad travel so the spring will

be compressed 10% at start of work.• Rubber springs must bear against a smooth uninterrupted surface, at least 10mm in diameter larger than

compressed diameter of spring.• Do not locate rubber springs over screw holes, keyways, etc.• In areas of limited die space, machine a clearance and mount the springs to a common plate.• Common plates are to be 30 mm min. thick to accommodate the mounting stud thread length.• Screws used to secure the common plate to the die shoe must hold the weight of the pad and the die

springs. (Use M-16 x 50 long screws).• Clearance cores for compressed springs to be same diameter as the spring boss.• Provide (4) tapped holes through the common plate for handling of sufficient size to handle the combined

weight of plate and springs (M24 minimum) (See section 15 for additional information.)

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PRESSURE SYSTEMSELASTOMER SPRINGS

URETHANE AND FIBER BELTED RUBBER DIE SPRINGS

10 NOV 08

25.35.00 01 of 03


20

20

PREFERREDCONSTRUCTION

SPRING FREE LENGTH

SPRINGCOMPRESSED

LENGTH

MOUNTING STUD

WORKTRAVEL PAD TRAVEL

20

OPTIONALCONSTRUCTION

NOTE:THIS PLATE MUSTSUPPORT PAD ANDSPRING WEIGHT.

30

EXAMPLE FOR TRIM & PIERCE DIES WITH EITHER FIBER BELTED RUBBER SPRINGS OR URETHANERUBBER SPRINGS:- (Work travel + 5 mm) x 3 = spring free length required. (To nearest standard increment)

[25% spring compression is preferred, 30% maximum with management approval.]- Pad travel = work travel + 5 mm = Spring Compression (Refer to 55.20.05 for binder wall trimming.)

NOTE: Work Travel = Distance working steels travel after initial contact with the panel.

Work Travel = 28Pad Travel = Work travel + 5 = 28 + 5 = 33Calculated Spring Free Length = Pad Travel x 4

= 33 x 4= 132 (use 140 long spring)

Spring Compressed Length = Actual Free Length - Pad Travel= 140 - 33= 107 (23.5% Compression)

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03 APR 09

25.35.00 02 of 03


• The stacking of springs is permitted only with management approval.• Only stack springs that are the same length and diameter together.• Stacking springs does not increase the pad force, only the pad travel.• Use the force produced by one (1) spring only.• Stacked free length of spring not to exceed two items (2x) the non-compressed diameter of the springs to

avoid buckling.• When stacking springs, use a 5.0 mm plate between the springs.• Make the plate and end bearing surface a minimum of 10.0 mm larger than the compressed diameter of the

spring.

10

20

5 PLATE

5 PLATE

10

60

NUTCORE DIA. = (3) TIMES SPRING I.D.

20

GUIDE ROD DIAMETER =SPRING I.D. MINUS 5 mm

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18 NOV 08

25.35.00 03 of 03


• Fasten nitrogen springs directly to die, hose together and connect directly to a 345 bar, liquid filledgage control panel. (360 bar for compact control panel. See section 90.)

• An optional method would be to mount nitrogen springs to a common plate, following the same hosingcriteria.

• Hose and mount gage control panel to all draw binders, form, flange and restrike holding pad dies.• Springs may run unhosed when,

- Used as a die storage block.- Used as a cam return.- Space is limited with management approval.- Used for trim and pierce stripping pads.

• Design intent charging pressure for all nitrogen gas spring systems shall be 125 bar when die is open.• Use the largest gas spring that die conditions permit.• Locate gas springs under work area. For draw dies, locate as close to binder opening as possible.• Springs that are filled through the piston rod are not allowed for safety reasons.• For unhosed nitrogen gas springs - the fill valve must be accessible when installed in die, so that all

nitrogen pressure can be exhausted prior to disassembly.• CNOMO or Micro style hosing may only be used when nitrogen systems contain 10 cylinders or less, for

cylinder body diameters of 45 or less.• CNOMO or Micro style hosing may only be used when nitrogen systems contain less than 5 cylinders, for

cylinder body diameters of 50, 75 95 and 120.• Do not use CNOMO or Micro style hosing when 150 or 195 cylinder body diameter nitrogen cylinders are

used.• Do not use CNOMO style hosing for dies with production in GMNA.• Use EO24 style hosing for all other applications.• One digital nitrogen pressure monitor to be mounted adjacent to and hosed to each lower die nitrogen

control panel.• See section 25.55.00 for pressure monitor mounting information.

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PRESSURE SYSTEMSNITROGEN GAS SPRINGSGENERAL INFORMATION

03 APR 09

25.40.00 01 of 03


• All lower die systems must allow for the system pressure to be adjusted, charged, exhausted, or continuouslymonitored from a common control panel through hosing and fittings.

• Locate the control panel at visible and accessible place.• Maximum cylinder travel is available stroke minus 5 mm. Preferred maximum travel is 80% of cylinder stroke

for progressive dies and 90% of cylinder stroke for all other dies.• The control panel MUST have a 345 BAR rupture disc.• DO NOT PRE-LOAD NITROGEN GAS SPRINGS. Do not allow springs to apply force on pad retainers.

Provide 2 mm clearance between the pressure pad and the spring rod when the die is in the open position.• Double pads: When driving an air pad with a nitrogen pad, drive all air cushion balancing pins with the

opposing nitrogen pad.• Provide a bleed down boss to prevent die components from bottoming the springs.• Safety wire or thread locking compound to be used on all nitrogen cylinder mounting screws.

20% OF STROKE PREFERRED FOR PROGRESSIVE DIES10% OF STROKE PREFERRED FOR ALL OTHER DIES5 mm MINIMUM

DIE OPEN POSITION

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03 APR 09

25.40.00 02 of 03


PROGRESSIVE DIES• Nitrogen gas springs are preferred for cam returns and all other nitrogen applications.• All cam return nitrogen cylinders for each cam slide must be hosed to a control panel.• Lifter delay gas springs are to be hosed together and to a separate 345 bar control panel.• Nitrogen systems are to be identified with a 1.5 x 25 x 50 aluminum tag adjacent to the control panel and

visible when reading gage. Aluminum tag to read “Station XX” in 6 mm high letters minimum.(XX = number of the die station with nitrogen cylinders.)

• Nitrogen manifold systems are to be used with “engineering approval only”.• Nitrogen manifold systems are to be designed to 80 BAR charging pressure, die open.• For progressive dies the preferred maximum travel is 80% of nitrogen cylinder stroke for improved heat

dissipation.• Use only EO24 style hosing for progressive dies, any deviation will require GM management approval.

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03 APR 09

25.40.00 03 of 03


MACHINE CORE MACHINECYLINDER

SIZE(kN)

A(DIAMETER)

B(DIAMETER)

C(DIAMETER)

D(DIAMETER)

+0.5 / -0.007 55 90 SQ 70 51.015 80 110 SQ 95 76.030 100 130 SQ 115 96.050 125 150 SQ 140 121.075 155 180 SQ 170 151.0

100 200 230 SQ 215 196.0

ROD END FLANGE MOUNT BASE MOUNTSQUARE MOUNT (ISO TYPE C-2)ROUND MOUNT (ISO TYPE C-1)

A

B

10

TWO PIECE HORIZONTAL MOUNT CLAMP STYLE BASE MOUNT

PREFERREDNO ADDITIONAL MOUNTS.FASTEN DIRECTLY TO PLATE.

HORIZONTALMOUNT

20

20

C

0

OPTIONALCLAMP STYLE MOUNTNOTE:THE CLAMP STYLE MOUNT CLAMPSSPRING BASE TO A PLATE OR CASTING.THE BASE OF THE SPRING MUST BEBACKED UP BY A PLATE OR CASTING.

D

(ISO TYPE A-2)

(ISO TYPE B)Þ


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PRESSURE SYSTEMSNITROGEN GAS SPRINGSINSTALLATION OPTIONS

03 APR 09

25.40.05 01 of 01


• Use binder tonnage requirements from formability results, if not available, use Global ChecklistFormulas.

• Never allow pads to bottom on nitrogen cylinders.• Provide drain cores at cylinder locations.• Lower binder draw dies:

NOTE: provide staggering of cylinders before any panel forming begins.- Minimum Stagger - step cylinder contact in 2 mm increments 5 times for a maximum of 8 mm.- Preferred Stagger - step cylinder contact in 3 mm increments 6 times for a maximum of 15 mm.- Provide a minimum of four (4) cylinders at initial contact.- (See example on pages 02 through 04.)- Use press tonnage chart for double action presses to determine correct number of cylinders

contacting binder at each stage of press cycle.- Provide bottoming blocks for lower nitrogen binder under the work area when qualified panel

surface is on binder (see sketch “A”).- These will serve as bleed down blocks for the nitrogen system.- Provide nitrogen bleed down blocks or bosses under binder to protect cylinders from over

travel (see sketch “B”), not required if bottoming binder (see above).- Provide only enough bosses to support dead weight of lower cushion.

EXAMPLE: Deck lids should have (6) bosses.- 20% of cylinders are to support lower binder in die open position.NOTE: Provide enough cylinders at initial contact to balance the binder.

- Engage remainder of cylinders in groups of 20%.

20

20

20

20

20

LOWER SHOE

DRAIN SLOT

BOTTOM BLOCK(AS CLOSE TO WORKAREA AS POSSIBLE)

NITRO CYLINDERBINDER

STRIKER PLATE

3

BLEED DOWN BOSS

SKETCH "B" SKETCH "A"

DIE CLOSED POSITION

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PRESSURE SYSTEMSNITROGEN GAS SPRINGSINSTALLATION REQUIREMENTS

14 APR 09

25.40.10 01 of 03


DRAW DIES

STRIKER PLATELOCATION

A B C D E

THICKNESS OFSTRIKER PLATE

32 29 26 23 20

Stagger of binder tonnage in lower cushion draw diesExample: - Binder travel (90 mm)

- 800 Tons (20 - 50 kN nitrogen cylinders) required- Stagger in 3mm increments- 20% of cylinders to engage at each increment

AB CD EA

AA BC DE

B

C

D

E

B

C

D

E

X

X

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PRESSURE SYSTEMSNITROGEN GAS SPRINGSINSTALLATION REQUIREMENTS / DRAW DIES

03 APR 09

25.40.10 02 of 03


A D B C E2531342837

SECTION X - XAT 12mm OF BINDER CONTACT

0 - 3 mm of binder travel• Striker plates marked ‘A’ support binder in die open position through 3 mm of binder travel• 20% of cylinders engaged• 20% of available tonnage bearing on binder

3 - 6 mm of binder travel• Striker plates marked ‘A’ & ‘B’ in contact with cylinders• 40% of cylinders engaged• 40% of available tonnage bearing on binder

6 - 9 mm of binder travel• Striker plates marked ‘A’, ‘B’ & ‘C’ in contact with cylinders• 60% of cylinders engaged• 60% of available tonnage bearing on binder

9 - 12 mm of binder travel• Striker plates marked ‘A’, ‘C’ & ‘D’ in contact with cylinders• 80% of cylinders engaged• 80% of available tonnage bearing on binder

12 mm or over of binder travel• All striker plates in contact with cylinders• 100% of cylinders engaged• 100% of available tonnage bearing on binder

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PRESSURE SYSTEMSNITROGEN GAS SPRINGSINSTALLATION REQUIREMENTS / DRAW DIES

03 APR 09

25.40.10 03 of 03


• Provide striker plates on all pads.• In non-bottoming pads, provide 75 mm diameter cast bleed down boss to prevent bottoming the cylinders.

See 25.40.10• When mounting gas springs to the plate, use the tapped holes in the base of the springs.

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PRESSURE SYSTEMSNITROGEN GAS SPRINGS - INSTALLATIONREQUIREMENTS / PADS - STRIPPERS

03 APR 09

25.40.15 01 of 01


VIEW 'Z'

‘A’

25MINIMUM

25 MINIMUM

8 MINIMUM

M16 x 50

VIEW ‘Y’

32 MINIMUM

PRECISIONSHUT HT.

MAXIMUM TRAVEL = STROKE - 5PREFERRED MAXIMUM TRAVEL IS80% OF STROKE FOR PROG. DIESAND 90% FOR ALL OTHER DIES.

REFER TO CHARTFOR CORE DIA.

25 CAST CLEARANCE

Z+.12-.00

20

20

SEE VIEW

Y

CYLINDER CLOSEDHEIGHT + 3

SEE VIEW ‘Y’DIM. x

Ø y

3 MIN. CLEARANCE

Nitrogen Cylinder PlateWeightin Kg

TappedHoles

(4 Req.)Dim. x Ø y

2100or less M16 X 2.0 32 66

2101to

5600M24 X 3.0 48 74

Cyl.Body

Dim.‘A’

ScrewSize

Dia. ISO Compact ISO Compact45 13 14 M8 x 25 M8 x 2050 13 14 M8 x 25 M8 x 2075 13 14 M8 x 25 M8 x 2095 13 14 M8 x 25 M8 x 25120 10 14 M10 x 25 M10 x 25150 10 13 M10 x 25 M10 x 25195 10 10 M12 x 25 M12 x 25

• Application for nitrogen springs attached to a plate.• Provide plates with (4) tapped through holes to permit handling from either side of the plate. Locate tapped

handling holes so that handling chains, hoist ring, or lifting device do not interfere with the springs. See chartbelow for handling hole size.

• If minimum thickness required at handling hole is greater than plate thickness, add a plate thread diameter +50 mm in diameter at each handling hole location. Plates to be welded all around. Normalize after welding.Clear casting for added plates. (See illustration below.)

• Use of thread locking compound (loctite blue #243 - medium strength, oil tolerant or equivalent) is requiredfor screws that attach cylinder to mounting plate.

• Consider hoses, fittings, and nitrogen springs when selecting handling hole locations.• Counterbored holes are to be deep enough to assure screw heads are below the finished surface.• Fastening screws for plate to die to be M16 x 50 long.• Provide enough screws to support the weight of the upper shoe assembly when installed in the upper or the

entire die when installed in the lower. Use a minimum of (1) M16 screw for every 5000 kg.• On the die design, show the plate installed flush to the base of the component that it is mounted to.• Machined pocket to show a tolerance of +.12 / -.00.• Install plate with a tolerance of +.00 / -.12.• Design ribs with sufficient casting thickness where nitrogen system is fastened to die.• Design system as an integral unit. Cast passages for all system components into the die. Make passages

large enough to ensure against disassembly of the system during installation.• For progressive dies - use of thread locking compound (loctite blue #243 - medium strength, oil tolerant or

equivalent) is required for screws that attach plate to die shoe.

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PRESSURE SYSTEMSNITROGEN GAS SPRINGS - INSTALLATIONREQUIREMENTS (PLATED SYSTEMS)

14 APR 09

25.40.20 01 of 01


• All systems must allow for the system pressure to be adjusted, charged, exhausted, or continuouslymonitored from a common control panel.

• Maximum travel of the cylinders is stroke minus 5 mm.• Every nitrogen manifold system is to have a 148 BAR rupture disc in an o-ring port plug.• Control panels shall have a 138 BAR liquid filled gage.• Provide an area on the front edge of the manifold plate for mounting of a 2 mm x 50 mm x 100 mm tag. This

tag is to have a detail number and is to be called out in the stock list as STANDARD CAUTION TAG.• Do NOT PRE-LOAD NITROGEN CYLINDERS.• Do not allow cylinders to apply force on pad retainers.• For upper installations, provide 2 mm min. clearance between the pressure pad and the cylinder rod when the

die is in the open position.• Double pads: When driving an air pad with a nitrogen pad drive all air cushion balancing pins with the

opposing nitrogen pad.• Nitrogen manifold systems must be protected against bottoming the cylinders.• Provide a cast safety block to prevent die components from bottoming the cylinders.

3 GAP (DIE CLOSED)BLEED DOWN BOSS

LOWER CUSHION TOGGLE

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Sub-title Link to



PRESSURE SYSTEMSNITROGEN MANIFOLD SYSTEMSSAFETY

03 APR 09

25.45.00 01 of 01


• Design intent charging pressure for all dies using nitrogen manifold systems shall be 100 BAR when dieis open, except for progressive dies (see below).

• Design system for 20% pressure rise.• Calculate the force required to perform the operation.• Refer to the chart below to determine the amount and the size of the cylinders.• Refer to 25.45.10 for cylinder travel information.• Use EO24 style hosing for all nitrogen manifolds.• All cylinders must be clearly identified as METRIC.

PROGRESSIVE DIES• Design intent charging pressure for all nitrogen manifold systems in progressive dies shall be 80 BAR,

die open.• Nitrogen systems are to be identified with a 1.5 x 25 x 50 aluminum tag, adjacent to the control panel

and visible when reading gage. Aluminum tag to read “Station XX” in 6 mm high letters minimum.(XX - number of the die station that the nitrogen manifold system is installed in.

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PRESSURE SYSTEMSNITROGEN MANIFOLD SYSTEMSGENERAL INFORMATION

03 APR 09

25.45.05 01 of 01


NUMBER OF CYLINDERSCYLINDER

SIZE 1 2 3 4 5 6 7 8 9 1051 49.64 99.28 149.92 198.56 248.2 297.84 347.46 397.12 446.76 496.436 35.6 70.0 105.0 140.0 175.0 210.0 245.0 280.0 315.0 350.023 22.2 44.4 66.6 88.8 111.0 133.2 155.4 177.6 199.8 222.0

ALL ABOVE VALUES ARE IN KILO-NEWTONS kN Þ


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PRESSURE SYSTEMSNITROGEN MANIFOLD SYSTEMSMANIFOLD CYLINDER SELECTION

03 APR 09

25.45.15 01 of 01


• When determining the manifold drilling configuration, adhere to the following:A. Figure length in only one direction when holes cross.B. Subtract the cylinder holes if reservoir holes are drilled through them.C. When shut height permits, provide a thicker manifold plate and use the largest diameter of drilled hole

the plate will accommodate.D. Extend the cavity below the cylinder to the maximum depth. Maintain 15 mm min. thickness under the

cylinder with a 2 mm min. clearance between cylinder and manifold.• Use the following formula to determine the length of drilled hole required for a nitrogen manifold with a 20%

pressure increase.

Following data used for example computation:51 kN cylinder (deep cavity) 90 mm diameter drilled hole100 mm stroke 130 mm (min.) thick manifold plate99 mm piston travel 8 cylinders required

13 mm cavity depth

1. Determine V1: Volume of cavity below cylinder.V1 = (.7854) x (cavity diameter) 2 x (cavity depth).7854 x (99.3) 2 x 13 = 100677.57 mm 3

2. Determine V2: Volume within cylinder body.V2 = (cylinder stroke) x (piston area)102 x 4964 = 506328 mm 3

3. Determine V3: Total of volume in cavity below cylinder and within cylinder body.V3 = V1 + V2100677.57 + 506328 = 607005.57 mm 3

4. Determine amount of nitrogen displaced from cylinder when die closes (swept volume).Swept Volume = (piston area) x (actual piston travel)4964 x 99 = 491436 mm 3

5. Determine amount of reservoir volume required to limit pressure rise to 20%.Required reservoir volume = (swept volume) / (.20)491436/.20 = 2457180 mm 3

6. Determine adjusted reservoir volume (required reservoir volume less volume of cavity below cylinder andwithin cylinder body).Adjusted reservoir volume = (required reservoir volume) - (V3)2457180 - 607005.57 = 1850174.5 mm 3

7. Convert reservoir volume onto linear millimeters of drilling required per cylinder.Drill hole per cylinder = (adjusted reservoir volume) / (drill hole area)1850174.5/6361.7 = 290.83 mm

8. Determine total amount of drill hole required.Total linear drilling = (drill hole per cylinder) x (number of cylinders)290.83 x 8 = 2326.6 mm total drill hole length

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Sub-title Link to



PRESSURE SYSTEMSNITROGEN MANIFOLD SYSTEMSRESERVOIR HOLE CALCULATIONS

03 APR 09

25.45.20 01 of 02


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• Tapped holes for components attached to the manifold plate are to be a minimum 10 mm and must bedimensionally located on the drawing.

• The minimum distance between reservoir holes is 20 mm and the minimum distance from the edge of themanifold plate to the edge of the reservoir hole is 35 mm.

• Fastening holes, keyways, dowels, etc., must be located a minimum of 10 mm from the reservoir holes,feeder holes and cylinder cavities.

• All Metric manifolds must be clearly and permanently identified as METRIC.• Stamp ALL ports with an “M” to identify it as Metric.

PROVIDE (4) M24 TAPPEDTHROUGH HANDLING HOLES

35 MINIMUM

AVAILABLESTROKEMINUS 2 MAXIMUM

20 MINIMUM BETWEENRESERVOIR HOLES

15 MINIMUM

SYMMETRICALABOUT THISCENTERLINE

DRILL & COUNTERBORE FOR M24SOCKET HEAD SCREW

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ME

TR

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Sub-title Link to



PRESSURE SYSTEMSNITROGEN MANIFOLD SYSTEMSMANIFOLD DESIGN

03 APR 09

25.45.25 02 of 02


• Providing the correct number of manifold to die attachment screws is critical.• Safety is the overriding priority. The weight of the manifold, the lower binder, and the entire upper shoe

assembly is supported by the manifold attachment screws.• Provide the larger number of attachment screws based on the following criteria.

Use M24 screws to attach manifolds to dies.Provide one screw for every 50 kN of manifold system output force.(Total system force (kN) / 50 kN = number of screws required)Provide one screw for every 5000 kg of total die weight.(Total die weight (kg) / 5000 kg = number of screws required)Provide one screw for every 600 mm of manifold perimeter.2x(length + width) / 600 mm = number of screws required.Provide a minimum of four (4) M24 attachment screws.

SYMMETRICAL ABOUTTHIS CENTERLINEEXCEPT AS SHOWNOR NOTED

0

0

600MAX.

600 MAX.

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Sub-title Link to



PRESSURE SYSTEMSNITROGEN MANIFOLD SYSTEMSINSTALLATION CRITERIA

03 APR 09

25.45.35 01 of 02


• Design manifold systems as an integral unit.• Cast passages for all systems components into the die.• Make passages large enough to ensure against disassembly of the system is during installation.• Locate cylinders directly under the work area (in line with) when ever possible.• Show and order nitrogen tag.• Provide manifold plates with (4) M24 tapped through holes to permit handling from either side of the plate.• Locate tapped handling holes so that handling chains do not interfere with the cylinders.• Counterbored holes are to be deep enough to assure that screw heads are below manifold surface.• Provide 10 x 50 mm drain cores in lower die shoes.• Core all cylinder clearance holes. Use chart for minimum diameters.• Show the manifold plate installed flush to the base of the component that it is mounted to. Dimension

machined pocket to show a tolerance of +.12/-.00.• On the detail drawing show and order the plate to the finished height plus .00 mm, minus .12 mm.• Cylinder rod end may push against a 75 mm diameter machined boss of casting for upper shoes

(Do not flame harden).• For non-bottoming dies, provide a 75 mm cast bleed down boss to prevent bottoming of cylinders.

PRECISIONSHUT

HEIGHT

MOUNT CONTROL PANEL TO ROUGH CASTING.DO NOT MACHINE THE BOSS.

REFER TO CHART INSECTION 25.40.05, PAGE 01FOR CLEARANCE HOLEDIAMETER

DIM +.12-.00

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Sub-title Link to



PRESSURE SYSTEMSNITROGEN MANIFOLD SYSTEMSINSTALLATION CRITERIA

03 APR 09

25.45.35 02 of 02


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• Hose and tank systems are to be used with management approval only.• All systems must allow for the system pressure to be adjusted, charged, exhausted, or continuously

monitored from a common control panel.• Maximum travel of the cylinders is stroke minus 5 mm.• Every nitrogen manifold system is to have a 148 BAR rupture disc in an o-ring port plug.• Control panels shall have a 138 BAR liquid filled gage.• Provide an area on a visible edge of the nitrogen tank for mounting of a 2 mm x 50 mm x 100 mm tag. This

tag is to have a detail number and is to be called out in the stock list as STANDARD CAUTION TAG.• Do NOT PRE-LOAD NITROGEN CYLINDERS.• Do not allow cylinders to apply force on pad retainers.• For upper installations, provide 2 mm min. clearance between the pressure pad and the cylinder rod when the

die is in the open position.• Double pads: When driving an air pad with a nitrogen pad drive all air cushion balancing pins with the

opposing nitrogen pad.• Nitrogen hose and tank systems must be protected against bottoming the cylinders.• Provide a cast safety block to prevent die components from bottoming the cylinders.

3 GAP (DIE CLOSED)BLEED DOWN BOSS

LOWER CUSHION TOGGLE

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Sub-title Link to



PRESSURE SYSTEMSNITROGEN HOSE AND TANK SYSTEMSSAFETY

03 APR 09

25.50.00 01 of 01


• Hose and tank systems are to be use only with management approval.• Design intent charging pressure for all dies using nitrogen hose and tank systems shall be 100 BAR

when die is open, except for progressive dies (see below).• Design system for 20% pressure rise.• Calculate the force required to perform the operation.• Refer to manufacturers catalog for cylinder travel, sizing and ordering information. Contact

manufacturer if additional information is required.• All cylinders must be clearly and permanently identified as METRIC.• Use EO24 style hosing, fittings and control panel, with hose and tank systems.• Nitrogen tanks are not to be used with self contained nitrogen cylinders.

NITROGENCYLINDER

RESERVOIRTANK

HIGH PRESSUREHOSE

CONTROLPANEL

TYPICAL NITROGEN HOSE AND TANK SYSTEM

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Sub-title Link to



PRESSURE SYSTEMSNITROGEN HOSE AND TANK SYSTEMSGENERAL INFORMATION

03 APR 09

25.50.05 01 of 01


GENERAL AND TECHNICAL INFORMATION• Provide (1) digital nitrogen pressure monitor for each lower die nitrogen pressure system on all dies.• Digital nitrogen monitor to stop the press in the event the nitrogen pressure falls outside of specified

range.• Mount digital nitrogen pressure monitor directly to the die shoe. DO NOT mount to nitrogen pressure

system plate or manifold.• Hose digital nitrogen pressure monitor directly to the control panel.• Route electrical cable through die to die identification box on lower die.• When (2) or more nitrogen systems are in one die, aluminum tags will be used to identify each system.• Die design to show and order tags. Construction source to stamp and install tags.• A digital nitrogen pressure monitor must be mounted on same side of die as control panel and digital

readout must be visible from outside press.• Mount digital nitrogen pressure monitor in a 50 mm deep minimum side core, or cast-up (2) vertical ribs

adjacent to each side of the digital nitrogen pressure monitor, approximately 35 mm wide x 150 mm high x50 mm from vertical wall and 75 mm apart.

• When multiple lower nitrogen systems are present use series sensor relay junction box to connect multipledigital nitrogen pressure monitors to the die electrical junction box. (See local press standards.)

75 50

5 mm RADIUS TYPICALAROUND RIBS

TYPICAL PARTIAL TOP VIEW OF LOWER DIE SHOE

C/L OF DIE AND PRESS

100 x 300NITROGEN

ACCESS CORE

35 mm x 150 mm RIB,50 mm HIGH (2) PLACES

DIGITAL NITROGENPRESSURE MONITOR(LOWER DIE ONLY)(SEE 90.25.225)

ELECTRICALCABLE

Ø 50 CORE

NITROGEN CONTROL PANEL

TYPICAL ELEVATION OF LOWER DIE SHOE

NITROGENCAUTION TAG(SEE 90.20.08)

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Link to


ELECTRICAL AND PNEUMATICPRESSURE MONITORING - DIGITALNITROGEN PRESSURE MONITORING KIT

03 APR 09

25.55.00 01 of 01


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Form _ Cutting Calculation

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