IN-DIE TAPPING TOOLS
TECHNICAL INFORMATION MANUAL
CALL TOLL FREE: 1-800-243-2659
FAX: 1-800-833-2659
© 2004 Danly IEM, A Division of Connell Limited Partnership
www.danly.com
THIS MANUAL CONTAINS INFORMATION APPLICABLE
TO THE FOLLOWING IN-DIE TAPPING TOOL MODELS:
HY1024
ME1024
LP25M6
(Patent #5173015)
TABLE OF CONTENTS
PAGE NUMBER
♦ PRODUCT SPECIFICATIONS
2
♦ ACCESSORIES
5
♦ TAPPING DEPTH/MATERIAL THICKNESS CHARTS
8
♦ FORMING TAP PRE-HOLE SIZE CHARTS
9
♦ APPLICATION DRAWINGS
11
♦ DESIGNING A CAM DRIVER
38
♦ RAPID T.A.P. CAM DESIGN SOFTWARE INTRODUCTION
39
♦ TROUBLE SHOOTING
40
1
HY1024 Series
for Hydraulic Presses
www.danly.com
Product Features
The HY is the smallest and most compact of the tapping tools.
The HY1024 is an economical solution for tapping from the top down
in a hydraulic press. Since the HY1024 is not cam actuated, the press
controls the acceleration and tap speed. The HY1024 will tap size
#0 - #12 or up to M5 and typically runs at production rates between
60 - 100 strokes per minute up to a maximum 200 (SPM) rate based
on strip material, tap size and tap pitch.
HY1024
By utilizing multiple tools in place of one special tapping tool, you
can control flexibility in the stamping operation and greatly reduce
downtime due to unscheduled maintenance.
NOTES:
♦
The HY1024 tapping tool cannot be used in a mechanical press. See the ME1024 or the LP25M6 for
applications requiring use in a mechanical press.
HY1024 footprint dimensions
Notes: ♦ Tapping depth/maximum material thickness can be found on Page 8.
♦ Metric dimensions are in italics.
2
ME1024 Series
for Mechanical Presses
www.danly.com
Product Features
The ME1024 is a simple and compact tool with a small footprint
for tapping top down in a mechanical or hydraulic press. The ME1024
utilizes a cam driver to control tool acceleration. The ME will tap size
#0 - #12 or up to M5 and typically runs at production rates between
60 - 100 strokes per minute up to a maximum of 200 (SPM) based
on strip material, tap size and pitch.
The cam driver is designed as a separate functional piece to maximize
die design flexibility and take the sinusoidal motion that is inherent
with mechanical presses and turn it into a rotary tapping motion. The
cam driver mounts easily on a punch plate or upper die shoe above the
tapping tool. The cam driver is application specific and can be
manufactured by using the free “Rapid TAP” CAD design software.
By utilizing multiple tools in place of one special tapping tool, you
can control flexibility in the stamping operation and greatly reduce
downtime due to unscheduled maintenance.
A = TAPPING STROKE + 5.776
ME1024 footprint dimensions
Notes: ♦ Tapping depth/maximum material thickness can be found on Page 8.
♦ All dimensions are in inches.
3
ME1024
LP25M6 & LP516M8 Series
for Mechanical Presses
www.danly.com
Product Features
The LP is the most versatile tool with a simple and compact design
for tapping top down, bottom up or at any angle. The LP utilizes a cam
driver to control tool acceleration and tap speeds. The LP25M6 will tap
size #0 - 1/4 or M6 and the LP516M8 will tap 1/4" - 5/16" or M8 while
making either right or left-hand threads. The LP typically runs at
production rates between 20 - 60 strokes per minute up to a maximum
of 100 (SPM) based on strip material, tap size and pitch.
LP25M6
The cam driver is designed as a separate functional piece to
maximize die design flexibility and take the sinusoidal motion that is
inherent with mechanical presses and turn it into a rotary tapping motion.
The cam driver mounts easily on a punch plate on the upper die shoe
above the tapping unit to provide the proper amount of tap acceleration
and a positive return. The cam driver is application-specific and can be
manufactured by using the free “Rapid TAP” CAD design software.
By utilizing multiple tools in place of one special tapping tool, you
can control flexibility in the stamping operation and greatly reduce
downtime due to unscheduled maintenance.
LP Cam Driver profile
Important
Note
The shut height from the bottom of the upper shoe to the
mounting surface of the unit cannot be less than 3.775",
unless modified (see installation manual).
LP25M6 & LP516M8 footprint dimensions
NOTE A:
Notes: ♦ Footprint dimensions are identical for both units.
However, performance variations exist between the
two units. Consult the Rapid Tap software.
Dowel pin holes ±0.001
Fastener holes ±0.005
♦ Tapping depth/maximum material thickness can be
found on Page 8.
♦ All dimensions are in inches.
4
Accessories and
Replacement Parts
LP Extensions
Some applications require a wide strip width incorporating a
tapped hole located a distance from the edge of the material. The LP
integrates modular extensions in combination with a standard tool to
provide flexibility in design and off-the-shelf type components.
The standard Cam Extension provides over 9" of extra length
while the extra long extension provides over 19". All components are
made from the best materials for maximum life and performance.
LP STANDARD EXTENSION
LP EXTRA LONG EXTENSION
Notes: ♦ All dimensions are in inches.
5
www.danly.com
www.danly.com
Accessories and
Replacement Parts
Forming Taps —
Product Features
The special forming taps used in the in-die taping units
are available in inch and metric standard sizes listed below. All
forming taps are sold with a TiN coating as standard. Other
coatings for special material applications are available on
request. Forming taps provide a superior quality and finish of
thread, with no chip formation.
Taps are sold in packs of 12.
INCH SIZES
Part Number
R-006004
R-006008
R-006033
R-006010
R-006013
R-006009
R-006012
R-006031
R-006014
R-006030
R-006017
R-006032
R-006016
R-006019
R-006018
R-006021
R-006090
R-006020
R-006091
R-006092
R-006093
R-006094
METRIC SIZES
Shank Size1 Tap Size & D Limit
Small
Small
Small
Small
Small
Small
Small
Small
Small
Small
Small
Small
Small
Small
Small
Medium
Large
Medium
Large
Large
Large
Large
Part Number
R-006042
R-006044
R-006045
R-006046
R-006047
R-006049
R-006050
R-006095
R-006096
R-006097
2 - 56 - RH3
4 - 40 - RH5
4 - 40 - RH7
5 - 40 - RH5
6 - 40 - RH5
4 - 48 - RH5
6 - 32 - RH5
6 - 32 - RH7
8 - 32 - RH5
8 - 32 - RH7
10 - 32 - RH6
10 - 32 - RH8
10 - 24 - RH6
12 - 28 - RH6
12 - 24 - RH6
1/4 - 28 - RH6
1/4 - 28 - RH6
1/4 - 20 - RH6
1/4 - 20 - RH6
5/16-32 – RH6
5/16-24 – RH6
5/16-18 – RH7
Shank Size1 Tap Size & D Limit
Small
Small
Small
Small
Small
Small
Medium
Large
Large
Large
M2.0 x .40 D5
M2.5 x .45 D5
M3.0 x .50 D5
M3.5 x .60 D6
M4.0 x .70 D6
M5.0 x .80 D7
M6.0 x 1.00 D8
M6.0 x 1.00 D8
M8.0 x 1.00 D8
M8.0 x 1.25 D8
Standard Stock Taps are TiN Coated
Special Tap Sizes, Pitches and Coatings are Available per Quotation
1
♦
♦
♦
Tap diameter shank size application:
Small – 0 - #12 (M2 – M5) diameter taps: use in HY1024, ME1024, LP25M6
Medium – ¼" (M6) diameter taps: use in LP25M6
Large – ¼" – 5/16” (M6 - M8) diameter taps: use in LP516M8
6
Accessories and
Replacement Parts
www.danly.com
Pitch Inserts/Tap Holders —
Product Features
Pitch inserts are interchangeable components of the tapping operation and are specific to
the tap pitch of the tapped hole. Each pitch insert contains a tap holder with a quick release
depression collar. Taps can easily be changed within seconds in most applications.
For applications needing a little extra reach to tap inside an embossment, a pitch insert
extension can be made specific to your needs. Our engineering department will work with you
on your specific application.
Pitch
Tap
Holder
Size1
INCH SIZES
Part
Number
for
HY/ME1024
Part
Number
for
LP25ME
Part
Number
for
LP516M8
56
48
40
32
28
28
28
24
24
20
20
18
Small
Small
Small
Small
Small
Medium
Large
Small
Large
Medium
Large
Large
R-002005
R-002006
R-002007
R-002008
R-002009
—
—
R-002010
—
—
—
—
R-002024
R-002025
R-002026
R-002027
R-002028
R-002031
—
R-002029
—
R-002030
—
—
—
—
—
—
—
—
R-002112
—
R-002113
—
R-002114
R-002115
METRIC SIZES
Tap
Part
Part
Holder
Number
Number
for
for
Size1
HY/ME1024 LP25ME
Part
Number
for
LP516M8
Small
Small
Small
Small
Small
Small
Medium
Large
Large
—
—
—
—
—
—
—
R-002116
R-002117
Pitch
0.40 mm
0.45 mm
0.50 mm
0.60 mm
0.70 mm
0.80 mm
1.00 mm
1.00 mm
1.25 mm
R-002048
R-002047
R-002046
R-002045
R-002044
R-002042
—
—
—
R-002068
R-002067
R-002066
R-002065
R-002064
R-002062
R-002060
—
—
7
Pitch insert for non-standard sizes or
pitches are by quotation.
1
Tap diameter shank size application:
♦ Small – 0 - #12 (M2 – M5)
diameter taps: use in
HY1024, ME1024, LP25M6
♦ Medium – ¼" (M6) diameter
taps: use in LP25M6
♦ Large – ¼" – 5/16" (M6 - M8)
diameter taps: use in LP516M8
www.danly.com
Maximum Tapping Depth/
Material Thickness
MAXIMUM MATERIAL THICKNESS (T) - INCH
Size and
HY & ME
Pitch
1024
LP25M6
LP516M8
2-64
2-56
3-56
3-48
4-48
4-40
5-44
5-40
6-40
6-32
8-36
8-32
10-32
10-24
12-28
12-24
1/4-28
1/4-20
5/16x32UN
5/16x24UN
5/16x18UN
0.080
0.091
0.091
0.106
0.106
0.128
0.116
0.128
0.128
0.159
0.142
0.159
0.159
0.213
0.182
0.213
—
—
—
—
—
0.168
0.194
0.194
0.230
0.230
0.253
0.280
0.280
0.280
0.272
0.261
0.261
0.261
0.248
0.248
0.230
0.230
0.205
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
0.319
0.305
0.277
0.355
0.286
MAXIMUM MATERIAL THICKNESS (T) - METRIC
Size and
HY & ME
Pitch
1024
LP25M6
LP516M8
M2 x .4
M2.5 x .45
M3 x .5
M3 x .6
M3.5 x .6
M4 x .7
M5 x .8
M5 x .9
M6 x 1.0
M8 x 1.0
M8 x 1.25
2.0
2.2
2.5
3.0
3.0
3.5
4.0
4.5
—
—
—
4.2
4.8
5.4
6.6
6.6
6.9
6.6
6.2
5.9
—
—
—
—
—
—
—
—
—
—
8.9
8.9
8.2
NOTE: Maximum material thickness (T) includes extrusion height and .020 inch (or 0.5mm) gap between
the tip of the tap and the top of the material stock.
8
Pre-Hole Sizes
www.danly.com
METRIC COLDFORMING TAPS
TAP SIZE/
PITCH (mm)
65% THREAD
THEOR. HOLE
SIZE (mm)
70% THREAD
THEOR. HOLE
SIZE (mm)
75% THREAD
THEOR. HOLE
SIZE (mm)
M3 x 0.5
M3 x 0.6
M3.5 x 0.6
M4 x 0.4
M4 x 0.7
M4.5 x 0.75
M5 x 0.8
M5 x 0.9
M6 x 1.0
M6.3 x 1.0
M7 x 1.0
M8 x 1.0
M8 x 1.25
M10 x 1.25
M10 x 1.5
M12 x 1.25
M12 x 1.75
2.779
2.735
3.235
3.823
3.691
4.169
4.646
4.602
5.558
5.858
6.558
7.558
7.448
9.448
9.337
11.448
11.227
2.762
2.714
3.214
3.809
3.667
4.143
4.619
4.572
5.524
5.824
6.524
7.524
7.405
9.405
9.286
11.405
11.167
2.745
2.694
3.194
3.796
3.643
4.118
4.592
4.541
5.490
5.790
6.490
7.490
7.363
9.363
9.235
11.363
11.108
NOTE: The shaded pre-hole sizes in the above table have been changed, as they were
incorrectly calculated in earlier versions of this manual.
PRE-HOLE SIZE CALCULATION
Hole size = Basic Major Diameter Example:
Percent of Full Thread x mm Pitch
147.06
Find the theoretical pre-hole punch size for M8 x 1.25mm to produce 65% thread:
Hole size = 8.00 - 65 x 1.25 / 147.06
= 8.00 - 0.5525
= 7.448mm
NOTE: Tapping an undersize hole may result in tap breakage due to excessive torque. As a
starting recommendation, 65% thread should be considered.
Tapping over 75% of thread is not recommended.
9
Pre-Hole Sizes
www.danly.com
INCH COLDFORMING TAPS
TAP SIZE/
PITCH (in)
65% THREAD
THEOR. HOLE
SIZE (in)
70% THREAD
THEOR. HOLE
SIZE (in)
75% THREAD
THEOR. HOLE
SIZE (in)
0 – 80 NC
1 – 64 NC
1 – 72 NF
2 – 56 NC
2 – 64 NF
3 – 48 NC
3 – 56 NF
4 – 40 NC
4 – 48 NF
5 – 40 NC
5 – 44 NF
6 – 32 NC
6 – 40 NF
8 – 32 NC
8 – 36 NF
10 – 24 NC
10 – 32 NF
12 – 24 NC
12 – 28 NF
1/4 – 20 NC
1/4 – 28 NF
5/16 – 18 NC
5/16 – 24 NF
3/8 – 16 NC
3/8 – 24 NF
7/16 – 14 NC
7/16 – 20 NF
1/2 – 13 NC
1/2 – 20 NF
0.0545
0.0661
0.0669
0.0781
0.0791
0.0898
0.0911
0.1010
0.1028
0.1140
0.1150
0.1243
0.1270
0.1503
0.1518
0.1717
0.1763
0.1977
0.2003
0.2280
0.2343
0.2879
0.2941
0.3474
0.3566
0.4059
0.4154
0.4660
0.4779
0.0540
0.0655
0.0633
0.0774
0.0785
0.0890
0.0904
0.1000
0.1020
0.1130
0.1141
0.1230
0.1260
0.1490
0.1507
0.1700
0.1750
0.1960
0.1989
0.2260
0.2329
0.2861
0.2927
0.3452
0.3552
0.4035
0.4137
0.4634
0.4762
0.0536
0.0650
0.0659
0.0769
0.0780
0.0884
0.0899
0.0993
0.1014
0.1123
0.1134
0.1221
0.1253
0.1481
0.1498
0.1688
0.1741
0.1948
0.1978
0.2245
0.2318
0.2842
0.2912
0.3431
0.3537
0.4011
0.4120
0.4608
0.4745
PRE-HOLE SIZE CALCULATION
Hole size = Basic Major Diameter Example:
Percent of Full Thread
Number of Threads per Inch
Find the theoretical pre-hole punch size for 1/4 - 20 to produce 65% thread:
Hole size = 0.250 - 0.0068 x 65/20
= 0.250 - 0.0221
= 0.2279 inches
NOTE: Tapping an undersize hole may result in tap
breakage due to excessive torque. As a
starting recommendation, 65% thread
should be considered.
Tapping over 75% of thread is not
recommended.
10
Application Drawings
www.danly.com
FIGURE #1
LOW PROFILE TOOLS TAPPING FROM THE BOTTOM UP
THIS DRAWING IS SHOWING THE LP25M6 IN THE CLOSED POSITION.
NITROGEN SPRING CAN BE USED
TO ELIMINATE TOO LONG OF A DIE SPRING.
SPRING TRAVEL IS BASED
ON TAPPING STROKE, PLUS
PRELOAD ON MATERIAL BEFORE
TAPPING. (PRELOAD WILL INSURE
PROPER STRIPPING FOR TAPPING.)
CUSTOMER CAN USE A BRIDGE
STRIPPER INSTEAD OF A SPRING
STRIPPER IF DESIRED.
UPPER DIE
MATERIAL
SPACER BLOCK
(IF NEEDED)
MATERIAL
DIE
STRIPPER
DIE
1/4 S.H.C.S.
8 PLACES
CAM
BOTTOM DIE
MACHINE POCKET IN
DIE SET FOR DESIRE
HEIGHT.
MACHINED POCKETS
FOR CAM CLEARANCE
HEEL BLOCK
MACHINE GROOVE TO ALLOW
PASSAGE FOR GREASE GUN.
D-04-1002
11
www.danly.com
Application Drawings
FIGURE #2
LOW PROFILE TOOLS TAPPING FROM THE TOP DOWN
LP25M6 IS BOLTED TO THE STRIPPER AND
THE SUPPORT BLOCK
REMOVE BRIDGE PLATE, (1.00 inch THICK)
THIS WILL ALLOW A SMALLER SHUT HEIGHT.
S.H.C.S. TO HOLD CAM TO DIE.
UPPER DIE
HEEL BLOCK
CAM
DIE
CAM
STRIPPER
BOTTOM DIE
BOLT
MACHINED POCKETS
FOR CAM CLEARANCE
SUPPORT BLOCK
D-04-1003
12
Application Drawings
www.danly.com
FIGURE #3
HEEL BLOCKS FOR LOW PROFILE TOOLS
FRONT HEEL BLOCK
BACK HEEL BLOCK
DRILL TAP
10-32 (3 PLS)
DRILL C-BORE FOR
10-32 SHCS (3 PLS)
.125 RAD (2PLS)
2.0000 2.6000
1.0000
1.3000
1.3120
3.1000
0.5000
DRILL TAP
6-32 (3PLS)
0.5000
.25 RAD (2PLS)
45°
X .02 (4PLS)
FRONT HEEL BLOCK
CLEARANCE POCKETS FOR CAM
BACK HEEL BLOCK
DRILL C-BORE FOR
6-32 SHCS (3PLS)
0.8000
CAM TRACK
1.3120
0.6560
CAM FOLLOWER
0.4000
0.2500
0.5000
0.3750
45°
0.9250
PARALLEL
0.2500
X .02 (4PLS)
0.2500
0.2500
SHIMS FOR CLEARANCE ON SET UP.
0.5000
13
D-04-1004
www.danly.com
Application Drawings
FIGURE #4
POSITION FOR CAM FOLLOWERS
(RIGHT-HAND THREADING ONLY)
POSITON A
8.125
POLYGON DRIVE
SHAFT.
D-04-1005
14
Application Drawings
www.danly.com
FIGURE #5
LP25M6 & LP516M8 CAM DRIVER MOUNTING INFORMATION
DRILL AND C-BORE
FOR 1/2-13 SHCS
(4PLS)
CAUTION
.500 DOWEL PIN
(2PLS)
BOLTS AND DOWEL
PINS CAN`T MOUNT
BELOW THIS SURFACE.
D-04-1006
15
www.danly.com
Application Drawings
FIGURE #6
LOW PROFILE TOOLS MOUNTED ON A STRIPPER PLATE
BRIDGE STRIPPER
HEEL BLOCK
HEEL BLOCK
BOSS
TIP OF TAP SHOULD NOT
EXTEND BELOW BOSS.
BOSS SHOULD NOT EXTEND
BELOW STRIPPER PLATE.
D-04-1007
16
Application Drawings
www.danly.com
FIGURE #7
RECOMMENDED LUBRICATION SYSTEM OPTION #1
STRIPPER PLATE
NOZZLE SHOULD BE
WITHIN .02 TO .100
OF THE DIA OF TAP.
MACHINE SLOT OR DRILL POCKET
FOR TUBE.
SLOT IS PROVIDED IN PITCH INSERT TO
ALLOW 3/32 BRASS TUBING TO PASS THRU.
3/32 OD X .06 ID BRASS TUBING
.093 ID X 1/8 OD TEFZEL TUBING
USE TUBING THAT WILL WITHSTAND
1,1,1 TRICHLORETHANE. THIS COMPOUND
IS USED IN GOOD TAPPING FLUIDS.
D-04-1008
17
www.danly.com
Application Drawings
FIGURE #8
RECOMMENDED LUBRICATION SYSTEM OPTION #2
STRIPPER PLATE
NOZZLE SHOULD BE
WITHIN .02 TO .100
OF THE DIA OF TAP.
MACHINE SLOT OR DRILL POCKET
FOR TUBE.
SLOT IS PROVIDED IN PITCH INSERT TO
ALLOW 3/32 BRASS TUBING TO PASS THRU.
1/8 OD X .097 ID BRASS TUBING
3/32 OD X .06 ID BRASS TUBING
EITHER USE SOLDER OR
E-POXY (JB WELD)
IF TUBE NEEDS TO BE BENT,
USE A TUBE BENDER
COMPRESSION FITTING
FOR 1/8 DIA TUBE
1/8 MALE PIPE
THREAD IS 5090K11
1/8 FEMALE PIPE THREAD IS 5089K11
D-04-1009
18
Application Drawings
www.danly.com
FIGURE #9
PITCH INSERT ASSEMBLY
BOSS OR
STRIPPER
COLLET
FEMALE
LEAD SCREW
TAP
KEY STOCK
MIS-FEED
SPRING
MALE
LEAD SCREW
D-04-1010
19
www.danly.com
Application Drawings
FIGURE #10
SHUT HEIGHT
0.050 OF CLEARANCE AT
THE END OF THE STROKE.
3.775
MIMIMUM SHUT
HEIGHT
CLEARANCE HOLES WILL
BE REQUIRED IN DIE SHOE
FOR CAM SIDE PLATES.
D-04-1011
20
Application Drawings
www.danly.com
FIGURE #11
FIXED CAM DIMENSIONS FOR THE LP CAM DRIVER
(RAPID TAP SOFTWARE WILL SELECT EITHER CAM A OR CAM B)
ENGRAVE JOB NUMBER.
B
.005 ABC
4.5500
2.5500
C
3/8 PRESS FIT
DOWEL PIN 4 PLS
CAM A
CAM B
4.0000
1.000 2 PLS
A
3/8 PRESS FIT
DOWEL PIN 4 PLS
TAP AND C-BORE FOR
5/16-18 X 1.00 S.H.C.S
4 PLS
5.5000
1.500 2 PLS
.375 2PLS
.875 2 PLS
TAP AND C-BORE FOR
5/16-18 X 1.00 S.H.C.S
4 PLS
1.0000
0.5000
2.425
.500
2.425
CAM TRACK
HEIGHT
CAM TRACK
HEIGHT
.50 OF STRAIGHT
.50 OF STRAIGHT
4.1000
1.1250
CAUTION
BOLTS CAN`T MOUNT
BELOW THIS SURFACE.
BREAK ALL SHARP EDGES
FINISH: NONE
1.1250
MATERIAL: 7075-T6 ALUMINUM
.500 MINIMUM DIM
MATERIAL CAM BE REMOVED
TO ADD CLEARANCE. .500 MIN
DIM FROM END OF CAM TRACK
TO EDGE OF MATERIAL.
D-04-1012
21
www.danly.com
Application Drawings
FIGURE #12
LOW PROFILE TOOLS MOUNTED ON A SPRING STRIPPER
SPRING TRAVEL IS BASED ON
TAPPING STROKE, PLUS .25 OF
PRELOAD.
4 NITROGEN SPRINGS EQUALLING
3000 LB BEFORE CAMS MAKE
CONTACT WITH CAM FOLLOWERS.
.500 DIA LOCATING PINS (4PLS)
THIS WILL KEEP THE STRIPPER
PLATE FROM SHIFTING WHEN
THE CAMS MAKE CONTACT WITH
THE CAM FOLLOWERS.
D-04-1013
22
Application Drawings
www.danly.com
FIGURE #13
TAPPED HOLE DETECTION
(TO DETERMINE WHETHER THE TAP FULLY PENETRATES THROUGHT THE MATERIAL)
SPRING LOADED
BRIDGE STRIPPER
MATERIAL STRIP
MATERIAL GUIDES
DIE SPRING
GUIDE PINS
DIE PLATE
SPRING
CLEARANCE BETWEEN MATERIAL
AND PLUNGER IS 2.5 X PITCH
SET SCREW WITH
THRU HOLE
SWITCH
D-04-1014
23
www.danly.com
Application Drawings
FIGURE #14
EXAMPLE OF 13 LP TAPPING UNITS
TAPPING FROM THE BOTTOM UP
D-04-1017
24
Application Drawings
www.danly.com
FIGURE #15
EXAMPLE OF LP25M6
TAPPING UP AND DOWN IN THE SAME STATION
D-04-1018
25
www.danly.com
Application Drawings
FIGURE #16
CAM DRIVER TEMPLATE FOR ME1024
CAM TEMPLATE FOR ME1024
9.785
14.000
2.00
6.000
.750
1.875
6.150
OIL HOLE
.375 RAD
(4 PLS)
.250
1.000
(2 PLS)
(2 PLS)
30
9.785
GREASE FITTING (45 DEG ANGLE)
.500
(2 PLS)
.500
10.785 MIN
1.300
DIA
NOTE:
1
CAM PROFILE DETERMINED
BY PRESS STROKE AND
TAPPING STROKE
SHADED AREA TO BE MACHINED BY
CUSTOMER BASED ON APPLICATION
MODEL ME STANDARD CAM
OPEN AND SHUT HIEGHTS
1.822
.75
1
1.875
5.02
4.396
D-04-1019
26
Application Drawings
www.danly.com
FIGURE #17
ME1024 CAM
FIXED DIMENSIONS
ENGRAVE JOB NUMBER
14.000
2.00
6.000
.750
1.875
.375 RAD
(2 pls)
.375 RAD
(4 PLS)
R 1.000 (4pls)
.250
1.000
(2 pls)
(2 pls)
30
(2 pls)
9.785
11.000
.6000
1.0000
.6250 DIA
7.0000
FINISH: NONE
MATERIAL: 7075-T6 ALUMINIUM
D-04-1021
27
www.danly.com
Application Drawings
FIGURE #18
ME1024 CAM
ON BRIDGE STRIPPER
.630 CLEARANCE HOLE
FOR DRIVE SCREW
SPRING LOADED
BRIDGE STRIPPER
MATERIAL STRIP
MATERIAL GUIDES
DIE SPRING
GUIDE PINS
DIE PLATE
D-04-1022
28
Application Drawings
www.danly.com
FIGURE #19
CAM DRIVER MOUNTING FOR ME1024 CAM
USING A SPRING STRIPPER
THIS SECTION IS REMOVED BY
END USER BASED ON PROPER
HEIGHT REQUIREMENTS.
THIS DIM. IS THE SAME FOR
ALL CAM`S, WHEN USED IN A
SPRING STRIPPER APPLICATION.
SUBTRACT AMOUNT OF PRELOAD
TRAVEL USED BEFORE TAPPING
FROM THIS 1.00 DIM. IN MOST CASES
USE .05 TO .100 OF PRELOAD TRAVEL.
THIS WILL INSURE PROPER STRIPPING
FOR TAPPING.
1.00
SPRING TRAVEL IS BASE
ON TAPPING STROKE, PLUS
PRELOAD ON MATERIAL BEFORE
TAPPING.
MATERIAL
CAUTION
IF USING A SPRING STRIPPER.
THERE SHOULD BE A SENSOR TO MAKE CERTAIN
THAT THE STRIPPER COMES DOWN 100%. IF STRIPPER
DOES NOT COME DOWN ALL THE WAY THE UNIT
COULD BOTTOM OUT, CAUSING THE CAM ROLLER
TO BREAK.
DIE
MICRO SWITCH
D-04-1023
29
Application Drawings
www.danly.com
FIGURE #20
MOUNTING THE ME1024 UNIT IN A HYDRAULIC PRESS
OPEN
.625 DIA X 1.35 DEEP RELIEF
HOLE IN PUSH BLOCK FOR SCREW
.100 MINIMUM
THIS KEEPS PUSHER
BLOCK FROM MAKING
CONTACT ON CAM
PLATES.
1.250
CAM PLATE
CLOSED
D-04-1024
30
Application Drawings
www.danly.com
FIGURE #21
TAPPING WITH MATERIAL LIFTERS
STOP BLOCK TO OVER
COME NITROGEN SPRINGS
SPRING BRIDGE STRIPPER
.50 DIA SPRINGS
MATERIAL
0.6250
NITROGEN SPRINGS
TRAVEL
MATERIAL LIFTERS
SUPPORT PAD
APPROXIMATELY 1800 LB OF NITROGEN PRESSURE.
D-04-1025
31
www.danly.com
Application Drawings
FIGURE #22
SAMPLE LAYOUT FOR MULTIPLE TAPPING
WITH 3 ME1024 UNITS IN ONE DIE
48.6781
ME1024 TAPPING UNITS.
22.9537
AIR CLAMP
AIR FEEDER
16.0000
4.1250
4.1250
NOTE: ALL DIMENSIONS ARE APPROXIMATE
D-04-1026
32
Application Drawings
www.danly.com
FIGURE #23
TYPICAL WAY OF APPLYING TAPPING UNITS TO IN-DIE TAPPING
FIRST HOLE
TAPPED
MOUNTING SCREWS
FOR CAM
9.300
PART PUNCHED OUT
12.103
SECOND HOLE
TAPPED
PUNCH HOLES
FOR TAPPING
THIRD HOLE
TAPPED
PART
THREE HOLES
TAPPED 10-32
THIS DIE HAS ONE
MACHINED POCKET
FOR ALL TAPPING
UNITS
TAPPING UNITS 1,2,3
3/8-16 S.H.C.S
MACHINED POCKET
.771
2.00
6.271
5.00
.600
2.00
3.00
5.00
DIE
THIS DIM. IS FROM THE TOP
OF THE MATERIAL OR EXTRUSION
TO THE TOP OF THE CAM
IN THE CLOSED POSITION
MATERIAL
BOTTOM DIE SET
PARALLEL
1.00
D-04-1027
33
Application Drawings
www.danly.com
FIGURE #24
SUB-PLATE FOR LP25M6
GUIDE RAIL
1/4-20
GUIDE RAIL
1/2-20
STOP BLOCK
SUB-PLATE
D-04-1031
34
Application Drawings
www.danly.com
FIGURE #25
SUB-PLATE FOR LP25M6 CAM
SUB-PLATE
5/16-18 S.H.C.S.
RAIL
STOP BLOCK
D-04-1032
35
www.danly.com
Application Drawings
FIGURE #26
SUGGESTED LAYOUT FOR TAPPING BOTTOM UP
WITH LOW PROFILE TOOLS AND USING A SUB DIE
DIE IN OPEN
POSITION
DIE IN
CLOSED
POSITION
D-04-1033
36
Application Drawings
www.danly.com
FIGURE #27
LP25M6 MOUNTED ON A SPRING STRIPPER
MATERIAL LIFTER
STOP BLOCKS OR NITROGEN
SPRINGS TO OVER RIDE
3,000 LBS OF SPRING
PRESSURE.
FORMING TRAVEL
APPROXIMATIELY 3,000 LBS
OF SPRING PRESSURE.
D-04-1034
37
www.danly.com
Designing a Cam Driver
(Models ME1024 and LP25M6 only)
1. TOOL MODEL:
ME1024 _______________
LP25M6 _______________
2. STROKE OF PRESS: _______________
3. TAPPING STROKE: _______________
The remaining stroke left after the material has advanced in its progression. Example: If a
6" stroke press requires 2" to advance or progress, the tapping stroke would be (6" - 2") = 4".
4. SPEED OF PRESS IN STROKES PER MINUTE: _______________
5. TOTAL THICKNESS OF MATERIAL (include extrusion if applicable): _______________
Material thickness must include the gap between the tip of the tap and the top of material or
extrusion. (Failure to do so could cause improper tap penetration.) (See Figure #15.)
6. MATERIAL TYPE: _______________
7. TAP SIZE: _______________
38
Rapid T.A.P. Software
www.danly.com
Rapid T.A.P. Software
(Tapping Application Program)
Software that aids in the
development of dies with Danly
IEM in-die-tapping tools. This
software is designed to educate
die designers and stamping
facilities on the benefits of In-die
Tapping (IDT) and provide easy
ways to design dies that
incorporate the IDT tools. Rapid
TAP replaces Campro, an earlier
DOS based computer program.
Rapid TAP produces needed
CAD information for the IDT Cam
Drivers that are proprietary to
Danly IEM tapping tools. Rapid
TAP’s program logic evaluates the
sinusoidal acceleration that is
inherent with mechanical presses
and converts it into a linear tapping
motion. This conversion is more
accurate than altering gear ratios
39
www.danly.com
1.
Trouble Shooting
DISTORTED THREADS
Threads are distorted and the go-gage will not go into the tapped hole. Check to see if any
portion of the die is hitting the top of the threads, such as the stripper plate, form block or
a hold-down form pad. If this is the case, provide clearance for the hole by grinding or
machining a counter bore.
2.
TAP BREAKS ON EVERY HIT
Make sure the hole is the correct size for a metal forming tap. If you are using a hole size
recommended for a cutting tap, it is too small and will result in tap breakage. Ensure that the
hole is being registered properly beneath the tap. See Mounting Procedures in the installation
manuals. For recommended pre-hole sizes, refer to the tables on pages 9 and 10 of this
manual.
3.
TAP BREAKS AFTER ONE TO FIVE HITS
Tap height may be misadjusted and stocking out below the nose piece or boss. This condition
often results in the tap catching on the material as at advances.
4.
TAP BREAKS PREMATURELY
Check the lubrication. A discolored or black tap indicates that an improper level nor type of
lubrication is being applied.
5.
TAP SPINS BUT DOES NOT PENETRATE THE HOLE
The tap is backed up by a spring for “no hole” conditions. If this spring is weak there may
not be enough pressure to get the tap started. If a spring stripper or a spring loaded bridge
stripper is used, adjust the tap so that is protrudes slightly from the nose piece. This will put a
preload on the spring and increase spring pressure. If this does not correct the condition, a
stronger spring will have to be used. Call the factory for assistance if this is the case.
6.
IF CHIPS ARE DEVELOPING
The pre-hole for the tap is too small. Opening up the hole by .002" to .003" will usually fix
the problem. Use 65% of thread to start with.
40
6779 Engle Road Suite A - F
Cleveland, OH 44130-7926
TOLL FREE:
FAX:
800.243.2659
800.833.2659
E-MAIL: [email protected]
VISIT US AT www.danly.com
© 2004 Danly IEM, A Division of Connell Limited Partnership
DM109-1 8/04