Problem Solving Guide

Solutions for punch wear, breakage, and other problems come from both time-tested techniques (e.g., adding a larger-than-normal radius under the head) as well as consideration for a wide range of leading-edge engineering solutions (e.g., head alterations) and specialty coatings designed to maximize the life of the punch.

This troubleshooting guide can help you determine the cause for your broken, chipped, or worn punches. It can also help you select the best solution—including Dayton products and services.

Punch Chipping & Point Breakage

Cause	Solution	Dayton Products & Services
High impact or compressive failure	Change punch materials	Dayton Versatile M2 & PS4, Ball Lock PS4, or TuffPunch® PS4
	Change to a larger body diameter punch
	Change from a Jektole® to solid punch
	Use guide bushings	Dayton Versatile product line
Misalignment resulting in lateral forces	Check for worn guide pins & bushings—replace, if necessary
	Check for loose gibs in the ram of the press
	Check overall die alignment
Part material movement	Use gas or spring-guided stripper	Dayton MaxLife® Die Springs
Part material movement	Use a retainer or punch-mounted stripper	Dayton DAYStrip® or SMARTStrip™ Urethane Strippers
Poor material control	Review die, press, & feeder setup
Excessive stripping force	Increase punch-to-die button clearance	Dayton clearance testing service
	Reduce punch-to-die entry
	Coatings to add lubricity	Dayton coatings
	Back taper on punch point "B"
	Polish punch point	Dayton VersaPlus® products
Punch point hardness too low	Verify hardness is minimum of 60 RC	Request technical assistance from Dayton to insure proper RC hardness
Punch point "B" too long	Reduce point length "B", if possible	Contact Dayton Regional Manager
Improper punch material selected	Change punch material	Dayton Versatile M2 & PS4, Ball Lock PS4, or TuffPunch® PS4—use technical assistance request form
Sharpening damage	Use flood coolant and proper sharpening techniques
Sharpening damage	Use correct speed & feed for grinding wheel—correct grinding wheel for steel type
Regrind burr	Remove regrind burr—break sharp corners on punch face
Tight die clearance	Increase clearance	Dayton clearance testing service
	Change punch material	Dayton Versatile PS or PS4, Ball Lock PS4, TuffPunch® PS4, or VersaPlus® punch
	Coatings/surface treatments	Dayton coatings
	Use guided stripper
Sharp corners on shaped punches	Increase clearance in the corners of die button	Dayton "L" or "K" punch
Flat punch face	Use shear angles	Dayton XS20 or XS21 on round & shaped punches
Flat punch face	Engineered edge break
Improper heat treatment	Check catalog RC specification	Use technical assistance request form for metallurgical heat treat check
	Triple tempered for high-speed tool steels	Dayton's in-house heat treatment monitored by staff metallurgist
	Cryogenics	Dayton's in-house heat treatment monitored by staff metallurgist
Punch RC wrong for application	Lower RC hardness	Contact Dayton Regional Manager
Improper punch stagger	Stagger should be less than the burnish length of the part material	Contact Dayton Regional Manager
Improper punch stagger	Cut-off operation & large point punches first to enter
Improper finish on punch point and/or punch face	Insure there are no harsh grinding or turn marks on the punch point and/or punch face	Contact Dayton Regional Manager
Grinding burn on punch point	Purchase punches from ISO certified source
Part material above 85,000 PSI	Change punch material	Dayton Versatile PS4, Ball Lock PS4, or TuffPunch® PS4

Slug Jamming

Cause	Solution	Dayton Products & Services
Tight die clearance	Increase die clearance	Dayton clearance testing service
Excessive land length	Reduce land to 1-4 times stock thickness	Dayton XB alteration
Excessive land length	Change relief from counter bore to taper	Dayton Versatile & Kommercial Die Buttons
Taper in the land of the die button	Verify there is no reverse taper in the land of the die button
Inadequate taper relief in die button	Increase per side taper	Dayton XAR alteration
Worn die button	Sharpen, replace, and/or change die button material	Dayton M2 or Versatile PS
Worn or chipped punch	Sharpen or replace punch
Rough land in die button	Use die buttons with smooth wire cut, or ground land
Slug tipping	Use shear angle on punch and/or check punch-to-die alignment	Dayton XS20 or XS21 on round or shaped punches
	Check lubrication—consider lubricating both sides of part material
	Use a Jektole® punch with a side vent hole	Dayton's Jektole® punch
Obstruction in slug relief hole	Examine slug path
Obstruction in slug relief hole	Increase the size of the relief hole in lower plate	Contact Dayton Regional Manager

Slug Pulling

Cause	Solution	Dayton Products & Services
Bellmouth wear in die button	Increase die clearance	Dayton clearance testing service
	Check alignment
	Change die button material	Dayton M2 or Versatile PS
Punch entry too deep	Use slug control system	Dayton XSC slug control
Punch entry too deep	Reduce punch entry	Contact Dayton Regional Manager
Punch entry not deep enough	Increase punch entry	Contact Dayton Regional Manager
Excessive die clearance	Reduce die clearance	Dayton clearance testing service
Excessive die clearance	Use a Jektole® punch with a side vent hole	Dayton's Jektole® punch
Slug not held in the land	Use slug control system	Dayton XSC slug control
	Use vacuum slug sucker
	Blow air through center hole in punch	Dayton XK alteration
	Check lubrication
	Demagnetize punch
	Use negative taper in land
	Rough up land
	Bellmouth the cutting edge of the die button	Dayton form die button W910 & W920
Not enough relief on die button	Increase taper relief or use counter bore die button	Dayton XAR alteration

Punch Wear and/or Galling

Cause	Solution	Dayton Products & Services
Tight die clearance	Increase die clearance	Dayton clearance testing service
	Coatings/surface treatments	Dayton coatings
	Change punch materials	Dayton Versatile M2 & PS4, Ball Lock PS4, TuffPunch® PS4, or VersaPlus®
Punch entry too deep	Reduce punch entry
Misalignment	Check die & press alignment
Regrind burr	Remove regrind burr—break sharp corners on punch face
Improper sharpening of punch	Use flood coolant, and correct grinding wheel speed & feed for steel type
Improper punch material	Change punch materials	Dayton Versatile M2 & PS4, Ball Lock PS4, TuffPunch® PS4, or VersaPlus®
Sharp corners on shaped punches	Increase clearance in the corners of the die button	Dayton "L" or "K" punches
Punch surface too rough	Punch finish improvements	Contact Dayton Regional Manager
Lack of lubrication on part and/or incorrect lubrication	Check lubrication
Prepainted & coated part material	Increase die clearance to accommodate powdering & flaking

Punch Head Breakage

Cause	Solution	Dayton Products & Services
Punch pumping	Verify head thickness is properly fit in the retainer counter-bore	Dayton "TT" alteration
Insufficient chamfer in retainer	Chamfer retainer to clear head fillet on punch
Backing plate too hard	Draw back backing plate to reduce hardness—RC 40-50
Head is too hard	Draw back head of punch to lower RC	Dayton draw heads RC 40-55
High impact or high compressive load on head	Use shear angle on punch point	Dayton XS20 or XS21 on round or shaped punches
	Increase head diameter and thickness	Dayton TuffPunch® products
	Increase shank diameter
Radius under head too small	Minimum radius should be .010

Problem Solving Guide

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