Entire Dayton Die Cushions Catalog
Contents
1. ut OVATIVE RIE n AS L j 1 3 DIE CUSHIONS M i ADJUSTABLE DIE USHI SPECIAL DIE CUSHIONS CUSTOMIZED TO FIT Fa 952 937 0702 FAX 952 937 1132 1 800 343 2874 DIE CUSH DAYTON DIE CUSHIONS 6330 INDUSTRIAL DRIVE EDEN PRAIRIE MN 55346 Se 9 They produce better work at less cost That s why more and more press operators are using Dayton Die Cushions They give more control over drawing and forming operations making it easier to do most jobs They also make it possible to perform some operations that would be impractical by other UNIFORM PRESSURE OVER ENTIRE BLANK Why use die cushions DAYTON DIE CUSHIONS methods By reducing actual working time and changeover time between jobs die cushions result in substantial savings in production cost All press manufacturers offer Dayton Die Cushions as standard equipment Dayton die cushions provide uniform pressure on all parts of a blank during an entire drawing operation This is true regardless of 4 6 10 or 20 inches of draw stroke Nitrogen springs or rubber bumpers cannot assure this They usually result in more pressure being applied to one side or the other UNIFORM PRESSURE THROUGHOUT ENTIRE STROKE With nitrogen springs or urethane pressure applied to the work increases sharply as the stroke increases If there is adequate pressure at the beginning of a stroke then press an2. CUSHION SELECTION CHART STANDARD PIN PADS HEIGHT CUSHION DRAW STD 11 5 8 13 11 16 15 5 8 17 5 8 19 3 4 22 24 3 4 26 1 4 28 7 8 O O O O O O CUSTOM TO SPECIFIC APPLICATION CONSULT FACTORY Height for standard draw only Does not include pin pad mounting plate thickness nor mounting rod nut that extends beneath Shorter than standard draws are available F B CIRCLE H Ep L R MOUNTING ROD SPECIFICATIONS FOR STANDARD BOLSTER MOUNTED DIE CUSHIONS Model LR FB H Thread S TN RN 8 19 32 1 IN BOLSTER PLATE TO ea ACCEPT THREAD HEIGHT 13 3 8 1 5 8 um im 15 1 8 1 5 8 ne 17 1 3 4 19 F B 21 1 4 22 3 4 24 7 8 b D AP DAYTON DIE CUSHIONS MODEL ADJUSTABLE PNEUMATIC DIE CUSHIONS The Model HD Die Cushion is very popular with the stamper who has a wide variety of jobs and who must frequently change dies An adjustable nut at the bottom of the piston provides stroke variations up to 2 Unit provides extremely high R H F in a limited space by using and air booster pump The unit has an exclusive adjustable stroke feature that allows the operator to adjust the die cushion draw rather than changing pressure pins for length when a different job is set up 200 PSI MAX INPUT PRESSURE SHOWN IN BOLSTER MOUNTED OPTION FEATURES standard v Lubrication fittings are positioned at the front of the lower flange on sta
3. T Se DAYTON DIE CUSHIONS MODEL HMC PNEUMATIC DIE CUSHIONS THE MOST POWERFUL PNEUMATIC DIE CUSHION AVAILABLE This rugged heavy duty unit produces extremely high R H F within a given area and is designed to withstand long continuous heavy stamping operations including compound blanking and drawing The unique center stem multiple piston and cylinder chambers coupled with a generous overlap between cylinder and piston walls assures maximum resistance to off center loading This series is particularly adaptable to medium large and very large presses 200 PSI MAX INPUT PRESSURE SHOWN IN BOLSTER MOUNTED OPTION FEATURES Mounting may be made to bolster plate to v An internal centralized lubrication system press frame or to the press superstructure with a large mounting plate to the mounting surface Construction is of high grade wrought steel welded and normalized with bronzed bearing surfaces for long wear Extra overlap between cylinder and piston and the center stem assures excellent internal guiding External guiding mechanism can be designed to eliminate off center load damage Custom pin pads with J I C strips or pads can be designed Common pin pads connecting two or more die cushions are available for large presses This series has a dual chamber design and includes a booster pump as standard equipment resulting in extremely high R H F distributes lubricant by channeling through
4. 5 7 8 17 9 16 3 3 4 19 9 16 18 1 16 3 3 4 20 1 16 19 1 2 3 3 4 21 1 2 22 3 8 4 3 4 24 8 7 21 15 16 5 3 4 24 7 16 Height for standard draw only and does include pin pad nor mounting structure thickness For stokes longer than standard use surge tank H OPER HEIGHT CIRCLE L R FLOOR LINE LELE D 5 DRILL TAP FOUR HOLES IN BOLSTER PLATE TO ACCEPT THREAD HEIGHT 4 Se DAYTON DIE CUSHIONS INTRODUCE QUICK DIE CHANGE TECHNOLOGY TO YOUR DIE CUSHION OPERATIONS WITH THE HSA1 v PUMPING CYLINDER LOWERS PIN PAD RELEASING CYLINDER RAISES PIN PAD SHOCK ABSORBER HYDRAULIC HAND PUMP HYDRAULIC ADJUSTMENT NUT v EFFICIENT v QUIET Sharp reduction of set up time Reduces return shock SAFE v SIMPLE INSTALLATION No hands under presses AFFORDABLE Once used exclusively in multimillion dollar transfer presses Dayton Die Cushions has made the efficiencies of hydraulic stroke adjustment affordable for smaller presses The HSA1 is a heavy duty hydraulic stroke adjustment designed to retrofit onto Dayton Die Cushions D Series cushions It allows the user to adjust the cushion stroke under full air pressure All stroke adjustments are made using a simple manual pump outside the press Heavy duty construction and superior sealing technology assure rock steady adjustments DAYTON DIE CUSHIONS MODEL C PNEUMATIC DIE CUSHIONS DAYTON DIE CUSHION
5. AGE AND RING HOLDING FORCE NECESSARY FOR DRAWING SHELLS A Tonnage for Drawing Shells In general the tonnage necessary to draw a shell of round or rectangular shape is a function of the area of metal in the wall i e mean perimeter and metal thickness This is true because at any given time the force necessary to deform the metal equals the area of metal being deformed multiplied by the yield strength of the material In calculating these forces tensile strength is used since this will either draw the part push out the bottom or tear the walls This is generally true for parts having odd shapes although there are other factors involved which complicate the operation 1 ROUND SHELLS oat la D d z D T TENSILE STRENGTH 2000 TONNAGE 2 RECTANGULAR SHELLS T As w 2 L W T TENSILE STRENGTH 2000 TONNAGE This information is general and should be treated as such Specific forces must be determined for each job 4 Se DAYTON DIE CUSHIONS Mechanical punch presses are designed to deliver their maximum tonnage near the bottom of the stroke Since drawing work actually starts before bottom the full tonnage will not be available The above results therefore should be multiplied by G factor Chart 1 when this type press is used FACTOR G CHART 1 B Ring Holding Pressure or Force The primary function of the draw ring is to hold the blank while it is being formed to prevent w
6. HMC model 96 88 80 72 64 56 48 40 32 24 16 SURGE TANK PRESSURE VRS CUSHION MODEL HMC 400 PSI OUTPUT PRESSURE 00 5 6 SIZE 6 SIZE 8 SIZE 10 SIZE 12 SIZE 14 SIZE 16 SIZE 18 SIZE 20 SIZE 22 SIZE 24 20 30 40 50 60 70 80 90 100 SURGE TANK PRESSURE PSI c h DAYTON DIE CUSHIONS INITIAL BUDGETARY CUSHION QUOTE REQUEST FORM resse HEIGHT FROM THE FLOOR TO THE BED TOP CUSHION SPECIFICATIONS DESIRED AREA TO COVER ALL PINS PIN PAD DIMENSIONS P DAYTON DIE CUSHIONS CUSHION ORDER FORM PRESS SPECIFICATIONS PRESS MANUFACTURER PRESS MODEL PRESS TONNAGE PRESS STROKE PRESS APPLICATION JOB SHOP PRODUCTION LINE PRESS SPEED IN S P M PRESS BED PRESS BED OPENING DIMENSIONS DIMENSIONS OF RIBS IN BED BED THICKNESS DIMENSIONS UNDER THE BED DIMENSIONS FROM THE BED TOP TO MOUNTING SURFACE LOCATION AND SIZES OF HOLES ON THE MOUNTING SURFACE HEIGHT FROM THE FLOOR TO THE BED TOP DOES PIT EXIST IS PRESS PUT ON THE MOUNTS CUSHION SPECIFICATIONS DESIRED CUSHION TONNAGE DESIRED CUSHION STROKE DESIRED AREA TO COVER ALL PINS PIN PAD DIMENSIONS PIN PATTERN CUSHION SHOULD STOP ON THE BOLSTER 1 2 BELOW THE BOLSTER WILL OPTIONAL HOLD DOWN BE REQUIRED 4 Se DAYTON DIE CUSHIONS TONN
7. ILS BOSSES ETC TO WHICH THE DIE CUSHION STRUCTURE IS TO BE ATTACHED DAYTON DIE CUSHIONS MINIMUM BED OPENING REQUIRED FOR DIE CUSHIONS MINIMUM BED OPENING CUSHION MODEL AND SIZE AYTON DIE CUSHIONS MAXIMUM PIN PAD SIZE FOR DIE CUSHIONS N D MAXIMUM PIN PAD 9 0 9 0 ce D 6 14 Se DAYTON DIE CUSHIONS TYPES OF MOUNTING BOLSTER PLATE MOUNTING v Bolster plate mounting is recommended for single units and for multiple installations when the press bed is without ledges or bosses v This type of mounting does not require any mounting structure v Please note that the cushion becomes an integral part of a bolster plate thus it has to be detached whenever there is a need to move a bolster plate v Four drilled and tapped holes are required for each cushion to be bolster plate mounted Please refer to page 34 for mounting rod locations You can also find this information with the description of each cushion model v the pin holes locations conflict with the mounting rod locations press bed mounting to the ledge boos rail or bolster plate should be chosen BOLSTER PLATE BOLSTER MOUNTING ROD BOLSTER PLATE MOUNTED DIE CUSHION DAYTON DIE CUSHIONS TYPES OF MOUNTING PRESS BED MOUNTING v Press bed mounting is used on single units and larger multiple installations v It is desirable in most installations because the bolster plate can be removed without disturbing
8. S most popular pneumatic Die Cushion is built to withstand long heavy duty stamping operations The unit may be collapsed whenever it is not needed The Model C Series of Die Cushions is suitable for small to medium size presses when used singularly or for large presses when assembled in batteries Excellent guiding is accomplished by adequate overlap between cylinder and piston walls 100 PSI MAX INPUT PRESSURE SHOWN IN BOLSTER MOUNTED OPTION FEATURES Operates at normal shop air pressure Booster pump is not required Mounting may be made to the bolster plate to the press frame or to the bed superstructure Construction is of wrought iron steel cylinder and cast iron piston Excellent internal guiding achieved by generous overlap between cylinder and piston and external guiding mechanism can be designed to insure against off center loading conditions When used in batteries common pin pads may be used Special raised pin pads may be designed for use with presses with smaller than normal bed openings Furnished complete with pin pad mounting structure regulator gauge hoses fittings surge tank with accessories Installation amp Service Manual Each installation is warranted for one year from date of shipment MODEL C OPTIONS AIR EXHAUST HOLD DOWN Air is exhausted at or near the bottom of its stroke held down for a predetermined length of time and then allowed to assume its normal extended positi
9. arts are interchangeable and removable Pressure Gauge 100 psi cushions without disconnecting the regulator from the airline i Regulator complete with No 6114 Pressure Gauge 100 psi cushions These regulators are equipped with special compound springs with sensitive instantaneous adjustment of secondary pressures ranging from 5 to 250 pounds per square inch The rubber nylon fabric diaphragm assures flexibility quick action and long life The baffle plate construction controls the action of the diaphragm in such manner as to assure positive opening and closing of ports preventing creep chatter and fluctuations Few working parts and simplicity of construction insure long life and freedom from repairs PRESSURE GAUGES These gauges have safety backs and 1 4 pipe thread on inlet Shipping weight 12 oz each 800343 2874 gt 160 DAYTONDE N A 4 18006267 00 USNS 7 O 5 DIAL GRADUATION DIAMETER NUMBER READING INTERVALS 284 160 Ibs 2 2 1 2 inches 6114 300 Ibs 5 2 1 2 inches Se DAYTON DIE CUSHIONS SURGE TANKS On deep drawing operations where the pin pressure pad is deflected to the maximum drawing capacity of the pneumatic die cushion a surge tank reservoir is used so that the air compressed in the cushion cylinder will not build up to prohibitive pressure at the bottom of the work cycle of the press The larger the surge tank used the more constant the ring ho
10. d dies are subjected to excessive stresses at stroke bottom A die cushion eliminates this problem by maintaining proper pressure through out the entire press stroke even if pressure changes in a shop airline EASY ADJUSTMENT WHEN CHANGING JOBS Nitrogen and spring setups must be adapted to each individual job often at a considerable cost or loss of valuable press time Dayton die cushions permit rapid changing of dies and easy pressure adjustment to suit the requirements of each new piece of work LONG TROUBLE FREE SERVICE Urethane deteriorates rapidly and nitrogen spring seals breakdown with use Both must be replaced often resulting in expensive maintenance and down time Dayton die cushions eliminate these costly problems since they are designed as part of the press for long trouble free service PLUS MANY OTHER ADVANTAGES Dayton die cushions are easily installed They are compact and will not interfere with press operation They simplify tooling on compound operations They make it possible to blank draw pierce and re draw in one stroke They permit draws than nitrogen springs rubber bumpers They usually require no change in construction of existing dies They can be quickly exhausted of air thus permitting easy removal of tools 4 Se DAYTON DIE CUSHIONS How Die Cushions Work The ram forces the upper die downward onto the blank material supported on a bind
11. e and to act as a pressure regulator by controlling its output pressure at any setting up to two times input pressure It is supplied as standard equipment with many die cushion models HC HD and HMC and is available separately for many intermittent or dead end applications The pump is an opposed cylinder type unit having 4 bore and 6 stroke which are controlled automatically with self contained cam operated lever arms All component parts are fastened to a common mounting plate so that the unit can be readily bolted to any press or machine tool No external power source is necessary other than the air to be compressed All necessary valves line filter lubricator as well as input and output gauges are included 2 X BOOSTER PUMP OPERATIONAL SPECIFICATIONS Power Connections Shop Air Line Max Input Pressure 150 psi Min Output Pressure 0 psi Max Output Pressure 250 psi Output Pressure Control Variation 596 2 X BOOSTER PUMP OUTPUT Minutes to Pump Given Tank Gallons from Shop Line Pressure to Maximum Pressure 12 18 33 51 125 1 50 2 05 5 10 11 30 15 0 4 Se DAYTON DIE CUSHIONS COMBINATION REDUCING REGULATING VALVE AND PRESSURE VALVES DAYTON DIE CUSHIONS Reducing and Regulating Valves reduce line primary pressures to lower desired working secondary pressures automatically maintaining such pressures with a minimum of attention Regulator complete with No 284 All working p
12. er ring drawing the material over the punch The force necessary to hold the blank is transmitted from the cushion to the draw binder ring via pressure pins This regulated resistance of the die cushion called its Ring Holding Force allows for a smooth uniform flow of material during the drawing process The result is a quality work piece by eliminating cracks and wrinkles The cushion helps evenly load the press preventing shock and fatigue damage to the drivetrain The ram retracts The die cushion s return stroke will force the pressure pins up forcing the draw ring to free the work piece from the punch This is called the cushion Stripping Force Die cushions can be used as an automatic knockout or for other stamping operations such as blanking piercing or forming The cushions may be equipped with a dwell or hold down feature for ease of part removal or where a fast return stroke would damage the work piece SINGLE ACTION PRESS STROKE UP STROKE DOWN STROKE UP AFTER DRAW BOLSTER PLATE Pin PAD BINDER RING CUSHION CYLINDER DIES CUSHION PISTON B pins FORMED PART DAYTON DIE CUSHIONS SELECTING THE DIE CUSHION Recommendations The die cushions R H F ring holding force should be equal to one sixth 1 6 the tonnage rating of the press to obtain full draw work capability _ BIG ENOUGH PIN PAD AREA PAGE 6 IF NOT CONSULT FACTORY FOR SPECIAL PIN PAD DESIGN C acre RA
13. hions Booster Pump not Required REGULATOR SETTINGS FOR CUSHION TONNAGE MODELS C D AND R 100 PSI OUTPUT PRESSURE N T SIZE 6 SIZE 8 7 YD 20 18 SIZE 10 D 16 SIZE 12 14 SIZE 14 5 12 SIZE 16 z O 10 SIZE 18 Z 8 O SIZE 20 6 T 5 SIZE 22 2 _ O SIZE 24 _ Q 0 20 30 40 50 60 70 80 90 100 INPUT PRESSURE PSI A DAYTON DIE CUSHIONS REGULATOR SETTINGS FOR CUSHION TONNAGE CUSHION TONNAGE FOR MODELS MC MD HC AND HD Cushion Surge Tank Pressure 0 o e v wo o 1 0 1 5 2 0 2 5 3 0 3 5 5 0 4 5 5 0 Diameter Booster Pump Furnished with HC and HD models 48 44 40 36 32 28 24 20 16 12 CUSHION TONNAGE US TONS SURGE TANK PRESSURE VRS CUSHION TONNAGE MODELS MC MD 100 PSI MAX OUTPUT PRESSURE AND HC HD 200 PSI MAX OUTPUT PRESSURE SIZE 6 SIZE 8 SIZE 10 SIZE 12 SIZE 14 SIZE 16 SIZE 18 SIZE 20 SIZE 22 SIZE 24 20 30 40 50 60 70 80 90 100 SURGE TANK PRESSURE PSI A DAYTON DIE CUSHIONS CUSHION TONNAGE US TONS REGULATOR SETTINGS FOR CUSHION CUSHION TONNAGE FOR MODELS HMC Cushion Surge Tank Pressure dem em 1 1 1 7 2 2 2 8 3 4 4 0 4 4 Booster Pump Furnished with
14. ilable md imn i F B H CIRCLE L R MOUNTING ROD SPECIFICATIONS FOR STANDARD BOLSTER MOUNTED DIE CUSHIONS DRILL TAP FOUR HOLES _1 INBOLSTER PLATE TO ACCEPT THREAD HEIGHT Pp ka di AP DAYTON DIE CUSHIONS MODEL MD ADJUSTABLE PNEUMATIC DIE CUSHIONS The Model MD Die Cushion is very popular with the stamper who has a wide variety of jobs and who must frequently change dies An adjustable nut at the bottom of the piston provides stroke variations up to 5 8 Unit provides extremely high ring holding force by virtue of a double piston design The unit has an exclusive adjustable stroke feature that allows the operator to adjust the die cushion draw rather than changing pressure pins for length when a different job is set up 100 PSI MAX INPUT PRESSURE SHOWN IN BOLSTER MOUNTED OPTION FEATURES Operates at normal 100 P S I shop air pressure v Mounting may be made to bolster plate to the press frame or to the bed superstructure v Construction is of wrought steel welded and normalized with bronzed bearing surface Standard pin pads are hardened ground Pin pads are available round rectangular or square shapes Raised pin pads can be supplied for fitting to smaller than normal bed openings or to allow for slug removal by adding a hole pin pad with a slug chute See page 1 v Lubrication fittings are positioned at the fro
15. is not needed FEATURES Operates at 200 psi pressure with booster pump v Mounting may be made to the bolster plate to the press frame or to the bed superstructure v Construction is of wrought steel welded and normalized with bronzed bearing surface Excellent internal guiding achieved by generous overlap between cylinder and piston and external guiding mechanism can be designed to insure against off center loading conditions v In batteries common pin pads may be used opecial raised pin pads may be designed for use with presses with smaller than normal openings gi v Furnished complete with pin pad mounting 200 PSI MAX INPUT PRESSURE structure regulator gauge hoses fittings surge SHOWN IN BOLSTER MOUNTED OPTION tank with accessories and Installation and Service Manual v Each installation is warranted for one year from date of shipment Model HC Option Hydraulically Controlled Hold Down Allows the cylinder to be held at or near the bottom of the stroke for a predetermined length of time and then allowed to assume its normal extended position at any desired rate The unit is completely versatile in that either one or both of these cycle phases can be quickly adjusted or omitted This type of installation is particularly useful in drawing operations where additional time is needed to remove the work or on long draws where a rapid return might distort the part d DAYTON DIE CUSHIONS
16. lding or pad pressure will be throughout the work cycle Too small a surge tank or one connected with too small a pipe will cause a noticeable increased pressure during the work cycle of the pneumatic die cushion unit The tanks are furnished complete with safety pop valve pressure gauge and drain cock with two large size openings and may be installed in a vertical or horizontal position Surge tanks can be operated at the working pressures indicated Safety pop valve is set to relieve at this pressure All tanks are furnished with ASME and National Board Certified Code Tag STOCK CAPACITY OUTLET NUMBER GALLON SIZE 4 Se DAYTON DIE CUSHIONS BOLSTER PLATES Most bolster plates are fabricated to J I C Standards and Dayton Die Cushions bolster plate mounting is especially designed to fit between standard pin locations Please refer to the Mounting Rod Specifications for Standard Bolster Plate Mounted Die Cushions Table for each cushion model to find bolster mounting rods locations or the table located on the next page Below you can find the sketch of J I C standard pin locations and Dayton Die Cushion rod locations Please note that if you have a non standard pin pattern press bed mounting structures might be the most optimal way to mount your cushion refer to pages 8 10 for more information on both types of mounting Use Dayton Die Cushions machining ability for custom T slots drilling tapping grinding etc Built to virtua
17. le In Fig 1 the mounting structure is designed in such way that the pin pad will come to rest below the press bed and permit the slugs to be removed from the top Fig 2 has a removable plug so the slugs will fall through the hole in the raised pin pad A slug chute may be designed to exit the slug in a predetermined direction If the cushion is to be used for drawing operations the plug can be put back and the entire top of the pin pad used for pressure pins Whenever the cushions required for a particular press is too large to fit the bed opening a raised pin pad similar to the one shown in Fig 3 can be used The cushion itself is positioned below the bed and the raised pin pad is used as a filler block between the top of the cushion and the top of the bed Fig 3 4 DAYTON DIE CUSHIONS DAYTON DIE CUSHIONS IN HIGH SPEED APPLICATIONS AIR CUSHION STANDARD SIZE STEEL CUSHION RAPID CUSHION 478 707 10 PRESS STROKE PRESS STROKE 382 573 12 14 16 PRESS STROKE PRESS STROKE _ 287 _ 18 20 22 PRESS STROKE PRESS STROKE 229 344 24 30 PRESS STROKE PRESS STROKE ESTIMATING VELOCITY WITHOUT CURVES L PRESS STROKE IN INCHES L PRESS STROKE IN INCHES SPM STROKES PER MINUTE OF PRESS SPM STROKES PER MINUTE OF PRESS L II SPM 0 ANGLE OF CRANK LINEAR RAM SPEED IN FEET MIN 12 cos 8 L IT SPM LINEAR RAM SPEED IN FEET MIN SEES SE C The cos 9 factor is the percentage of maximu
18. lly any shape size or thickness For firm quotation please submit complete specifications or drawing if available L KY 1 No N 15 e i C cU fy s 6 14 4 M 5 fo ESO fay finn FS 3 XM C A ed WM zm h i fa J A CS FR C 0 o O i O O y X N PE Ral e Co r DAYTON DIE CUSHIONS MOUNTING ROD SPECIFICATIONS FOR STANDARD BOLSTER PLATE MOUNTED DIE CUSHIONS CUSHION MODEL A B C THREADSIZE THREAD DEPTH 2 7 8 3 5 8 4 19 64 5 7 16 6 7 1 8 8 1 4 3 5 8 4 19 64 5 7 16 6 7 1 8 8 1 4 8 7 8 10 1 4 11 1 8 12 4 19 64 5 7 16 6 7 1 8 8 1 4 8 7 8 10 5 8 11 3 8 12 7 16 4 15 16 5 27 32 6 11 16 7 9 16 8 1 2 9 1 2 10 5 8 11 3 8 12 7 16 4 15 16 5 27 32 6 11 16 7 9 16 8 1 2 1 15 16 2 2 51 64 3 3 16 4 7 32 5 1 8 5 1 2 2 2 51 64 3 3 16 4 7 32 5 1 8 5 1 2 6 3 8 7 1 8 7 3 4 8 3 8 2 51 64 3 3 16 4 7 32 5 1 8 6 3 8 7 5 8 8 3 8 9 1 16 3 3 8 4 1 8 4 3 4 5 7 16 6 1 8 6 7 8 7 5 8 8 3 8 9 1 16 3 8 4 1 8 4 3 4 5 7 16 6 1 8 h P DAYTON DIE CUSHIONS REGULATOR SETTINGS FOR CUSHION TONNAGE CUSHION TONNAGE FOR MODELS C D AND R Cushion INPUT Pressure Regulator Setting vanoor m o o o so 0 3 0 4 0 6 0 7 0 8 1 0 1 1 1 2 1 4 Low Pressure 100 psi Die Cus
19. m linear ram speed under formula 1 If 6207 its cos is equal to 1 and the linear ram speed reaches its maximum value At 905 cos 0 20 and there is no linear movement the ram is at dead bottom It is recommended that 8 is equal at least 30 DISENGAGE DAYTON DIE CUSHIONS NEW DEVELOPMENTS JUST INTRODUCED Our BULLDOG line of cushions is a combination of air and hydraulic unit These cushions can achieve up to four times the tonnage in a given press bed area They are designed for cylinder diameters of 18 to 48 In addition to reaching new tonnage standards these cushions also have v an automatic lubrication system simplifying maintenance v more robust off center loading more die placement freedom v an automatic block up feature not letting the pins down at night v adecelerator ram speeds up to 150 feet per minute v an internal hydraulic stroke adjustment like our famous D line The units are all pre machined to accept optional advanced hydraulic valving that can easily be tied into your press electronics This provides you with a numerically controlled NC cushion coupled with a hydraulic hold down This option is often requested for larger presses in particular transfer type presses or robotically loaded presses Die setups and work piece removal are being driven even faster These new cushion design advantages anticipate the next ten years of press development Don t settle for le
20. ndard v Booster Pump supplied as equipment to double shop air pressure to achieve high ring holding forces Mounting may be made to bolster plate to the press frame or to the bed superstructure Construction is of wrought steel welded and normalized with bronzed bearing surface Standard pin pads are soft but hardened and ground Types are available in round rectangular or square shapes at customer option Raised pin pads stools can be supplied to fit small bed openings or to allow for slug removal by adding a hole in the pin pad with a slug chute see page 11 designs An external centralized greasing system is available at customer option The unit features excellent guiding by use of an internal cylinder rod and generous cylinder to piston overlap An external guiding mechanism is available at customer option Furnished complete with pin pad mounting structure surge tank regulator gauge hoses fittings booster pump and Installation Service Manual Each installation is warranted for one year from date of shipment A DAYTON DIE CUSHIONS CUSHION SELECTION CHART HEIGHT CUSHION DRAW STD pipe DRAW 13 11 16 15 5 8 17 5 8 19 3 4 CIRCLE MOUNTING ROD SPECIFICATIONS FOR STANDARD BOLSTER MOUNTED DIE CUSHIONS ETA REC r MCN T 11 11 16 13 3 8 15 1 8 1 4 uil 17 3 8 DRILL TAP FOUR HOLES IN BOLSTER PLATE TO ACCEPT THREAD HEIGHT T
21. nt of the front of the lower flange on standard designs An external centralized greasing system available as a customer option v The unit features excellent guiding by use of an internal cylinder rod and generous cylinder to piston overlap External guiding mechanism available v Furnished complete with pin pad mounting structure surge tank regulator gauge hoses fittings and Installation and Service Manual v Each installation is warranted for one year from date of shipment lt d DAYTON DIE CUSHIONS CUSHION SELECTION CHART STANDARD PIN PADS HEIGHT CUSHION DRAW STD ADT 7 1 4 3 8 1 8 3 10 3 16 3 12 1 4 4 13 1 2 3 8 19 32 5 19 32 10 7 8 6 3 8 12 8 7 16 10 1 4 11 IN BOLSTER PLATE TO ACCEPT THREAD HEIGHT b p DRILL TAP FOUR HOLES T L R 4 Se DAYTON DIE CUSHIONS MODEL HC PNEUMATIC DIE CUSHIONS The Model Heavy Duty Pneumatic Die Cushion produces very high R H F within a given area The unit is built to withstand extremely long heavy stamping and forming operations such as compound blanking piercing and drawing The DAYTON DIE CUSHION HC Die Cushion is particularly suitable for use with medium and larger presses and can be fitted singularly or in batteries for larger beds Excellent internal or self guiding is accomplished by extra overlap between the cylinder and piston even at the top of the stroke It is also collapsible whenever a cushion
22. on at any desired rate The unit is completely versatile in that either one or both of these cycle phases can be quickly adjusted or omitted This type of installation is particularly useful in drawing operations where additional time is needed to remove the work or on long draws where a rapid return might distort the part Qe A DAYTON DIE CUSHIONS CUSHION SELECTION CHART TONS STANDARD PIN PADS HEIGHT CUSHION DRAW 100 P S I O O O O O C Height for standard draw only Does not include pin pad mounting plate thickness nor mounting rod nut that extends beneath Shorter than standard draws available Guide rods extend beneath cushion thru 16 size No guide rods on bolster mounted types F B CIRCLE H N EB T L R MOUNTING ROD SPECIFICATIONS FOR STANDARD BOLSTER MOUNTED DIE CUSHIONS DRILL TAP FOUR HOLES H IN BOLSTER PLATE TO ACCEPT THREAD HEIGHT _ a 4 Se DAYTON DIE CUSHIONS MODEL MC PNEUMATIC DIE CUSHIONS The Model MC Series incorporates a dual piston design with a very ruggedly built frame to double the ring holding force RHF of other models of similar diameter in approximately the same price This series of cushions is adaptable to medium size and large presses where a great deal of H H F is required It is built to withstand long heavy stamping operations such as compound blanking forming and drawing at normal shop airline pres
23. one inch As a result the operator may adjust the cushion draw rather than changing pressure pins for length when a new job is set up 100 PSI MAX INPUT PRESSURE SHOWN IN BOLSTER MOUNTED OPTION FEATURES Operates at normal shop air pressure Booster v Raised pin pads can be provided to fit smaller pump is not required than normal bed openings or to allow for slug removal by adding a hole in the pin pad with a slug chute Requires that cushion be mounted to press frame Mounting may be made to the bolster plate or to the press frame or bed superstructure v Construction is of wrought steel cylinder welded amp normalized with a hard chromed internal cylinder rod and a cast iron piston The unit features excellent internal guiding by use of a cylinder rod amp generous cylinder to piston overlap Standard pin pads are hardened and ground Special pin pads are available in round rectangular or square shapes to fit bed opening Y Furnished complete with pin pad mounting structure regulator gauge hoses fittings and Installation Service Manual Surge tanks Lubrication fittings are positioned at the front of optional for increased die cushion draw strokes the lower flange on standard designs v Each installation is warranted for one year from date of shipment DAYTON DIE CUSHIONS CUSHION SELECTION CHART HEIGHT STD OPER HEIGHT STD DRAW 12 3 16 2 11 16 13 7 16 14 1 8 3 1 4 1
24. rinkles Since the resistance to wrinkling becomes greater as the metal thickness increases the necessary R H F decreases Experience indicates that a close approximation to the R H P can be obtained by multiplying the tonnage required to draw the shell by J factor Chart 2 Note Disregard G factor for this calculation FACTOR J CHART 2 0 1 0 09 0 08 0 07 0 06 0 05 0 04 0 03 0 02 0 01 STOCK THICKNESS 0 0 1 0 2 0 3 0 4 0 5 FACTOR J 4 Se DAYTON DIE CUSHIONS C Press Tonnage oize of press necessary to draw shell in question is as follows MINIMUM PRESS TONNAGE z SHELL TONNAGE PLUS CUSHION TONNAGE RHP D Example Determine the size of mechanical press required to draw the shell pictured DRAW TONNAGE rfr 127 T 1 5 G 19 0 T CUSHION TONNAGE 12 7 T 0 133 J z1 7 T MINIMUM MECHANICAL PRESS TONNAGE 19 0 T 1 7 T 20 7 T MINIMUM HYDRAULIC PRESS TONNAGE 12 7 17 T 14 4 T
25. space provided between concentric tubes within the piston rod thereby eliminating grease tubing Eternal centralized fittings available at customer s option This series has a dual chamber design and includes a booster pump as standard equipment resulting in extremely high R H F All units are complete with standard or custom built pin pad all necessary mounting structure pressure regulator gauge booster pump hoses fittings surge tank with safety pop off valve drain cock and Installation Service Manual Each installation is warranted for one year from date of shipment DAYTON DIE CUSHIONS CUSHION SELECTION CHART STANDARD PIN PADS HEIGHT CUSHION DRAW STD 3 3 3 O 4 4 3 5 5 O 6 6 CUSTOM TO SPECIFIC APPLICATION CONSULT FACTORY Height for standard draw only Does not include pin pad mounting plate thickness nor mounting structure thickness N F B H a L R fi MOUNTING ROD SPECIFICATIONS FOR STANDARD BOLSTER MOUNTED DIE CUSHIONS DRILL TAP FOUR HOLES IN BOLSTER PLATE TO 9 7 8 1 1 4 7 11 11 16 1 1 4 7 ACCEPT THREAD HEIGHT 13 3 8 1 1 2 6 15 1 8 1 1 2 6 7 1 3 4 5 Ez 19 2 4 1 2 21 1 4 2 1 4 4 1 2 22 3 4 2 1 2 4 24 7 8 2 3 4 4 4 Se DAYTON DIE CUSHIONS BOOSTER PUMP DAYTON DIE CUSHIONS Custom Built Booster Pump is a self contained automatic air pumping unit Its primary function is to increase shop line pressur
26. ss when making your next major press investment DAYTON DIE CUSHIONS CHOOSING BETWEEN AIR AND NITROGEN ADVANTAGES OF AIR v Less Die Space Less Die Materials Cost Less Workpiece Cost v Less Die Pocketing Less Machining Less Diemaker s Time v Less Gas Costs Less Shop Space Less Running Cost v No Exotic Gases No Vendor Waiting No Recharging Cost v Simple Steel Pins Simple Maintenance Simple Changes v 1 10th the Pressure 1 10th the Seal Failure 1 10th the Repairs v Small Open Height Small Press Small Scheduling Problem v Easily Adjustable Pressure Easily Adjustable Holding Force v Easy Stroke Changes Easy Pin Changes Easy Setup Changes v No Try and See Hope it Works 70 Year MFG and Installation History No Unknown Life Cycle Many Customers Run 40 years no problem One Time Installation Not Redone For Every Die Shop Floor Job Setup at 15 HR Not Toolroom Setup at 65 HR Can Easily Accept Workpiece Material Variations MAKE YOUR DECISION FOR A DAYTON AIR CUSHION DAYTON DIE CUSHIONS MODEL D ADJUSTABLE STROKE PNEUMATIC DIE CUSHIONS The Model D Die Cushion has an exclusive adjustable stroke draw feature This series is very popular with the shop that runs a wide variety of stamping jobs and must frequently change dies This self contained unit features an adjustable nut at the bottom of the die cushion that provides stroke variations up to
27. sure 100 PSI MAX INPUT PRESSURE SHOWN IN BOLSTER MOUNTED OPTION FEATURES Operates at normal 100 psi shop air pressure Mounting may be made to bolster plate to the press frame or bed superstructure v Constructed of wrought steel cylinder welded and normalized cast pistons and solid steel center rod Standard pin pads are hardened and ground Pin pads are available in round rectangular or square shapes Raised pin pads can be made to fit smaller than normal bed openings or to allow for slug removal by adding a hole in the pin pad with slug chute see page 11 v Lubrication fittings are positioned at the front of the lower flange on standard designs External centralized greasing systems available at customer option v The unit features excellent guiding by use of internal cylinder rod and generous cylinder to piston overlap External guiding mechanism available v Furnished complete with pin pad mounting structure surge tank regulator gauge hoses fittings and Installation Service Manual v Each installation is warranted for one year from date of shipment P DAYTON DIE CUSHIONS CUSHION SELECTION CHART STANDARD PIN PADS HEIGHT CUSHION DRAW STD 7 1 4 8 1 8 10 3 16 12 1 4 13 1 2 13 1 2 16 1 4 16 1 4 18 3 4 20 1 4 22 1 8 CONSULT FACTORY Height includes pin pad thickness and maximum adjustment but NOT mounting structure thickness Shorter strokes are ava
28. the cushions v Very desirable on presses where different tools are being used v Press bed mounting structure is designed to fit each particular model of the press STOP amp GUIDE MOUNTING ROD STRUCTURE PRESS RAIL SPECIAL MOUNTING STRUCTURES can be designed to fit specific bed and applications These designs will accommodate unusual press structure multiple installations or die cushions with external guiding mechanisms Special mounting structure can be designed to fit any press RG h DAYTON DIE CUSHIONS TYPES OF MOUNTING PRESS BED MOUNTING TO BOLSTER Press bed mounting to the bolster plate is used when there are no ledges or bosses to mount the cushion to the press bed and pin hole locations do not allow to use standard bolster plate mounting Mounting structure is designed and it requires four drilled and tapped holes in the bolster plate which location is specified by the factory Already existing in the bolster plate holes can be also used to mount the die cushion this way BOLSTER PLATE SUSPENSION ROD MOUNTING PLATE PRESS BED MOUNTED TO THE BOLSTER PLATE DIE CUSHION Se DAYTON DIE CUSHIONS APPLICATION AND DESIGN OF RAISED PIN PADS When a die cushion is used for stripping with a compound blanking and piercing die it may be necessary to use a raised pin pad to permit the slugs or parts to fall through the die Fig 1 and 2 show two of the more common designs and many other designs are availab
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