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According to OSHA 29 CFR 1910.217, “The employer shall provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the press.” They are not required during die setting unless die blocks are included in your die setting procedure. They also satisfy the lockout/tagout requirements for isolating mechanical energy.
Aluminum Die Safety Block System
This high-strength die safety block is lightweight and comes in several sizes. The unique shape and mechanical properties of the 6063-T5 material have been calculated according to stringent structural aluminum design analysis standards to provide high strength.
The actual static load that the die safety block(s) will support is determined by adding the actual weights of the press slide and slide components (ram-adjustment assembly, connection rod[s] or pitman arm[s], and the upper die).
Allow 2000 pounds of static load for each cubic foot displaced in the press bed area (front to back x right to left) multiplied by the shut height (die space) of the press. Note: When using this formula, the calculated approximated static load has a safety factor of two (2).
With the machine at the top of its stroke; stroke up—adjustment up (S.U.A.U.–see previous page), measure the space between the upper and lower die set plates (not the distance between the bolster and slide). This gives the maximum safety block length. To determine the stroke up—adjustment down (S.U.A.D.–see previous page) measurement, subtract the ram adjustment from the S.U.A.U. figure. This provides the minimum length of the die safety block.
When an adjustable screw device is added to an octagonal safety block and the screw is all the way inside of the safety block, it will add 2" to the overall length of small and medium safety blocks and 2 1⁄2" to the overall length of large safety blocks. Therefore, subtract 2" for small or medium blocks and 2 1⁄2" for large blocks to determine the length of the aluminum portion of the die block.