Product Manual A
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15
Your Ironworker is capable of punching materials as listed in the
Ironworker Specications as well as described on the capacity
labels positioned adjacent to the Punch station.
Setup
Your Edwards Ironworker has been shipped with a punch and die
installed within the punch station. Punch and dies are wearing parts
and will need to be maintained or replaced over time. Refer to the
Maintenance Manual for removal and replacement instructions. When
changing the punch and die during typical operation please observe the
following steps.
Turn off power to machine by depressing the red stop/off button or
lockout upstream power at the main electrical panel.
1. Swing Stripper Bar away by loosening 4 bolts (2 on either side
of punch station) with a 3/4” wrench. After swinging Stripper Bar
away, re-tighten one bolt to prevent it falling back on you.
2. Remove punch by loosening the punch nut assembly with factory
supplied wrench.
3. Remove die by loosening the set screw at the side or front edge of
the punch table and then lifting die from the die holder. If the die
resists removal gently tap the die from the underside of the punch
table to loosen the die for removal.
4. Install new die and tighten set screw. If loading a shaped die, align
the whistle spot with the set screw and tighten.
5. Install new punch and tighten punch nut with wrench. If using a
shaped punch, align the locating keystock of the punch with the
corresponding slot within the punch stem assembly and tighten
the punch nut with the wrench.
6. Check for punch and die alignment by powering up the machine
and inching down the punch to meet the die with the foot pedal.
Check to see that the punch is centered in the die.
7. In the event that the punch and die are not aligned, loosen the
bolts under the table allowing the table to be moved to center the
die. When aligned, tighten the table bolts to secure the table.
8. Loosen bolts and swing the stripper bar back in place. Adjust of
stripper bar for minimal clearance between the top of the material
and the bottom of the stripper.
Safe Operation
Please observe the following guidelines when operating the Punch
Station:
• Follow manufacturers punch and die clearance recommendations.
Follow punch tonnage requirements (Figure 1).
• Never exceed the capacities of the machine or tooling as
described in the Ironworker specications or listed at the tooling
station.
• The thickness of the material you are punching should not exceed
the diameter of the punch being used.
• Check punch and die alignment after every tooling change or
extended punch operation.
• Adjust the punch stripper supplied with your Edwards Ironworker
to allow for material positioning and material stripping.
• Do not stack material to punch in the punching station.
• Use one or two drops of oil at the punch to aid in stripping
material from the punch as well as to extend the life of the
punch tooling.
• Punch complete holes only – partial holes will side load the punch
tooling and could result in punch breakage and operator injury.
• Use punching aids when working with small items at the punch
station.
Punch Station
26 ga. (.0179) 0.18 0.27 0.36 0.45 0.54 0.63 0.72 0.81 0.90 0.99 1.07 1.16 1.25 1.34 1.43
24 ga. (.0239) 0.24 0.36 0.48 0.60 0.72 0.84 0.96 1.08 1.20 1.31 1.43 1.50 1.67 1.89 1.91
22 ga. (.0299) 0.30 0.45 0.60 0.75 0.90 1.05 1.20 1.35 1.50 1.65 1.80 1.95 2.10 2.24 2.39
20 ga. (.0359) 0.36 0.54 0.72 0.90 1.08 1.26 1.44 1.62 1.80 1.98 2.15 2.33 2.51 2.69 2.87
18 ga. (.0478) 0.48 0.72 0.96 1.20 1.43 1.67 1.91 2.15 2.39 2.63 2.87 3.11 3.34 3.58 3.82
16 ga. (.0598) 0.60 0.90 1.20 1.50 1.79 2.09 2.39 2.69 2.99 3.29 3.59 3.89 4.19 4.49 4.78
14 ga. (.0747) 0.75 1.12 1.49 1.87 2.24 2.61 2.99 3.36 3.73 4.11 4.48 4.86 5.23 5.60 5.97
12 ga. (.1046) 1.05 1.57 2.09 2.62 3.14 3.66 4.18 4.71 5.23 5.75 6.28 6.80 7.32 7.85 8.57
10 ga. (.1345) 2.02 2.69 3.36 4.04 4.71 5.38 6.05 6.73 7.40 8.07 8.74 9.42 10.09 10.76
3/16 (.187) 2.81 3.74 4.68 5.61 6.50 7.48 8.42 9.35 10.29 11.22 12.16 13.09 14.03 14.96
1/4 (.250) 5.00 6.25 7.50 8.75 10.00 11.25 12.50 13.75 15.00 16.25 17.50 18.75 20.00
3/8 (.375) 11.25 13.13 15.00 16.88 18.75 20.63 22.50 24.38 26.25 28.13 30.00
1/2 (.500) 20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50 40.00
5/8 (.625) 31.25 34.38 37.50 40.63 43.75 46.88 50.00
3/4 (.750) 45.00 48.75 52.50 56.25 60.00
7/8 (.875) 61.25 65.63 70.00
1” (1.000) 80.00
1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1”
Stock Thickness Hole Diameter
Figure 1 - Punch Tonnage Requirements
Punch Operation
1. Clear the punch station of any tools or debris prior to powering the
machine on.
2. Place the material to be punched between the punch and die.
Check to see that your material is spanning the stripper plate and
that adequate material is available to safely position the material.
3. Clear your hands from the working area and depress the foot pedal
to move the punch through the material and into the die.
4. When the punch is complete, release the foot pedal to automati-
cally strip the material from the punch and return the punch to its
neutral position.
Punch and Die Operating Clearances
Maintain the following clearance between punch and die.
Material Thickness Total Clearance
16 gauge and lighter .006”
15 gauge - 13 gauge .010”
3/32” - 5/32” 1/64”
3/16” - 15/32” 1/32”
1/2” - 23/32” 1/16”
3/4” and heavier 3/32”
Punching Capacities
You can determine the tonnage required to punch A36 mild steel (yield
strength 36,300 psi, 65,000 psi tensile) by applying the following for-
mulas for round or shaped holes. For materials other than mild steel
please refer to the multiplier table.
Round Holes
Punch Dia. x Material Thickness x 80 = Tons of pressure required
Example: How many tons of force do I need to punch a
3/8” hole in 1/4” mild steel?
.375 x .25 x 80 = 7.5 tons
Punch Tonnage Requirement (Figure 1)
Shaped Holes
1/3 Punch Perimeter x Material thickness x 80 =
Tons of pressure required
Example: How much force do I need to punch a 3/8” x 1”
rectangular hole in 1/4” mild steel?
(.33 x 2.75) x .25 x 80 = 18.1 tons
Material Multiplier
When punching materials other than mild steel rst calculate tonnage as
shown above then apply the multiplier for the listed material.
Aluminum(2024-0) 0.36
Brass (1/4 hard) 0.70
Copper (1/2 hard) 0.52
Steel (50% carbon) 1.60
Steel (cold rolled) (1018) 1.24
Stainless Steel (303) 1.50