What is the issue?
Despite the common thinking punching on aluminum requires special attention, if is a cluster tool the attention needs to be multiplied.
Tell us what went wrong
Q: why am I finding littles slugs on the sheet?
A: check the penetration of the tool into the die, often a short stroke ends up in stacking of the slug. This increases the tonnage and can create slug pull. A correct tool penetration should be 2,5-3 mm into the die.
Q: why are the inserts breaking prematurely?
A: the dust particles removed from the punch create what is called a “galling effect”. The particles attach to the punch surface with a process called “cold welding”. Punch thickness increases and the die tolerance is no longer correct, punch gets stuck, machines axis move and the crack happens!
CLUSTER ON GALLING MATERIALS
Soft is not always good, hardness is not always the issue, some soft materials can be more problematic than hard ones.
No worries MATRIX is here to share their experience with you.
How to prevent the problems
First aspect is to be aware on what can happen processing specific materials and how to “prevent” the problems. Coating is not enough: although the punch is properly Cleaning and proper maintenance is a critical aspect, needs to be done regularly. This alone will prevent most of the issues.
Proper die penetration
As said before another critical aspect is the die penetration. Slug needs to pass the threshold of 2,5-3mm. Especially on ant slug dies this is fundamental to properly use the advantages of the slug prevention die technology.
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Aluminium dust traces on the sripper plate
Stacked slugs removed from the bottom of the die