2 day course (1 day Classroom, 1 day Hands-on)

COURSE OBJECTIVE:

Learn the process for welding and repair of draw, trim/pierce, flange and cam dies. You will learn how to repair defects on panels using various welding and grinding methods. Emphasis is placed on proper techniques for tool steel welding and in-and-out of press repair methods. Students will learn and practice the proper techniques for welding and repair using Mig, Tig and Stick applications.

Click here for a sample of the manual

WHO SHOULD ATTEND:

Tooling Supervisors, Process, Manufacturing and Tooling Engineers, and Tool and Die Makers, Plant Welding Personnel.

COURSE OUTLINE:

1.0 Welding Overview

1.1 Types of Welding and Equipment
- GTAW Gas Tungsten Arc Welding (TIG), SMAW Shielded Metal Arc Welding (Stick), GMAW Gas Metal Arc Welding (MIG), Choosing the proper equipment
1.2 Welder Settings for Different Types of Die Steels
1.3 Pre-Heating and Steel Preparation
- Estimating temperature change by color
1.4 Welding Rod Types
- 0-1, A-2, D-2C, Cast Steel, Aluminum

2.0 Draw Die Weld Repair

2.1 Draw Bead Repair
- Fixing a Bead by Welding, Grinding and Polishing
2.2 Repairing a Welded Flat Surface
- Steps to Welding, Grinding and Stoning a Flat Surface by Hand
2.3 Repairing a Welded Curved Surface
- Steps to Welding, Grinding and Stoning a Curved Surface by Hand
2.4 Repairing a Welded Feature Line
- Steps to Successfully Blend a Welded Feature Line

3.0 Trim Die Weld Repair

3.1 Punch Trim Line Repair
- Fixing Cutting Problems Associated with Burrs by Welding
3.2 Die Trim Line Repair
- Fixing Cutting Problems Associated with Burrs by Welding
3.3 Trim Line Change to Reduce Panel Size
- How to Successfully Move a Trim Line by Welding
3.4 Trim Line Change to Increase Panel Size
- How to Successfully Move a Trim Line by Welding
3.5 Scrap Cutter Repair
- Steps to Grinding a Welded Inserted Cutter

4.0 Pierce Die Weld Repair

4.1 Pierce Die Repair
- How to Grind Welded Cutting Edges
4.2 Pierce Punch Repair
- How to Grind Welded Cutting Edges

5.0 Flange Die Weld Repair

5.1 Verifying Flange Clearance
- Steps to Successfully Establish Proper Clearances
5.2 Flange Line Change to Reduce Panel Size
- Using Plotted Points to Successfully Grind a Welded Bend Line
5.3 Flange Line Change to Increase Panel Size
- Using Plotted Points to Successfully Grind a Welded Bend Line

6.0 Production Die Repair & Welding

6.1 Cracking and Wrinkling
- What to look for and ways of fixing Panel Conditions during Production
6.2 Panel Stoning and Deforms
- Identifying the Common Types of Deforms by Panel Stoning
6.3 Emergency Repairs for Negative Deforms
- Temporary Time Saving Repairs for Draw Dies that can Reduce Press Downtime
6.4 Emergency Trim Line Repairs
- Temporary Time Saving Repairs for Trim Dies that can Reduce Press Downtime

7.0 Hands-On Welding Applications – 8 hours

7.1 GTAW-TIG Welding
- Students perform a variety of welding applications
7.2 SMAW-Stick Welding
- Students perform a variety of welding applications
7.3 GMAW-MIG Welding
- Students perform a variety of welding applications

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