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FAQ (Frequently Asked Questions)
Air Presses
Q: Do the palm buttons have to be on the top of the press?
A: This is the design of the Danly IEM Air Press units. The palm buttons can be mounted in a more convenient location, providing safety is not corrupted. When doing so, be sure the logic air lines between the palm buttons and the logic board are the same length, within 1/4" or closer, this eliminates the palm buttons from becoming sensitive.
Q: How can I adjust the air supply to my press?
A: An accumulator tank can be added to assure the press is receiving the proper air supply.
Q: How do we control the speed of the press stroke for specific applications?
A: A Flow Control can be added either up or down to control the speed of the press stroke.
Q: How much air pressure is needed to operate an air press?
A: We recommend 50 to 125 PSI depending on the application. Be sure the air supply line is adequate, insufficient volume could make the press chatte on the down stroke. On an average, most presses will run on normal 80 to 85 lbs. shop air.
Q: Is it possible to increase or decrease the die space on an air press?
A: The die space on custom size air presses may be adapted to a specific application. For more information, contact your Danly IEM sales representat ve or product manager.
Q: Is the Air Toggle Press more powerful than the Air Press?
A: Yes, the air toggle press is more powerful than the air press, because it operates on a mechanical arm and linkage to magnify the force of the tonn ge in the cylinder.
Q: My application requires the air press to hold in the closed position, is this possible?
A: To hold in a closed position, a dwell timer can be installed to the press.
Q: My slide plate sticks during the cycle. What can cause this?
A: Make certain the pins and bushings are properly lubricated and the posts are aligned to the die set, if not, this could cause binding during operation, also an unbalanced die design can also cause the slide to come down unevenly. Danly IEM Nitrogen Springs can be added to balance the load, or add equal weight to balance the load on the slide plate.
Q: What kind of lubrication should I use on my air press?
A: We recommend Danly IEM lubricant for the pins and bushing, however, a light oil spray will do.
Cams
Q: What is an External Cam?
A: In an External cam, the die spring is external or outside of the body of the unit. Advantages include easy access to the spring for replacement. The external unit is longer than the internal style where the spring is mounted inside the cavity of the unit.
In Die Tapping
Q: How Do I Calculate The Travel Required For The Hy1024 Tapping Unit?
A: The HY1024 unit does not make use of a cam. The motion of the press ram is directly converted to the rotation of the tap. Therefore, the travel equired in the unit must be calculated as follows:
  • From tap pitch and material thickness, calculate number of tap revolutions required to tap the part
  • Add 3 revolutions to allow for the tap lead-in threads
  • Multiply the total revolutions required by the lead screw pitch, 0.157 inches, or 4 mm. This will be the required distance the unit must be compressed to fully tap the hole
  • Note that this travel cannot exceed the available unit travel, i.e. 1.25 inches, or 31.75 mm
  • Q: Maximum Material Thickness - What Is The Limitation On Material Thickness That Can Be Tapped In-Die?
    A: Each of the units is limited in maximum material thickness that can be tapped by the number of revolutions available in the lead screw that drives the tap. The thickness will depend also on the pitch of the thread being tapped:
    TAPPING UNIT ENGLISH FORMULA (inch) METRIC FORMULA (mm)
    HY1024 1 pitch(threads per inch) X 5.1 pitch(mm) X 5.1
    ME1024 1 pitch(threads per inch) X 5.1 pitch(mm) X 5.1
    LP25M6 the smaller of
  • 1 pitch(threads per inch) X 12.5
  • .380 inches minus (3 revs x 1/#TPI )
  • the smaller of
  • pitch(mm) X 12.5
  • 9.652 mm minus(3revs x Pitch)
  • Note also that material thickness measured must include any extrusion of the hole and any gap that will exist between the end of the tap and the entrance to the hole before the tapping cycle begins.
    Q: Maximum Press Speed - How Fast Can I Tap In-Die?
    A: These units are designed to operate at up to 200 strokes per minute. However, the optimum speed will depend on tap diameter and pitch, material t pe, and material thickness being tapped, as well as press stroke and tapping stroke. Recommended press speeds are displayed by the Campro software program. Note that these recommended speeds are guidelines only and are based upon tap performance/speed.
    Q: Press Minimum Shut Height Requirements - How Much Shut Height Do I Need To Accommodate Danly In-Die Tapping Units?
    A: Minimum shut height requirement refers to space available in the closed position to accommodate the tapping unit, without crushing it, or over-tra eling it. The mounting surface of the tool referred to below is the surface that is doweled and bolted to the lower die shoe or the surface of a stripper.
    HY1024 4.075" 103.51mm from bottom of driver to mounting surface of unit
    ME1024 5.771" 146.58mm from the top of the cam to the mounting surface of unit
    LP25M6 3.775" 95.89mm from mounting surface of cam to mounting surface of unit
    Q: Press Tapping Stroke/Stripper Travel - What Do You Mean By This?
    A: For the ME1024 and LP25M6 units (which are cam driven) the minimum amount of press stroke that is required to drive the lead screw a sufficient nu ber of revolutions to cause the tap to fully penetrate and tap the part can be determined using the Campro software provided. Stripper travel must be at least equal to tapping stroke, or preferab y about " more, to ensure that the strip is held firmly in place throughout the tapping operation.
    Warning: this is typically 2 inches (50mm) or more, and depends largely on tap pitch, press stroke, and input value for material thickness
    Q: Press Type - In Which Types Of Presses Can I Use The Danly In-Die Tapping Units?
    A: The ME1024 and LP25M6 units are both cam operated, and as such are designed to run in mechanical presses. The shape of the cam profile compensate for the sinusoidal acceleration and deceleration of the press ram to produce optimal tap speeds. The motion induced by the cam "ramps" the tap to speed, maximizing tap life and minimizing shock o the tapping unit drivetrain.
    The HY1024 unit is not cam operated, and may only be operated safely using a hydraulic press or in a press brake that can engage the unit at a controlled rate, or slide form machine with a external cam
    Q: Tap Size - What Hole Sizes Can I Tap?
    A: The three DANLY units are engineered to tap up to a specific maximum tap size, due to the torque requirements of roll-form tapping. Do not exceed the limitations that are designed into these units. HY1024; M5 or #12. ME1024; M5 or #12. LP25M6; M6 or 1/4"
    Q: Tool Lubrication - What Are The Lubrication Requirements Of The Danly In-Die Tapping Units?
    A: It is essential that access to lubrication points is available.
    Please read the installation manual carefully for these requirements. Failure to follow the recommendations could result in unsatisfactory threads and severe tool damage.
    Q: When tapping an extruded hole, which tapping direction gives the best tap life?
    A: Tap life is usually better if you tap into the sharp end, that is opposite to the direction of the extrusion.
    We do not know for sure why, but it is possible that this provides ridged support for the extrusion without elasticity, and the tap bites in without causing the last thread or two to move a ay. There would also be no possibility of the tap skidding on a work hardened surface before _biting in_, to start the roll forming process. Another benefit of tapping this way is that the extru ion radius gets nearly filled with the rolled thread; resulting in a longer, stronger thread without frayed ends.
    Q: Tap Lubrication - Do I Need To Use Tapping Fluid, And If So, How?
    A: Yes! A suitable system for tap lubrication should be installed; it should provide a direct flow or pulse of tapping fluid onto the tap at the star of each stroke. Failure to adequately lubricate the tap will result in poor tap life, and excessive load on the tapping system.
    Q: Tap Selection - How Do I Select The Correct Tap?
    A: Pitch diameter limits:
    Our special forming taps are stocked in the more common sizes and H or D limits, for English or metric taps, respectively as listed in our price sheet. If you require a special fit, or a p e-plate oversize tap, do not forget to specify this when ordering. Non-standards are generally not available from stock, and prices may vary.
    Tap surface treatments:
    The special coldforming taps specified for use with Danly In-Die tapping units are Titanium Nitride coated as a standard procedure. This has been found to be a good all-round treatment for most forming applications, and will effectively contribute to extended tap life. However, certain metals and alloys require different surface treatments to optimize tap life, and Danly makes the e available as specials. Normally this means that they cost more than the standard TiN treated taps, and price will be dependent on quantity ordered.
    Nitrogen Cylinders
    Q: What are nitrogen cylinders used for?
    A: Danly IEM Nitrogen Gas Cylinders are used in a wide range of tooling applications to provide a constant pressure beginning with the point of conta t or where more force is required within the tool.
    Nitrogen gas springs are specifically used in a number of applications including draw dies, form dies, stripper pad applications, in cam slide units, and as stock lifters.
    Pins and Bushings
    Q: Do you have any max. speed recommendations for a pin & plated bushing die set
    A: The key to longevity for pins and bushings is proper and constant lubrication of the contact surfaces. The Danly IEM Microme pin will enhance the performance of any die set. Danly IEM self-lubricated bushings remove the need for outside lubrication and maintenance.
    Danly IEM does not have a published maximum rating either by press strokes per minutes or linear travel inches per minute for pins and bushings. Field service reports have shown bronze pla ed bushings running in 250 to 300 spm applications. However, the key to pin and bushing functionality is constant lubrication of the wearing surface along with the control of all the die stamping variables. These include: press operating condition, material thickness, operations being performed in the die, punch and die clearances, cam slide action, and the operating environment (cleanlin ss).
    Q: Why are some Guide Pins chromed plated and others not? What is the reason for the plating?
    A: The Danly IEM Microme plating gives an exceptionally smooth, hard wearing surface, providing resistance to corrosion, less friction and maintenanc or the close working fit. The Microme plating greatly increases the accuracy and working life of the die set or other equipment using these guide posts.
    Q: I Would like to know if you make toggle pin bushings (self lubricated) for injection molding machine clamping units?
    A: Danly IEM offers many various sizes and styles of self-lubricated aluminum bronze bushings for use in metalworking tools, injection mold and speci l machinery. Diameters from 3/4" to 5" and lengths from 7/8" up to 6" are our standard bushing product offering, though other sizes are available as specials. The styles include straight sleeve nd shoulder bushings both of which may be used in the toggle section of the press.
    Punches and Die Buttons
    Q: What is a good steel for punch and button selection?
    A: This would depend on your application. In general M-2 High Speed steel is an excellent material for punches and A-2 Air Hardened steel works well or die buttons
    Q: What should I do to stop Slug Jamming.
    A: To eliminate Slug Jamming, you can increase die clearance, reduce land in die button (on thin stock), or check the lubricant you are using.
    Q: What should the die clearance be for the material being punched?
    A: The die clearance should be 10% to 15% of the material thickness.
    Q: Why do the heads keep breaking on my punches?
    A: There are several things that could be happening, it is a process of trial and error in some cases. This is a checklist of what to consider when searching out the breakage problem.
  • Heads are not drawn back on the punch.
  • Correct punch material for application.
  • Backing plate too hard.
  • Increase head diameter.
  • Increase head thickness.
  • Grind angle on top of head of punch.
  • Change point configuration - grind a shear angle on the point.
  • Q: What to do if my punch is galling?
    A: There are several things that can be done if your punch is galling:
  • Check Die and Press alignment,
  • Check die clearance,
  • Use coating on punches (nitride),
  • Use a different punch material,
  • Put back taper on punch points,
  • Reduce the penetration into the die button.
  • Springs
    Q: Are die springs available in stainless steel?
    A: Danly IEM can manufacture special springs. Let us know what you are looking for and we will get you a quote.
    Q: How Do I Get The Best Service From Die Springs?
    A: Understand what the die springs are required to do before selecting a particular size and rating. Dies that cycle slowly, or are used for short ru s, can make use of springs operating at a higher % of their theoretical capacity and still provide good life.
  • The more springs that can be designed into the die set the better. This will produce the required loading at the least deflection and increase the useful life of the springs.
  • Make sure springs are properly guided to avoid buckling.
  • Always preload correctly to avoid shock loading and stress surges.
  • Replace all the springs in a die at predetermined intervals. This will redistribute loads evenly, instead of on top of an unbalanced, mixed assembly of old and new springs.
  • Do not mix springs of different types in the die set. The critical factor here is the cost of downtime, not the price of the springs.
  • Avoid a hostile environment which could lead to spring failure. Protect the springs where possible from excessive temperatures, corrosion and damage from metal and other obstructions.
  • Never modify die springs by cutting off coils or grinding the inside or outside diameters. This will lead to early failure and possible die damage.
  • When resharpening a die, the spring pockets should be deepened proportionally. This will maintain the correct spring travel and load level.
  • Q: How Do I Go About Selecting Suitable Die Springs For My Application?
    A: Work through the spring selection steps on pages 4 and 5 in the DANLY DIE SPRING CATALOG. These steps will help you choose suitable springs.
    Q: Should I Use A Rod Or A Pocket To Support The Spring?
    A: In general, a rod is better for long springs because it will keep the spring straighter; however, if the deflection is minimal, it won't be necessa y. The consistency of the spring surface quality is critical to spring life; any fracture or damage to the surface is potentially a breakage point - therefore you need the spring as free standing as possible. Rubbing on the sides of a poorly finished pocket is a typical cause of premature failure. Spring cages or retainers also help extend spring life.
    Q: Up To What Temperature Can I Operate Danly Die Springs?
    A: The maximum recommended operating temperature for Danly Die Springs is 425 degrees F. (218 degrees C). In fact, some load loss or relaxation may a so be experienced at temperatures of 300 degrees F. (150 degrees C)
    Remember that apart from external conditions, heat generated by the working die may be significant in some applications.
    Q: What Is The Life Expectancy Of A Die Spring?
    A: Because each application is different, it is impossible to say. Generally, the shorter the deflection the longer the life; at optimal deflection, illions of strokes are possible. The life of a particular spring can be affected by whether there is a sufficient number of springs in the die and whether they are all working equally. (Brands of springs should not be mixed, even if they have similar load ranges - the thickness of the wire and performance will have an impact on spring and die performance.) The environment, such as atmo phere and temperature will also have an effect. How well the spring is seated and guided, the length of stroke, the number of strokes per minute, and the amount of preload used are also factors.< TD>
    Q: Why And How Much Should I Pre-load Die Springs?
    A: There is no hard and fast rule for the minimum amount of initial compression to be designed into a spring application, but more is better than less We suggest that preload be at least 1/6 of total deflection, and stroke 5/6 of total deflection, when total deflection is equal to maximum operating deflection as listed in our catalog. Avoid s tuations where a spring is to be operated with little or no preload. In these situations, the die spring could actually "bounce" in the pocket, causing harmonics, which lead to fracture. Bear in mind that where you have only a little preload, the spring may eventually take a set, and have a shorter free length, and you will end up with no preload at all.
    Q: Why Are The Die Springs Made From A Rectangular Wire Cross-Section?
    A: Rectangular or close to rectangular cross section wire is used for die springs because this reduces the solid height required, even though stress d stribution is not as even as it is in round wire springs. Also, more material can be incorporated into the allocated space. All major spring manufacturers now use this type.
    Q: Danly Sells Both Mechanical And Gas Springs. Which Should I Use For My Application?
    A: Both types have distinct advantages in certain applications. In general, the gas or nitrogen spring will give you more force on contact than the m chanical spring, with a small pressure rise. This has benefits in some applications, but is not necessary nor is it worth the extra cost, in others. Also, for long stripper travel, the gas sprin will give you more stroke for a given height than a mechanical spring. However, gas springs are limited to an operating temperature of 150 degrees, and a cycle rate of 200 inches per minute.
    Q: Why Are The Spring Ends Closed And Ground?
    A: Coils on each end are closed during the coiling operation to provide a large bearing surface. Ends are ground square so that springs will stand on either end - which is key to long spring life. If the ends are too thin, pieces may break off and cause problems. DANLY IEM spring ends are just long enough to allow for maximum bearing surface nd standing up straight, without having the risk of broken ends.
    Wear Plates
    Q: How long does the product last?
    A: The operating environment of the application determines the longevity of the products. Harsh environments with acids or steam will be detrimental o the product. The use of petroleum cleaners may decrease the effectiveness of the product.
    Q: Where do I use these products?
    A: Wear products are used anywhere friction exists in a tool, machine, or a mold. Danly IEM self-lubricated products provide a contamination-free env ronment of mold applications. Other uses have included automation equipment and conveyors.
    Wear Products
    Q: Can I grease the product? What happens when the product is greased?
    A: The Danly IEM self-lubricated products should NOT be greased at any time.
    Q: What is "self-lubrication"?
    A: Self-lubrication is the science of providing lubrication to the frictional wear surfaces without ancillary lubrication lines, oil or grease grooves, or spraying systems. This technology creates a light lubricating barrier between the wear surfaces created by the frictional heat of the moving components. Oil is drawn out of the oil-impregnate graphite plug onto the wear surface by the minimal heat created by the surface friction. The oil adheres the graphite to the wearing surface generating the lubrication barrier.

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