Punch & Dies Selection and Troubleshooting Guide

Making Metal Work

The Punch and Die Range

We stock a large range of punch and dies so they are available for next day delivery. Our stock range includes all rounds, squares and most popular sizes of slots for Geka 5, Geka 8, Kingsland & Morgan Rushworth machines.

All of our punch and dies are manufactured in the UK to the highest production standards and produced from hardened steel.

Punches and dies are an ideal means of piercing sheet metal with precision and high repeatability, but one which has a low set-up cost and is almost completely maintenance-free. And all this while producing scrap that is manageable rather than piles of swarf. Punching, it seems is an ideal process for low to medium volume workshops, but there still seems to be a certain mysticism about punch and die systems, what they can achieve, and when to replace them.

As well as selling a wide range of punch and dies, we often have customers call us to trouble shoot problems they’re experiencing, in the following pages we cover the vast majority of issues you may encounter when using a steelworker, and the solutions to rectify them.

Selmach’s punches & dies are produced to exacting standards and are suitable for all types of steelworkers and punching machines. Proven manufacturing techniques and a closely controlled heat treatment process guarantee optimum punching performance. In addition to the comprehensive range of standard stock products, we can offer oversize tooling and design solutions for virtually any application.

Punches with Shear Angle for Stainless Steel are available on request.

Punch and Die Tooling

PUNCH & DIE STOCK CODES

Morgan Rushworth / Kingsland

To fit machines up to 95 tonnes

To fit machines up to 100 tonnes and above

As well as these standard tooling options, we can offer a wide range of specialist tooling for specific use cases, including tooling for notching vent holes for galvanising processes, radius corner tools or counter sinking punches and much more!

Looking for a specialist solution? Speak to our team to discuss your requirements, and how a specialist punch and die could assist you.

Specialist Punch & Dies

PUNCH & DIE STOCK CODES

To order, state the relevant stock code, followed by size required - eg. 14mm x 27mm slot punch for Geka 5 - 12026-14 x 27

Large stocks available for same day / next day delivery.

Any special sizes can be manufactured upon request within 3 to 5 days.

Call today quoting the stock code above to discover the vast range of punch and dies we hold in stock, or scan this QR code to visit Selmach Tooling and order directly online.

01432 346 579

Punch and Dies - Problem Solving

PROBLEM PROBLEM CAUSE SOLUTION

Stripping Failure

Angular Fracture

Failure:

• A portion of the punch is broken off in the material.

Probable Cause

• Too much stripper clearance.

Stripper

Chipping and Galling

Heavy Galling Chipping

Compressive Failure

Failure:

• Occurs when the compressive strength of the punch has been exceeded and the entire working end shatters.

Possible Solution

• Adjust stripper closer to the material.

Failure:

• Punch face chipping or heavy galling on one area of the punch.

Probable Cause

• Poor alignment between punch and die, causing the punch to drag.

Possible Solution

• Adjust alignment between punch and die to clearance all around.

Material Movement

Probable Cause

• Attempting to punch extremely hard or thick materials, or complete misalignment of the punch and die.

Punch and Dies - Problem Solving

PROBLEM PROBLEM CAUSE SOLUTION

Punch Head Failure

Failure:

• Punch head fractures or breaks off.

Probable Cause

• Using a loose or worn coupling nut or punch stem.

Ringing

Failure:

• Material being punched is deformed with each stroke of the press.

Probable Cause

• Material is thicker than the working length of the punch, or the punch is entering into the die too far.

Correct Setup

Ringing

• The punch side of the slug will have a center point indentation and a slight burr.

Possible Solution

• Frequently check and re-tighten the coupling nut. Verify that the face of the punch stem is smooth and flat.

Possible Solution

• Adjust the stroke length to enter into the die a maximum of 1/16’’.

• When punching mild steel 1/8” or thicker, the die side of the slug will be a distance of 10% to 20% of the material thickness.

Punch and Dies - Problem Solving

PROBLEM PROBLEM CAUSE SOLUTION

Double Shear

Failure:

• Double shear indicates insufficient clearance between punch and die.

Uneven Burr

Failure:

• Uneven burr indicates worn tools or misalignment of punch and die.

Heavy Burr

Failure:

• Heavy burr on die side of material indicates too much clearance between punch and die.

Poor Hole Quality

Failure:

• Uneven punches

• Poor hole quality

• Hydraulic lock out

Problem cause

• Over-worn punch causing a lock of a sharp edge

Possible Solution

• Increase punch to die clearance.

Possible Solution

• Check condition and alignment of punch and die.

Heavy Burr

Possible Solution

• Decrease die clearance.

Possible Solution

• Replace the punch (and die if also worn)

Punch and Dies - Useful Videos

We have a wide range of useful videos on our YouTube Channel to assist you with the set-up or maintenance of your Morgan Rushworth Steelworker:

Remove

Adjust the Material Clamping System

Adjust

If you need a service, or spare parts for your Steelworker, contact our service team for help, advice and parts.

We offer a wide range of Steelworker’s, so if you’re thinking about adding to your collection of machinery, be sure to contact our sales team, or browse the range of Steelworker’s on our website.

Scan here to browse the full range of Steelworker’s we can offer.

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