S B Whistler & Sons, Inc. XimmiX Modular Hard Dies

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The innovative "bump die" design of XimmiX^Ž tooling delivers hard die quality and performance at just a fraction of the cost. Template-positioned tooling and spring-loaded alignment posts ensure excellent punch to die alignment and repeat accuracy. With no heavy die set or top ram attachment, the lightweight design of XimmiX^Ž dies simplifies handling and setup, permitting die changes to be made in just seconds. Small tool "footprint" allows standard tools to be clustered more densely than in any other modular system, reducing costs and increasing productivity. Best suited for intermittent or repetitive work of moderate production volume, XimmiX^Ž punches and notches materials up to 1/4" (6.35 mm) thick mild steel. (click image for larger view)

The XimmiX^Ž system consists of these basic components: Spring-loaded, precision alignment posts which insure proper punch-to-die alignment and return the die to open when the press ram is up; template sets that locate the tool holders in accordance with the desired hole pattern; punch drivers that assemble through the punch template to hold the punches; punches and die bushings, referred to as the cutting members, specified with the proper die clearance for the material being punched and secured to their holders with cap screws, punch guides which act as precision stripper plates and control the final concentric alignment of punches; die pods, which elevate the die bushings to proper punching position; clips, which secure punch driver and die pod assemblies to the templates. The final components are gages, which attach to the die template for accurately locating the work piece for punching.

Unlike other systems, XimmiX^Ž dies feature a unique method of positioning and stripping the punch members. The punch is secured to the driver component and then assembled to the guide. The guide actually performs three functions 1) to hold the material in place just prior to punch entry, 2) to concentrically guide the punch, and 3) to strip the material off the punch point after piercing. The die bushing is located on it's diameter through a hole which is machined in the template set. The template fabricating process ensures high accuracy between punch and die members. The spring-loaded alignment posts provide the "bump" action, through internal springs which return the upper template section to it's open position.

Templates and tools are assembled manually offline and away from the press, quickly and easily and without any special skill requirements or tools. When ready to run the job, it takes only a minute to set the template assemblies onto the press bed or bolster and secure them with clamps. Once installed, production can begin and there is no need for first-part inspection. When the production run is completed, tools can be reused on another job if needed, or stored as assembled, or disassembled for cabinet storage. The unique modularity of XimmiX^Ž dies insures that the tools can be reused repeatedly on many jobs and produce consistently accurate stampings, every time.

APPLICATIONS

Below is an overview of the capacity choices available with XimmiX^Ž tooling systems. If you believe either of these matches the requirements for your application, you can request a quotation by completing the quote request steps identified on our request page. Before making your choice, however, we do encourage you to continue reading to learn more our other systems. Theres no obligation for the quote.

Available in Two (2) basic styles - each designed to pierce a specific range of material thickness and hole sizes.
standard	heavy duty
Mild steel up to .125" (3.1mm). Maximum hole 3.150" (80mm)	Mild steel up to .250" (6.3mm). Maximum hole 3.150" (80mm)

LAYOUT and SETUP

Accuracy of punched holes depends on the accuracy of machined template sets. Template layout is achieved by machining a set of two (2) plates together, using any conventional or CNC mill. Whether you have CAD or only simple layout tools, you can design your template to achieve the final product by simply identifying the center coordinates of each hole feature, then accurately machining or boring their respective holder positions. For those with CAD systems, complete layouts can be computer-generated by using our DXF disk, which is filled with all the standard system components. Our disk helps you quickly identify the items you will need and lets you create a layout that can be used in the shop for fabricating the template set, as well as for tool and template assembly of each job.


BLANK LAYOUT		CAD SETUP

	Identify the center coordinates for each hole feature. The machining or bore size for each series is provided in the user guide. For special shapes, a slot is cut to engage an orientation pin on the body of every shaped punch and guide. Locate gages, pilots and notch dies as needed and release the details to the shop for manufacture.		Start by opening your subject and simply insert each of the tool holder blocks, gages and pilots as needed from the DXF disk. Position each on the subject and review the completed layout for correctness and fit. The inserted blocks contain layers, which once ungrouped, allow you to view only the machining requirements for the templates.

SERIES FEATURES

Each XimmiX^Ž series includes standard and accessory items available for correct punching and notching of your subject. Each series is defined by its range of tool holders for a given hole size. The retainer required is based on the hole size being pierced. For conditions with close hole centers, punches and dies can be made as clusters, referred to as multiples. Multiples utilize one of the standard punch diameters to accommodate more than one feature of the subject and can be used to reduce the number of hits and or tools needed for a job.


standard		heavy duty
Series 12 up to .460" (12mm) holes Series 20 up to .787" (20mm) holes Series 35 up to 1.378" (35mm) holes Series 55 up to 2.165" (55mm) holes Series 80 up to 3.150" (80mm) holes		Series 20 up to .787" (20mm) holes Series 35 up to 1.378" (35mm) holes Series 55 up to 2.165" (55mm) holes Series 80 up to 3.150" (80mm) holes
Accessories
Pilots Gages Coil control accessories for guiding and lifting coil-fed materials. 4 X 4 (101.6 mm x 101.6 mm) Corner Notch Dies are used for 90˚ corners and / or 90˚ edge notches. Can also be used for Cutoff.

custom sub-dies

For those larger features on your subject or for hole groupings or clusters that exceed the size capacity of standard punch and die holders, Whistler provides custom sub-die tools, designed to operate in conjunction with standard XimmiX^Ž system tools. These sub-dies achieve patterns that won't fit in the standard retainer options and are essentially limited in size by only the work area of your press. Sub-dies are typically used for higher production volumes as a way to reduce the number of hits required to complete the part.

SPECIAL APPLICATIONS

When working with formed parts, Whistler can provide post extensions along with punches, guides and die bushings of varying heights, to accommodate simultaneous punching of multiple elevations within the same subject. These "higher / longer / shorter than standard" cutting members provide the ultimate in modular tooling flexibility, further enhancing the potential capacity of the XimmiX^Ž die system.

How to Buy
What information we need and methods you can use
	Request a Quote

Send your prints to our engineering department via mail, courier or fax, or better yet - send them via email in DXF file format. We will review and discuss your requirements with you up front and recommend a modular die system best suited your specific application. Detailed system quotations will then be developed, clearly identifying all necessary system components. There is no charge for this service.

You can choose to start with a single job or an entire family of subjects. Click here to review the information needed when requesting quotations.