The design and press tool building process involves a number of phases.

This phase involves close consultation with the customer to define dimensions, critical tolerance and functionality of the component part. In most cases R&D is carried out to determine best practice and data required to design and build the fine blanking press tooling. 

Phase 2. Design 

A CAD 'strip layout' is created to simulate how the component will be fine blanked from the steel strip. If there are a number of progressions required to produce the final component part the strip layout will highlight what happens at each station during the progression, the final station will be where the blanked and formed component is fully fine blanked and seperated from the strip. When the strip layout is evaluated and approved the fineblanking press tool is designed and solid modelled in 3D (SolidWorks). Once the designs are validated the component drawings and CNC codeare generated for manufacturing tooling components  

Phase 3. Manufacturing, calibration and trials of the new press tooling 

When the tooling designs are signed off the tooling component drawings are created. The CNC code is generated from the component drawings for specialised machines such as CNC wire cut's, EDM drill, EDM spark eroders and CNC mills. The tooling components are manufactured and the press tooling is assembled and calibrated. The press tool is then fitted to the production press where further fine tuning and trial components are produced for validation checks. Once tooling set up is optimised the tool is ramped up in speed to full production stroke rate. Trial run components are 100% tolerance inspected by our quality assurance department to ensure that all tolerances are in consistent compliance with part drawing specifications.  

Innovation, prototyping and development

Over the years DC Ross has invested heavily in design software, CAM software and advanced precision engineering machinery such a EDM spark eroders and EDM wirecut technology. DC Ross designers and precision engineers have invested much time and effort in R&D to push the boundaries of fine blanking cabability.

The ongoing R&D / constant improvement focus has made DC Ross very efficient at 'thinking outside the box' and developing innovative solutions for our clients.