How can I increase tool life without sacrificing edge quality too much?
It is fair to say that tool life becomes dramatically reduced by the severe tool contact created when the tolerance is tightened. Conversely, tool life can be extended as the tolerance is loosened to acceptable parameters for the application. There is a way to increase tool life without sacrificing edge quality too much. Instead of shearing the blank by applying tools at a 90-degree angle, the shearing can be done gradually by using an inclining angle either to the die or to the punch. The benefit of the angled tools is that they come in contact with the blank gradually, allowing the material to be sheared locally instead of applying the shearing to the entire tool periphery. Because less force is required, and consequently the concentrated contact pressure between the tool and blank from tool misalignment is minimized with a lower shearing force, angled tools can decrease tool wear during production.
