Practical Solutions to Keep Your Press Shop Running Smoothly
Even with the most advanced press tooling, manufacturers often face common production issues that can lead to downtime, poor part quality, and increased maintenance costs.
At iNDUSTRY TOOLING, we help our clients not only design and manufacture precision press tools but also troubleshoot and prevent these common tooling problems.
Here’s a breakdown of frequent press tooling issues and proven solutions to keep your operations efficient and reliable.
🚨 1. Burr Formation
Problem:
Burrs are unwanted sharp edges or material projections on stamped parts.
Causes:
- Dull punches and dies
- Incorrect die clearance
- Misaligned tooling
Solutions:
✅ Regularly sharpen or replace cutting edges
✅ Adjust die clearances to material thickness
✅ Inspect and align tools properly during setup
🚨 2. Part Misalignment
Problem:
Parts come out with inconsistent shapes or don’t meet dimensional specifications.
Causes:
- Poor strip feeding
- Incorrect die and punch alignment
- Worn guide pins and bushings
Solutions:
✅ Ensure accurate feeding and straight material entry
✅ Use precision locating pins and proper die setup
✅ Regularly inspect and replace worn guide components
🚨 3. Excessive Tool Wear
Problem:
Premature wear of punches, dies, and forming surfaces, leading to poor part quality and tool failure.
Causes:
- Incorrect material hardness or coatings
- Insufficient lubrication
- Poor die clearance selection
Solutions:
✅ Use appropriate tool steel and protective coatings
✅ Apply correct lubricants to reduce friction
✅ Set proper cutting clearances for the material
🚨 4. Spring-Back in Formed Parts
Problem:
Formed parts return slightly toward their original shape after release, affecting part accuracy.
Causes:
- Inadequate forming pressure
- Improper tooling angles
- Material spring-back characteristics not accounted for
Solutions:
✅ Design forming tools with spring-back compensation
✅ Use controlled forming sequences and accurate pressure
✅ Validate tooling through forming simulations
🚨 5. Tool Cracking and Chipping
Problem:
Cracks or chips appear on the cutting edges or forming surfaces, causing part defects and tool failure.
Causes:
- Improper heat treatment
- Excessive press force
- Material inclusion or stress concentration
Solutions:
✅ Use high-quality tool materials with proper heat treatment
✅ Check press force settings and load distribution
✅ Eliminate sharp internal corners in tooling design to reduce stress
🚨 6. Material Jamming and Strip Feed Issues
Problem:
Material jams in the tool, causing press stoppage or part misfeeds.
Causes:
- Incorrect strip layout
- Improper feed progression
- Poor strip lubrication
Solutions:
✅ Optimize strip layout and feed progression
✅ Use properly maintained feeding equipment
✅ Apply adequate lubrication to prevent sticking
🛠️ Our Preventive Approach at INDUSTRY TOOLING
We help clients reduce tooling problems by:
- ✅ Designing with advanced CAD/CAM simulations
- ✅ Recommending preventive maintenance schedules
- ✅ Offering training on tool handling and press setup
- ✅ Providing fast support for troubleshooting and tool refurbishment
🏭 Real-World Example: Problem Solved
A client in the automotive sector experienced high scrap rates due to burrs and misalignment.
After our team adjusted their die clearances, improved tool alignment, and implemented a sharpening schedule, they:
✔️ Reduced burr formation by 85%
✔️ Increased part acceptance rates
✔️ Saved significant material and labor costs
📞 Facing Press Tooling Challenges? Let’s Solve Them Together.
Contact INDUSTRY TOOLING for expert tooling support, maintenance tips, and high-performance press tools designed to minimize production issues.
📧 Email: info@industrytooling.com
📞 Phone: +919914199883
👉 Follow our blog for more expert advice on tooling optimization and press shop problem-solving.