AND METHOD FOR METAL FORMING DIES

BACKGROUN D OF THE I NVENTION

[0001] The present invention relates to metal forming dies and the like, and in particular to a modular pilot assembly with self-contained stripper and associated method.

[0002] Figs. 5-8 illustrate several well known prior art metal forming dies and associated pilot mechanisms, which further represent the background of the present invention. For example, Fig. 5 illustrates one half of a die set 100, which includes a first die member 101 having a plurality of longitudinally spaced apart work stations 102 at which various bending, forming, cut-off and/or punching operations are performed on an elongate strip of metal stock 103. As best illustrated in Fig. 6, the prior art pilot mechanism 104 for the illustrated die set 100 includes a pierce tool punch 105 located at an upstream portion of stock strip 103, which, in the illustrated example, forms a vertically oriented through hole 106 in the stock strip 103 at regularly spaced apart intervals along the stock strip. The through holes or pilot holes 106 are selectively engaged by a series of pilot pins 107 positioned on at least selected ones of the die work stations 102, which serve to precisely locate the stock strip 103 in the work stations, and retain the same in place during the metal forming stroke of the die tools. After each metal forming stroke of the die tools, the pilot pins 107 are retracted out of their associated pilot holes 106 in the stock strip 103, and the stock strip is then shifted longitudinally to the next adjacent work station 102, until the metal part has been completely formed and cut off of the stock strip.

When the pilot pins 107 are retracted out of the pilot holes 106 in the stock strip 103, the stock strip tends to stick on one or more of the pilot pins, thereby requiring some type of stripper mechanism to separate them, such that the stock strip can be quickly and sequentially advanced longitudinally through the various die stations.

[0003] Fig. 7 illustrates another known prior art pilot assembly that includes a

rectangularly shaped block or base 111 that is mounted in a blind hole pocket 112 in an associated upper die member 113. The base block 111 includes a central aperture 114 in which a pilot pin 115 is retained, and two laterally offset reaction apertures 116 in which a pair of stripper assemblies are received and retained. A female punch tool 117 is positioned in the lower die member 122, and closely receives the pilot pin 115 to precisely locate the stock strip 5 in the associated work station 112. Each of the stripper assemblies comprises a plunger shaped rod 118 having an outer end 119 protruding outwardly from base block 111 toward the stock strip 103, and an inner end 120 with a coil spring 121 received thereover which resiliently urges the rods 118 outwardly on opposite sides of pilot pin 15, and serve to strip the stock strip 103 from the exterior surface of the pilot pin 115 as the pilot pin and associated upper die member 113 are raised to a diverged condition relative to the lower die member 122.

[0004] Fig. 8 illustrates yet another known prior art pilot assembly, which includes an enlarged, flat mounting plate 126 which attaches to the upper surface 127 of the upper die member 113 using a pair of cap head screws 128 having threaded shanks 129 that are anchored in the upper die member 113. The upper die member 113 includes a central aperture 114 in which a pilot pin 115 is received and retained, along with a pair of reaction apertures 116 disposed on opposite sides of pilot pin 115, each of which receives and retains therein a plunger shaped rod 118. The outer ends 119 of the rods 118 protrude outwardly from the lower surface of upper die member 113, while the inner ends 120 of rods 118 have coil springs 121 received thereon which resiliently urge rods 118 outwardly, such that the outer ends 119 of rods 118 serve to strip the stock strip 5 away from the exterior surface of the pilot pin 115, and thereby permit the stock strip 5 to be shifted longitudinally into the next adjacent work station.

[0005] Large manufacturers of formed metal parts, such as those which supply parts to automobile companies and the like, have an extensive inventory of metal forming dies and related metal handling machinery. Through the years, such companies have standardized on several different styles and sizes of pilot punches and associated pins for use with their various dies, so as to maximize efficiencies when combining various tooling for a specific project. Similarly, the metal forming die industry generally has adopted such standard pilot punch and pin sizes and shapes to minimize the effort and expense of making, installing and maintaining the dies and related metal handling equipment. When a new die is designed and fabricated by a tool and die maker, the customer will often specify that the die maker use a specific shape and size of pilot punching pin, which is often one of several styles that are standard or non-custom, and are commercially readily available. Sometimes, the customer will actually provide to the die maker the pilot punch and pilot pins that it desires to be incorporated into a specific progressive metal forming die, or portion thereof.

[0006] While such prior pilot assemblies have proven generally successful, they are rather expensive and time consuming to construct and install in an associated die set, such that further improvements and enhancements to the same, as well as metal forming dies generally, would be clearly advantageous, and are disclosed herein.

SUMMARY OF THE INVENTION

[0007] One aspect of the present invention is a pilot assembly that can be easily installed in an associated die member by simple machining a single pocket and a single tapped retainer hole therein, and a related method. The pilot assembly has a self-contained stripper with no loose pieces or parts, is constructed from fewer components than prior art pilot devices and positively prevents the stock strip from sticking to the pilot pin. The pilot assembly includes a pilot sleeve with a central aperture configured to receive and retain therein one of a plurality of differently sized and shaped, conventional, and/or commercially available, pilot pins to facilitate the use of common parts throughout the metal forming die. The body portion of the pilot sleeve itself provides the precise location of the stripper assembly in an associated die pad at a location close to the stock strip. The stripper assembly has a modular design that can be economically

manufactured, has a small profile and footprint, and can be easily assembled and disassembled from an associated die member. Due to the design of the pilot assembly, the ejector pins can be located in close proximity to the pilot pin, so as to positively and dependably, repeatedly strip the stock strip from the pilot pin. The pilot assembly has a single screw mounting system for quick and easy installation in an associated die member. The pilot sleeve can be machined from a single piece of solid material in one setup to achieve tighter tolerances and better concentricity between the pilot sleeve and pilot pin, as well as reduced manufacturing cost. The pilot assembly is efficient in use, economical to manufacture, capable of the long operating life, and particularly well adapted for the proposed use. [0008] These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Fig. 1 is a perspective view of a modular pilot assembly with self-contained

stripper embodying the present invention, shown installed in a die set carrying a stock strip in which pilot holes have been formed.

[0010] Fig. 2 is an exploded perspective view of the pilot assembly shown in Fig. 1.

[0011] Fig. 3 is a perspective view of a portion of the pilot assembly in an assembled condition, taken from an outer end thereof.

[0012] Fig. 3A is a vertical cross-sectional view of the portion of the pilot assembly shown in Fig. 3.

[0013] Fig. 4 is a top plan view of the pilot assembly.

[0014] Fig. 5 is a partially schematic perspective view of a representative, prior art die member shown in an open condition with a stock strip positioned along the various work stations of the die member.

[0015] Fig. 6 is a partially schematic cross-sectional view of a prior art pilot assembly.

[0016] Fig. 7 is a partially schematic cross-sectional view of another prior art pilot

assembly.

[0017] Fig. 8 is a partially schematic cross-sectional view of yet another prior art pilot assembly.

[0018] Fig. 9 is a cross-sectional view of the pilot assembly embodying the present

invention, shown installed in a die set.

[0019] Fig. 10 is a perspective view of a pilot sleeve portion of the pilot assembly, taken from an inner end thereof.

[0020] Fig. 11 is a perspective view of the pilot sleeve, taken from an outer end thereof.

[0021] Fig. 12 is a plan view of the inner end of the pilot sleeve.

[0022] Fig. 13 is a plan view of the outer end of the pilot sleeve.

[0023] Fig. 13A is a fragmentary, vertical cross-sectional view of the pilot sleeve, showing a blind threaded puller tool aperture. [0024] Fig. 14 is a cross-sectional view of the pilot sleeve taken along the line XIV-XIV of

Fig. 10.

[0025] Fig. 15 is a vertical cross-sectional view of the pilot sleeve taken along with the line XV-XV of Fig. 11.

[0026] Fig. 16 is a perspective view of a first pilot pin portion of the pilot assembly.

[0027] Fig. 17 is a vertical cross-sectional view of the first pilot pin shown in Fig. 16.

[0028] Fig. 18 is a vertical cross-sectional view of an assembled portion of the pilot

assembly with the first pilot pin of Fig. 16 installed therein.

[0029] Fig. 19 is a perspective view of the pilot assembly with the first pilot pin of Fig. 16 installed therein.

[0030] Fig. 20 is a perspective view of a second pilot pin, different from the first pilot pin of Fig. 16, which can also be used in the pilot assembly.

[0031] Fig. 21 is a vertical cross-sectional view of the second pilot pin shown in Fig. 20.

[0032] Fig. 22 is a vertical cross-sectional view of an assembled portion of the pilot

assembly in which the second pilot pin of Fig. 20 is installed.

[0033] Fig. 23 is a perspective view of the pilot assembly with the second pilot pin of Fig.

20 installed therein.

[0034] Fig. 24 is a top plan view of an ejector pin portion of the pilot assembly.

[0035] Fig. 25 is a side elevational view of the ejector pin.

[0036] Fig. 26 is a bottom plan view of the ejector pin.

[0037] Fig. 27 is a top plan view of a mounting screw portion of the pilot assembly.

[0038] Fig. 28 is a side elevational view of the mounting screw.

[0039] Fig. 29 is a bottom plan view of the mounting screw.

[0040] Fig. 30 is a plan view of a retainer ring portion of the pilot assembly.

[0041] Fig. 31 is an exploded side elevational view of the pilot assembly, shown with the first pilot pin of Fig. 16 for installation therein.

[0042] Fig. 32 is an enlarged, fragmentary cross-sectional view of the pilot sleeve,

showing the ejector pin and associated retainer ring mounted in place.

[0043] Fig. 33 is a perspective view of the pilot assembly of Fig. 31 shown in an

assembled condition, from an inner end thereof. [0044] Fig. 34 is a plan view of an upper pressure pad portion of a die member, that has been machined for installation of the pilot assembly therein, oriented with the normally lower mounting surface facing upwardly for illustration purposes.

[0045] Fig. 35 is a perspective, cross-sectional view of the machined die member of

Fig. 34, taken along the line XXXV-XXXV of Fig. 34.

[0046] Fig. 36 is an exploded perspective view of the pilot assembly prior to installation into the normally lower mounting face of the machined upper die pressure pad die member shown in Figs. 34 and 35.

[0047] Fig. 37 is an exploded, perspective view of the pilot assembly partially installed in the normally lower mounting face of the upper pressure pad die member shown in Figs.

34-36.

[0048] Fig. 38 is a perspective view of the pilot assembly installed in the normally lower mounting face of the upper pressure pad die member shown in Figs. 34-37.

[0049] Fig. 39 is a vertical cross-sectional view of the pilot assembly, shown installed in the upper pressure pad die member of Figs. 34-38, oriented in the running condition, with the pilot pin fully inserted into the pilot aperture in the stock strip.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] For purposes of description herein, the terms "upper," "lower," "right," "left,"

"rear," "front," "vertical," "horizontal" and derivatives thereof shall relate to the invention as oriented in Figs. 1, 2 and 3A. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0051] The reference numeral 1 (Figs. 1-4) generally designates a modular pilot assembly with self-contained stripper embodying the present invention. As shown in Fig. 1, the pilot assembly 1 is particularly adapted for use in conjunction with a multi-station progressive metal forming die 2, having at least two mutually converging and diverging die members 3 and 4, between which an elongate stock strip 5 is shifted longitudinally to form parts from the stock strip. The pilot assembly 1 includes a pilot sleeve 10 operably supported on one of the two die members 3, 4 and having a generally cylindrical shape with an outer end portion 11 oriented toward the stock strip 5, an oppositely disposed inner end portion 12 oriented away from the stock strip 5, and a central aperture 13 extending through the outer and inner end portions 11, 12. The outer end portion 11 of the pilot sleeve 10 has a generally flat outer end 14 oriented toward the stock strip 5, a generally recessed inner end 15 oriented away from the stock strip 5, and an outer sidewall 16 with at least one fastener relief 17 therein having an arcuately shaped, radially inwardly curved relief sidewall 18 that extends axially from the flat outer end 14 to a generally flat, arcuately shaped relief end surface 19 facing toward the stock strip 5 and spaced axially outwardly a predetermined distance from the recessed inner end 15. The outer end portion 11 of pilot sleeve 10 also includes at least one axially extending ejector pin aperture 20 which opens through the flat outer end 14 and into the recessed inner end 15. The inner end portion 12 of the pilot sleeve 10 has a generally annularly shaped spring retainer collar 25, with an outer end 26 oriented toward the stock strip 5, an inner end 27 oriented away from the stock strip 5, and an outer sidewall 28 with a diameter that is less than the diameter of the outer sidewall 16 of the outer end portion 11 of the pilot sleeve 10, thereby forming an annularly shaped spring groove 29 adjacent the outer end 26 of the spring retainer collar 25. The pilot assembly 1 also includes a rigid pilot pin 35 having at least a portion thereof shaped for close reception in the central aperture 13 of the pilot sleeve 10 in an assembled condition. Pilot pin 35 includes a circularly shaped innermost collar portion 36 disposed adjacent the flat outer end 14 of the pilot sleeve 10 in the assembled condition shown in Figs. 3 and 3A, and shaped for close reception in a pilot hole 6 in the stock strip 5, a generally frusto-conically shaped outer portion 37 configured to engage the pilot hole 6 in the stock strip 5, and guide the stock strip 5 to a predetermined position in an associated die forming station 102, and a base portion 38 positioned opposite the frusto-conically shaped outer portion 37. The pilot assembly 1 also includes at least one rigid ejector pin 42 slidingly received and retained in the ejector pin aperture 20 in the outer end portion 11 of the pilot sleeve 10, having an inner end 43 oriented away from the stock strip 5 and an outer end 44 oriented toward the stock strip 5 and protruding outwardly from the flat outer end 14 of the outer end portion 11 of the pilot sleeve 10 when urged to an extended position to contact the stock strip 5 and strip the same away from the pilot pin 35, and retracts toward the pilot sleeve 10 when urged to a retracted position. The pilot assembly 1 also includes a spring member 48 having a generally hollow interior 49 that is received onto and over the spring retainer collar 25 on the inner end portion 12 of pilot sleeve 10, an outer end 50 oriented toward the stock strip 5, which is received in the spring groove 29 and operably engages the inner end 43 of the ejector pin 42 to bias the ejector pin 42 outwardly to the extended position, and an inner end 51 oriented away from the stock strip 5 and positioned adjacent to the base portion 38 of the pilot pin 35 in the assembled condition shown in Figs. 3 and 3A. The pilot assembly 1 also includes a mounting screw 56 having an enlarged head portion 57 with a circular plan shape that is at least partially, closely received in the fastener relief 17 in the outer end portion 11 of the pilot sleeve 10, an annularly shaped inner face 58 oriented away from the stock strip 5 and abuttingly engaging the relief end surface 19 of the fastener relief 17 in the outer end portion 11 of the pilot sleeve 10, and a threaded shank portion 59 anchored in one of the die members 3, 4 to securely, yet detachably mount the pilot assembly 1 on an associated one of the die members 3, 4 in a manner which causes the ejector pin 42 to automatically reciprocate between the retracted and extended positions relative to the pilot sleeve 10 during operation of the metal forming die to insure that the stock strip 5 is consistently fully stripped away from the pilot pin 35.

The term "die member," as used herein, refers to any portion of a metal forming die or die set, including, but not limited to, an upper die member or a die shoe, a lower die member or a die shoe, and all other die components, whether stationary or reciprocating, including a reciprocating pressure pad, or the like. In the illustrated example, the pilot assembly 1 is shown mounted in a reciprocating upper die pad 3 located above a lower stationary die shoe 4. However, as will be appreciated by those skilled in the art, pilot assembly 1 can be mounted in other types of die members and/or components in a variety of different positions and orientations, as necessary to precisely locate the stock strip 5 in the various workstations 102 of a metal forming die 100. [0053] The illustrated pilot sleeve 10 (Figs. 10-15) has a one-piece construction formed from a solid bar of rigid material, such as metal or the like. The spring retainer collar portion 25 of the illustrated pilot sleeve 10, includes a retainer groove 64 disposed adjacent the inner end 27 of spring retainer collar 25. As best shown in Figs. 2, 30 and 31, a retainer ring 65 is detachably retained in the retainer groove 64 in the spring retainer collar 25 and selectively abuts the inner end 43 of each ejector pin 42 to capture or retain each ejector pin 42 within the associated ejector pin aperture 20 in the outer end portion 11 of pilot sleeve 10. As discussed in greater detail below, the illustrated retainer ring comprises a conventional, split C-ring having a generally circular lateral cross-sectional shape. Furthermore, the outer end portion 11 of the illustrated pilot sleeve 10 includes a plurality of fastener reliefs 17 having a substantially identical configuration and arranged in a circumferentially spaced apart pattern around the outer sidewall 16 of the outer end portion 11 of pilot sleeve 10 to facilitate mounting the pilot assembly 1 at various hold down locations and orientations on one or more of the die members 3, 4. As best illustrated in Fig. 4, the illustrated outer sidewall 16 of pilot sleeve 10 includes three fastener reliefs 17, two of which are disposed generally diametrically opposite one another, and the third of which is oriented at an angle approximately 30°- 40° from the fastener relief 17 in which the mounting screw 56 is received in the illustration of Fig. 4.

[0054] Since the illustrated pilot sleeve 10 has a one-piece construction formed from a solid bar of rigid material, such as metal or the like, preferably, all machining operations on the solid bar of rigid material are made during a single machine setup, so as to achieve greater accuracy and consistency of the pilot sleeve 10, as well as reduced manufacturing costs. The outer end portion 11 of the illustrated pilot sleeve 10 has a plurality of ejector pin apertures 20 having a substantially identical configuration and arranged in a circumferentially spaced apart, mutually parallel, axially extending pattern through the outer end portion 11 of pilot sleeve 10 to insure effective and consistent stripping of the stock strip 5 from the pilot pin 35. As best shown in Figs. 4 and 11-13, the illustrated pilot sleeve 10 includes four ejector pin apertures 20 which are spaced opposite from one another on the flat outer end 14 of pilot sleeve 10, and are radially positioned close to the central aperture 13 of pilot sleeve 10, so as to improve the stripping action of the same. The illustrated pilot assembly 1 also includes four substantially identical ejector pins 42 which are slidingly received and retained for reciprocation in the ejector pin apertures 20 of the outer end portion 11 of the pilot sleeve 10. As best illustrated in Figs. 24-26, the outer ends 44 of ejector pins 42 have a size and shape similar to the elongate body portions of ejector pins 42, each with a generally flat circular plan configuration best suited for abuttingly engaging the stock strip 5, while the inner ends 43 of ejector pins 42 are enlarged relative to the size of the elongate body portions of ejector pins 42, and define cylindrically shaped, enlarged heads, each with a generally circular, flat inner face which facilitates engagement with the outer end 50 of spring member 48. With reference to Figs. 4, 13 and 13A, the illustrated pilot sleeve 10 includes a threaded blind installation aperture 46 which extends axially into the closed outer end 14 of the pilot sleeve 10 at a location spaced radially outwardly from and circumferentially in-between the ejector pin apertures 20. A puller tool 68, shown schematically in Fig. 38, is configured for threaded engagement in the blind installation aperture 46 in pilot sleeve 10 to facilitate removal of the assembled pilot sleeve 10 from the associated die member 3, 4, as discussed in greater detail below. Installation aperture 46 is disposed generally opposite the three fastener reliefs 18 in pilot 1, as best shown in Figs. 4 and 13.

As best illustrated in Figs. 16-23, the pilot sleeve 10 is adapted to securely, yet detachably receive and retain therein one of a plurality of differently shaped and sized types of pilot pins to accommodate a wide variety of different die applications and various users. For example, the pilot pin 35 illustrated in Figs. 16-19 is a pointed pilot and has a relatively sharply tipped bullet-like profile, wherein the base portion 38 is in the form of an enlarged circular disk that is integrally formed with a cylindrical or a barrel- shaped medial portion 39, with a frusto-conical outer portion 37 that tapers arcuately to a relatively small, circular flat tip 40. The medial portion 39 of pilot pin 35 is radiused radially inwardly at lead 41 to cylindrical collar portion 36, which is sized for close reception in smaller diameter pilot holes 6 in stock strip 5. As best illustrated in Fig. 18, the medial portion 39 of pilot pin 35 is closely received and retained within the central aperture 13 of pilot sleeve 10, while the arcuate stepped lead 41 adjacent the collar portion 36 is disposed within the interior of pilot sleeve 10 in the assembled condition of Fig. 18. In contrast, the pilot pin 35a illustrated in Figs. 20-23 is a straight pilot and has a relatively blunt tipped, bullet-like profile, wherein the base portion 38a is in the shape of an enlarged circular disk, the medial portion 39 is cylindrical, with the outermost end defining the collar portion 36a that is sized for close reception in larger diameter pilot holes 6 in stock strip 5. A rolled over arcuate edge leads to the frusto-conical outer portion 37a, which has a circular end tip 40a which is substantially larger in diameter than the circular end tip 40 of pilot pin 35. As best illustrated in Fig. 22, like pilot pin 35, the medial portion 39a of pilot pin 35a is closely received within the central aperture 13 of pilot sleeve 10. As noted above, pilot pin 35 is designed to be closely received within a pilot hole 6 that is somewhat smaller in diameter than the pilot hole in which pilot pin 35a is received. In any event, it is apparent that a wide variety of differently sized and shaped pilot pins can be assembled in pilot sleeve 10 in accordance with the desires of the die maker and/or die user. The pilot pins 35, 35a may be of a conventional, and/or commercially available design, and may even be provided by the die user or die maker themselves, such that they need not be included as part of the purchased pilot assembly 1. The only requirement for any given pilot pin 35 is that the inner end thereof has a diameter that fits closely within the central aperture 13 of one of several differently sized pilot sleeves available.

[0056] The illustrated spring member 48 comprises a conventional closed coil spring, which may have partially flattened or ground ends 50, 51 to more securely abut the inner ends 43 of ejector pins 42, as well as the bottom of the die pocket 80 in which the pilot assembly 1 is to be mounted, as described in greater detail hereinafter.

[0057] With reference to Figs. 27-29, the illustrated mounting screw 56 comprises a conventional socket head cap screw having a tool engaging socket 60 in the outer face 61 of the head portion 57 of mounting screw 56, opposite inner face 58, and the threaded shank portion 59 includes a self-locking nylon patch 62, which prevents mounting screw 56 from inadvertently loosening from its tightened condition in die member 3, 4.

Mounting screw 56 constitutes a single mounting screw system, configured for at least partial reception in and engagement with any one of the three fastener reliefs 17 in the outer end portion 11 of pilot sleeve 10, which provides the sole support for mounting the pilot sleeve 10, pilot pin 35, ejector pins 42 and spring member 48 in the die member 3, 4, with a compact profile and footprint that facilitates ease of die design, operation and maintenance. The single mounting screw attachment of pilot sleeve 10 and related parts to die member 3 also provides quick and easy installation and removal. As will be appreciated by those skilled in the art, pilot assembly 1 can also be used with a lock washer (not shown) positioned on the shank portion 59 of mounting screw 56.

[0058] The pilot 1 is assembled by inserting four ejector pins 42 into the associated

ejector pin holes 20 in the outer end portion 11 of pilot sleeve 10, with the enlarged circular outer ends or heads 50 oriented away from the stock strip 5. Retainer ring 65 is then inserted into the retainer groove 64 adjacent the inner end of spring retainer collar 25, as best shown in Fig. 32, so as to capture each of the ejector pins 42 within the ejector pin apertures 20 of pilot sleeve 10. The spring member 48 is then inserted over the spring retainer collar 25 at the inner end portion 12 of pilot sleeve 10, and into the spring groove 29, such that the outer end 50 of the spring member 48 abuts the inner ends 43 of the ejector pins 42, so as to complete the assembly of pilot 1.

[0059] With reference to Figs. 34-39, the assembled pilot assembly 1 is quickly and easily installed in the illustrated upper die pad 3 in the following manner. The upper die pad 3 shown in Figs. 34-38 is illustrated with the normally lower mounting face 7 oriented upwardly in a non-running condition similar to the orientation in which a die maker would install the various tools and/or other components on a particular die half, so as to better visualize the various pilot mounting apertures. However, as is apparent to those skilled in the art, pilot assembly 1 is typically mounted in the lower mounting face 7 of an upper pressure pad 3 or similar die component, and runs or operates in the orientation shown in Figs. 1, 9, 18-23 and 39. Initially, a non-threaded pilot pocket or blind hole 80 is formed in the lower or mounting face 7 of the upper die pad 3 using simple machining techniques and no special tooling, and is shaped to closely receive and retain the pilot sleeve 10 therein. The illustrated pilot pocket 80 has a stepped construction, with a larger diameter aperture 81 defined by sidewall 82 disposed closest to stock strip 5 and lower die mounting surface 7, and a smaller diameter aperture 83 defined by sidewall 84 and circular bottom wall or base 85, disposed furthest away from the stock strip 5 and lower die mounting surface 7, with an annular lip or collar 86 formed therebetween. The outer sidewall 16 of the outer end portion 11 of pilot sleeve 10 fits closely within the larger aperture 81 of the pilot pocket 80, and the recessed inner end 15 of the outer end portion 11 of pilot sleeve 10 engages lip 86 to axially locate the assembled pilot sleeve 10 within pilot pocket 80. The circularly shaped bottom wall or base 85 defines the closed end of the smaller aperture 82 portion of pilot pocket 80, which with sidewall 84, provides a cup-shaped portion 86 of pilot pocket 80. In the orientation illustrated in Figs. 34-38, bottom wall 85 faces upwardly. The spring retainer collar 25 of pilot sleeve 10, along with the spring member 48 and retainer ring 65 are captured in the cup-shaped portion 86 of pilot pocket 80. The depth or vertical dimension of the cup-shaped portion 86 of pilot pocket 80 is less than the length of spring member 48, as measured between its opposite ends 50, 51 in the relaxed condition shown in Fig. 2. Consequently, when the assembled pilot 1 is inserted into the pilot pocket 80, the inner end 51 of spring member 58 contacts the end wall 85 of pilot pocket 80, and spring member 48 is pretensed to a predetermined biasing force sufficient to resiliently urge ejector pins 42 toward their normally extended position, as shown in Figs. 37-38. Furthermore, in the installed condition shown in Figs. 37-39, the flat bottom surface 45 of pilot pin 35 abuts flush against the bottom wall or base 85 of the cup-shaped portion 86 of pilot pocket 80 to securely locate pilot pin 35 vertically or axially, in the manner shown in Figs. 1 and 37-39. A single, threaded mounted screw aperture 88 is formed in the lower or mounting face 7 of die pressure pad 3 at a location spaced laterally apart a predetermined distance from the pilot pocket 80, and is shaped to closely receive therein the shank portion 59 of mounting screw 56. It is noteworthy that screw aperture 38 can be located at several different positions on the mounting face 7 of die member 3 to avoid interference with other die components that may be mounted thereon, so long as mounting screw 56 can be aligned with one of the three fastener reliefs 17 in the outer end portion 11 of pilot sleeve 10, as shown in Figs. 34-39. A lateral pocket 90 having a generally U-shaped plan configuration is formed between and connects the threaded screw hole 85 and the larger pilot aperture 81 of pilot pocket 80 along the lower mounting face 7 of upper pressure pad 3, and is sized to receive a portion of mounting screw 56 therein. As will be appreciated by those skilled in the art, assembled pilot 1 can also be installed in an upper pressure pad 3 or other die component machined as outlined above, with the pressure pad 3 and any other related die components oriented in the run condition shown in Figs. 1, 9 and 39. [0060] The assembled pilot 1 is then aligned with and inserted into the pressure pad 3 in the manner illustrated in Figs. 36 and 37. The pilot sleeve 10 is rotated in pilot pocket 80, so that one of the three fastener reliefs 17 in the outer end portion 11 of pilot sleeve 10 is laterally aligned with the threaded screw aperture 88 in the mounting face 6 of die member 3. Mounting screw 56 is then inserted into the threaded retainer aperture 88 in the upper die pad member 3. The tightening of mounting screw 56 in the mounting screw aperture 88 in the die member 3 abuttingly engages at least a portion of the innerface 58 on the head portion 57 of mounting screw 56 against the relief end surface 19 on the outer end portion 11 of pilot sleeve 10 to securely, yet detachably mount the pilot assembly on the die member, and simultaneously compress spring member 48 to the predetermined biasing force, and draws the bottom surface 45 of pilot pin 35 abuttingly against the bottom wall or base 85 of pilot pocket 80. Consequently, ejector pins 42 automatically reciprocate between the retracted and extended positions, relative to the pilot sleeve 10 during operation of the metal forming die to insure that the stock strip 5 is consistently and fully stripped away from the pilot pin 35. As will be

appreciated by those skilled in the art, under special and/or abnormal conditions, multiple mounting screws 50 may be used to secure pilot 10 in die member 3.

Essentially, the fully cylindrical areas of the outer end portion 11 of pilot sleeve 10, when closely received in the larger diameter portion 81 of pilot pocket 80, precisely locate and support the pilot assembly in the die work station, and the single mounting screw 56 securely, yet detachably retains the assembled pilot in the set, aligned condition, in the pilot pocket 80.

[0061] The pilot sleeve and related pilot assembly 1 may be readily removed from die member 3 by simply reversing the sequence of the installation steps described above. In the illustrated example, a puller tool 68 (Fig. 38) is provided to facilitate safe removal and handling of the pilot 10. More specifically, puller tool 68 has a threaded outer end 66a that is threadedly engaged in the threaded aperture 46 in pilot sleeve 10, and a weighted sliding handle 68 which is manually shifted outwardly along the rod shaped body of puller tool 68 to impact an enlarged head 68c, thereby imparting sufficient outwardly directed forces to easily extract pilot sleeve 10 from the pilot hole 80 in die member 3. Alternatively, pilot sleeve 10 can be removed from die member 3 by tapping it out of pilot hole 80 with a punch and hammer applied from the outer end of pilot sleeve 10.

[0062] Figs. 1 and 39 illustrate the operation of pilot assembly 1, wherein Fig. 1

illustrates the upper pressure pad 3 with pilot assembly 1 mounted therein converging against the stock strip 5 that is supported on the upper surface 8 of the lower die member 4. In this position, the ejector pins 42 are fully extended, and just start to abut against the upper surface of the stock strip 5. The frusto-conical portion 37 of the pilot pin 35 is received through the most closely aligned one of the pilot holes 6 in stock strip 5 and into the female pilot pad portion 9 in the bottom or lower die member 4, but the collar portion 36 of pilot pin 35 is not. Next, the upper die pad 3 converges or closes completely against the stock strip 5 and lower die member 4 supporting the same in the manner illustrated in Fig. 39, such that the abutting contact between the outer ends 44 of the ejector pins 42 and the upper surface of the stock strip 5 overcome the biasing force of pretensed spring member 48 on ejector pins 42, further compresses spring member 48, and shifts or retracts the ejector pins 42 back toward the interior of the outer end portion 11 of pilot sleeve 10. As shown in Fig. 39, the collar portion 36 of the pilot pin 35 is now fully received in the aligned pilot hole 6 in stock strip 5 and the female pilot portion 9 in the bottom die member 4. The metal forming operation in the associated die work station 12 is then completed with the pilot assembly 1 in the position shown in Fig. 39, such that the stock strip 5 is precisely located and securely held in place during formation and further processing of stock strip 5. As the upper die pad 3 diverges or moves away from the stock strip 5 and the lower die member 4, the resilient force generated by spring member 48, urges the ejector pins 42 back outwardly toward and abuttingly against the stock strip 5 and separates or strips the stock strip 5 from the pilot pin 35, such that the stock strip 5 can then be quickly shifted longitudinally to the next work station 12 for further processing.

[0063] As will be appreciated by those skilled in the art, pilot assembly 1 can be provided in a wide variety of different sizes to accommodate many different metal forming die applications. The all-in-one, modular construction of pilot assembly 1 not only provides a self-contained stock stripper that uses only one spring, but can be quickly and easily installed directly in a die member using simple machining techniques, and a single mounting screw.

[0064] Pilot assembly 1 has an uncomplicated construction with relatively few

components and is therefore quite durable and economical to manufacture. The single mounting screw attachment of the pilot assembly to an associated die member provides quick and easy installation and removal. The spring member 48 and pilot pin 35 are backed up or axially supported by the die member itself for greater strength and convenience. Pilot assembly 1 has a self-contained stripper which positively separates the stock strip from the pilot during operation of the metal forming die, and provides a very compact, low profile shape that can be used at various locations and orientations on the various die members. The installation of the pilot assembly 1 can be achieved with simple machining, so as to reduce installation time and cost. The pilot sleeve portion 10 of the pilot assembly 1 is configured to receive and retain a wide variety of differently sized and shaped pilot pins therein, partially those with a conventional and/or commercially available configuration, so as to accommodate many different applications and users.

[0065] In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.