A stamping facility had a high speed perforating operation. The idea was to punch holes into a matrix at a fast feed rate. In their operation, they started to see issues with the punched holes, and they also noticed that the punch points were prematurely failing. With a tight punch-to-matrix clearance, heat was building up from the friction. This effect was galling the material and affecting the hole appearance and dimensions. They also noticed heat damage to the punch points. They either had to slow their process down, or find a way to cool the punch points. They contacted EXAIR to see if we could help.
To remove heat, you need to have a fluid moving across the material to carry the heat away. For this customer, the fluid would be air. Just like a hot cup of coffee, you can cool it by blowing across the top of it. In this instance, EXAIR can blow a lot of air with using very little amount of compressed air. Because of the gap opening of the tool die was narrow, I suggested the Super Air Knife. It has a compact design and can blow nicely between the upper and lower die. With slight modifications, they were able to mount the Super Air Knives right into the base set. Because the tool die was a “bowl” type design, I suggested that they should use two pieces of the model 110206 Super Air Knife. They could mount one to each side to make sure to hit all the punch points. (Reference the picture below).
EXAIR Super Air Knives are the most efficient compressed air knives in the market. It is designed to have a 40:1 amplification ratio. That means for every one part of compressed air, it will entrain 40 parts of the free ambient air. As with the coffee reference above, the more air that you can blow, the better the cooling effect. With the Super Air Knife, we can reach a velocity of 11,800 feet per minute at 80 PSI. After the customer installed the Super Air Knives, they were able to increase production by 10%. Also, they found that the punch points were lasting twice as long. They were so impressed with the effectiveness of the Super Air Knives, they mounted them to all their punch press machines.
If you find that heat is affecting your process, EXAIR could have a product to help you. We have a variety of efficient air movers to cool your parts. As for this customer above, we were able to increase production and extend the life of their tools.