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Press Tool Design-Project Report
Press Tool Design-Project Report
L.Dinesh Reddy
(07241A0304)
R.shiva Kumar
(07241A0319)
ABSTRACT
PRESS TOOLS
The process of designing and developing auxiliary equipment, methods, and
techniques required to improve efficiency and productivity of manufacturing, production with
large production volumes and higher production speeds require special helper tools known as
press tools.
Manufacturing of dust cap is accompanied by two types of press tool operation namely blanking
and drawing.
BLANKING
It is a metal stamping operation by which the sheet metal is punched to get the
required outer profile of the sheet metal component. During the blanking process the blanking
punch penetrates into the sheet metal and forces the material into the blanking die. The portion of
the sheet metal which comes out through the blanking die opening is the component with the
required profile.
PIERCING
Piercing operation consists of simple hole punching. It differs from blanking in
that the punching (or material cut from stock) is the scrap and the strip is the work piece.
Piercing is nearly always accompanied by a blanking operation before, after or at the same time.
DRAWING
Drawing is a metal forming process involving pulling a workpiece (cold or hot)
through a die providing reduction of the cross section of the workpiece.As the cross section
decreases after passing each die, the length of workpiece increases, requiring corresponding
increase of the speed.
Page no
Blanking die
24
25
26
27
28
29
30
31
31
10
39
11
Bearing cup
43
12
52
13
Strip layout
53
14
Bearing cup
59
15
58
Page no
45
47
49
54
54
54
7
8
54
Cost analysis
S.no
APPENDIX
Page no
Bush
25
Die plate
25
Pillar
25
Pillar set1
25
Pillar set2
26
Punch
26
27
Punch holder
27
Standard Punch
27
10
Stripper plate
15
NOMENCLATURE
S no
Name
Symbol
Bend radius
Punch radius
R
r
Bend allowances
Die clearance
Stock thickness
Shearing strength
Bend angle
Span
10
Shearing constant
11
Su
12
Maximum deflection
INDEX
S.NO
TITLE
PG-NO
Acknowledgement
ABSTRACT
List of figures
Nomenclature
Introduction
6-7
1
10
11
1.3 Strippers
15
17
23
31
40
Statement of problems
43
Design calculations
45
Drawing calculations
45
Strip Layout
53
Cost analysis
54
Conclusion
55
Appendix
56
INTRODUCTION
PRESS TOOL
Press Tool is a set of plates with a relief, or depth-based design, in them. The metal is placed
between the plates, and the plates are pressed up against each other, deforming the metal in the
desired fashion. This may be blanking or piercing or drawing or forming or coining etc.
There are different types of press machines:
Some of them are
9 C-type( fixed type & open back inclinable press)
9 Single action straight side press
9 Typical Hydraulic press
BEARING CAP
A bearing cap can be described as a number of things, but the most common reference is the part
of the engine block which contains the main bearings of a crankshaft. In an engine block, the part
of the engine that the crankshaft runs through is split. Once the main caps are removed, the
crankshaft can be set in the block on top of one-half of the main bearings. The other half of the
main bearings are in the bearing cap and are placed in order onto the crankshaft and the
corresponding other half of the main saddle. The bolts are then torque to specification, thereby
holding the crankshaft in place.
Piston rods also use a bearing cap to hold the piston rod onto the crankshaft. Like the main
bearings, the piston rod is split into two pieces: the rod and the cap. The rod bearings are divided
into two pieces, with one half of the bearing going into the bottom of the rod and the other half
going into the rod cap. The rod is slid into location onto the crankshaft rod through the journal.
The rod bearing cap is placed onto the bottom of the rod and around the crankshaft, completing
the union of the piston rod and the crankshaft with the connecting rod bolts being torque to
specification.
Die: A Die is an assemblage of parts used for producing different sheet metal components .
The Die is also called press tool as the dies are used on different types of presses based on the
cutting forces required for the component.
In this project a blanking die , piercing die , drawing die is produced for production of Bracket
used in supporting the fuel tank of an automobile. Before venturing into making of die , the
die making depends on many factors . Below given are the important points regarding die to
press relationships , die sets , strippers.
Capacity of press:
The force in kilo new tons indicates the capacity of press ram can exert on work piece safely. If
the capacity of force is expressed in tones of force, then it is referred as press tonnage.
Feed Height:
For dies, which are fed manually, the fed height is not critical. How ever, when dies are used in
conjunction with automatic feeding devices, the height of the stock line of the die must be with
in the range permitted by feeding device.
The die set is one of the basic tools of the stamping industry, and while not a glamour product, such
as numerical controls, electrical discharge machines, and exotic metals, it is as vital to metal working
as the tool bit, drill, reamer, and a grinding wheel
DIE SET
The industries which manufacture die sets commercially compromises six national and eight to ten
regional companies whose overall volume is relatively small in contrast to the importance of its
product to metal working mass production. The die set industry operates through assembly
branches or distributors on a national scale or locally with independent special die set
manufacturers on a small scale.
10
Accuracy of the setup: The die can be installed in the press as a self-contained unit,
assuring proper alignment of the various punch and die members.
2.
Improved piece-part quality: The quality of the work produced is enhanced by the
assured setup accuracy.
3.
4.
Minimum setup time: Setup time is kept to minimum because the die is installed as a
unit.
5.
6.
Alignment of punch and die members: A die set can be a means of keeping the punch
and die members properly during the working process. However, a die set cannot be
expected to compensate foe a punch press, which is not in good condition. Neither should
a die set be expected to operate satisfactorily if heavy, unbalanced work forces exist.
Such loads should be compensated for in the design of the die; they should not be
transferred to the guide posts and bushing of the die set.
7.
Facilitation of storage: On completion of the production run, the die can be stored as a
unit ready to be replaced in production again immediately.
11
2.
3.
Also used in plastics, die casting, paper and fiber, and other industries.
12
1.
Die shoe: The die set base is called the die shoe. This remains true even though punches are
sometimes mounted on this lower shoe. The great majority of standardized die sets have the
guideposts in the die shoe.
2.
Punch holder: The die set type member is called punch holder. This remains true even
though die blocks are sometimes mount on this top member. The great majority of
standardized die sets have the guide bushings mounted in the punch holder.
3.
Shank: Most punch holders in the smaller sizes are made with the shank, which fits the
clamping hole in the lower end of the punch press holder to ram. These shanks are generally
an internal part of the punch holder.
4.
Guideposts: Guideposts are cylindrical pins, which provide a means of alignment for the die
set.
5.
Guidepost bushings: These are installed in the opposing whole and engage the guide posts
with a closing fit. The posts and bushings, acting together, align the die sets.
6.
Flange: A ledge which is flush with the bottom surface of a die shoe or the top surface of a
punch holder. The ledge extends beyond the die area to provide a means for clamping the
choke member to the bolster plate or press ram, which is appropriate. Flanges are more
commonly provided on the die shoes on the punch holders.
7.
Die area: The area is available on the top surface of the die whole and the lower surface of
the punch holder for the mounting of punch and dies components. The die set guideposts and
bushings are normally located outside this area.
HCHC
2.
13
1. Catalog sets: Advances in die sets design have brought about an almost endless choice of
catalog types and styles within a limited size rang which are produced by commercial
manufacturers of die sets and stocked for fast assembly with pins bushings. In addition to these
catalog sets, die set manufacturers can produce any practical type and size of die set the die
designer specifies, usually at lower cost than would result from in plant manufacturing.
a.
Back post: Two guideposts are located toward the back of the set.
b.
Center post: Two guideposts at the left and right sides of the set on the shank centerline. The
two guideposts should differ in diameter in order to foolproof the set.
c.
Diagonal post: Two guideposts, one located at the right corner and the other at the left
corner. These sets can be supplied with reversed guidepost locations, the two guidepost
diameters must differ in order to foolproof this type of set also.
d.
Four post: One guidepost located at each of the four corners of the die set. One guidepost
center must be offset for fool proofing.
2. Special sets: A special die set is one, which differs in anyway from the standard catalog
specifications. Special die sets are made to order. They may be similar to catalog sets, or they may
be radically different. Special die sets may have pockets, slots, or cutout areas. These may be
rough in or completely finished by the die set manufacturer.
Die sets are [through] stress relieved by the manufacturers before finishing rough machining
of deep pockets cut outs etc should be done by the die set manufacturer before the stress relieving
14
operation, if residual stresses are not removed, they will be gradually released in service. This can
be the source of distortion and dimensional changes, which can have serious consequences.
Punch and die holders: Top and bottom surfaces of these parts are usually ground, with
some manufacturers finishing surface ground finish for ease of layout on the working areas
where shank are cast integral or welded, the shanks have a smooth turned finish.
2.
Guide pins: Most guide pins are ground with a 20in. finish, but major manufacturers of the
die sets now improve this finish to 9in., which is ideal for wear and lubrication qualities required in
the operating die sets.
3.
Bushings: Press fit or slip fit diameters on bushings are also ground with a fine finish, but
only to simplify insertion into holes in the punch holders. The ID of the bushing is ground smooth
but always honed or lapped to a smooth finish when fitted to the guide pins.
2.3 Strippers:
Strippers is the act of removing the work from the punch or punches. A stripper is a device for
stripping.
STRIPPER PLATE
15
Choice of material for stripper plate depends upon the cost and quality factors pertaining to
each specific instance. In the majority of box stripper applications, the stripper plate is made of
low-carbon steel, left soft. Both cold drawn and hot rolled steel are used.Plain stripper plates are
often made from cold drawn steel, because it is well suited to this type of stripper construction and
because its initial cost is low. Also, machining time is minimized. Channeled plates and offset
plates are also often made from cold drawn steel
The following materials listed in descending order of quality and durability are commonly employed
for making stripper plates,
1.
2.
3.
4.
5.
Hot rolled low carbon steel, including low carbon ground stock
6.
Cold drawn low carbon bar stock, commonly called cold rolled steel
16
Stock material: Material, which have a high friction value and material, which tend to
cling more and more difficult to strip.
2.
Conditions for cutting edges: When the cutting edges are sharp, less stripping effort is
required.
3.
Surface condition of side walls: A punch which has a smooth finish on its side walls
strips more easily than a punch which is not as smooth.
4.
Distance between punches: More effort is required to strip punches that are close
together.
17
Blanking : Blanking is used to produce blanks of desired contour and size by cutting them out
of the stock strip. Blank is the desired piece part made by Blanking Die. The material.
remaining after blanking is called as scrap.
Introductory Terminology:
Piece part: A piece part is the product of a Blanking Die. It may be complete product or it may
be only the component of a product consisting of many and different parts.
Stock material: It is the raw sheet metal from which the piece part is produced.
Punch: A punch is the male member of a complete die, which mates in conjunction with
female die to produce a desired effect upon the material being worked. .A Die can be a simple
Tool composed of punch, die block and stripper or float.
Stripper: Stripper is a device, which is used for stripping the piece part from the punch as the
punch traverses in the reverse direction.
18
Pilot: Pilot is a locating device, which position the work or stock strip accurately for die
working. When the pilots bring the work into the required position, it is said to be registered.
Shedder & Knockout: Shedder is a device, which acts to expel the work piece from the die
cavity. Shedder actuation is done by means of Knockouts bars.
Nest gage: The next gage is a device, which is used to locate and position the work piece
properly in the die.
Pushers: Pushers are installed for the purpose of holding the required edge or edges of the
work securely in contact with the appropriate gauging member.
Die stops: Die stops are installed in dies for the purpose of arresting the feeding movement of
the stock strip.
Shearing action:
The result of the forces imposed on the stock material by the working of the blanking dies is a
shearing action. The shearing action may be considered in three stages, which are important to
the Die maker because of their direct relationship to the dimensional qualities and appearance
of piece parts. They are also related to the effective working and life of the die.
19
Cutting Clearance:
20
Cutting clearance is the space between a side of the punch and the corresponding side of the
die opening at the cut edge when the punch is entered in the die opening. Cutting clearance
should be thought of and expressed as the amount of clearance per side.
Proper cutting clearance is necessary to the life of the die and the quality of the piece part.
Excessive cutting clearance results in objectionable piece-part characteristics. Insufficient
cutting clearance causes undue stress and wear on the cutting members of the tool because of
the greater punching effort required.
Angular clearance:
Angular clearance is a draft or taper applied the side walls of a die opening in order relieve
internal pressure of the blank slug as it passes through the opening.
In any Blanking or Piercing operation where the blank passes through die, it is imperative that
angular clearance be provided on the sidewalls of the die opening. The importance of angular
clearance cannot be over emphasized. The Blank-through type of the die will not run
successfully unless there is relieve for the pressure developed with in the die opening by the
blanks or slugs as they are through. This pressure can build up rapidly. Failure to relieve it
causes distortion and burring the material passing through the die opening and culminates in
pressure accumulations so great that punches break and die blocks burst.
Angular clearance should be expressed in terms of the amount of clearance per side. The
optimum angular clearance for any die opening depends upon the type of material to be run,
production requirements and the method of die construction. The strength of cutting members
also influences the amount of angular clearance to be used.
21
The appearance characteristic of material that has been blanked or pierced depends on the
amount of clearance between the punch and die and alignments of punch with die opening.
Burr side:
The burr side is adjacent to the break. Burrs should be practically non-existent if the cutting
clearance between the punch & the die is correct and if the cutting edges are sharp. In fact,
when a die is running in production, the degree of burr on the piece part is an indication
whether the die is ready for sharpening.
The burr side of a blank or slug is always toward the punch. The burr side of a punched
opening is always toward the die opening.
22
Piercing: This operation consists of simple hole punching. It differs from blanking in that the
punching (or material cut from stock) is the scrap and the strip is the work piece. Piercing is
nearly always accompanied by a blanking operation before, after or at the same time.
23
Introductory Terminology:
Piece part: A piece part is the product of a Blanking Die. It may be complete product or it may
be only the component of a product consisting of many and different parts.
Stock material: It is the raw sheet metal from which the piece part is produced.
Punch: A punch is the male member of a complete die, which mates in conjunction with
female die to produce a desired effect upon the material being worked. .A Die can be a simple
Tool composed of punch, die block and stripper or float.
Stripper: Stripper is a device, which is used for stripping the piece part from the punch as the
punch traverses in the reverse direction.
24
25
26
27
28
29
30
31
Drawing
Fundamentals of Drawing
A flat blank is formed into a cup by forcing a punch against the center portion of a blank that
rests on the die ring.
The progressive stages of metal flow in drawing a cup from a flat blank are shown schematically
in Fig. 1.
During the first stage, the punch contacts the blank (Fig. 1a), and metal section 1 is bent and
wrapped around the punch nose (Fig. 1b). Simultaneously and in sequence, the outer sections
of the blank (2 and 3, Fig. 1) move radially toward the center of the blank until the remainder
of the blank has bent around the punch nose and a straight-wall cup is formed (Fig. 1c and d).
During drawing, the center of the blank (punch area, Fig. 1a) is essentially unchanged as it forms
the bottom of the drawn cup. The areas that become the sidewall of the cup (1, 2, and 3, Fig. 1)
change from the shape of annular segments to longer parallel-side cylindrical elements as they
are drawn over the die radius.
Metal flow can occur until all the metal has been drawn over the die radius, or a flange can be
retained.
32
Types of drawing
Redrawing
Reverse drawing
1) Using the single-draw drawing technique it is possible to produce a drawn part from
a blank with a single working stroke of the press (Fig).
33
(Fig).
This comprises a punch, a bottom die and a blank holder, which is intended to
prevent the formation of wrinkles as the metal is drawn into the die.
In special cases, the punch or die can also be from a soft material.There are
drawing methods which make use of active media and active energy.
Drawing using active media is the drawing of a blank or hollow body into a rigid
die through the action of a medium. Active media include formless solid
substances such as sand or steelballs, fluids (oil, water) and gases, whereby the
34
Sheet steels and other sheet metals with higher strengths and better formability have
recently become available.
Other metals and alloys that can be deep drawn include aluminum and aluminum alloys,
copper and alloys, some stainless steels, and titanium.
Low-carbon sheet steels are the materials that are most commonly deep drawn and are
commonly used, for example, in the Automotive industry. Materials such as 1006 and
1008 steel have typical yield strengths in the range of 172 to 241MPa (25 to 35 ksi) and
elongations of 35 to 45% in 50 mm (2 in.). These materials have excellent formability
and are available cold or hot finished in various quality levels and a wide range of
35
thicknesses. Table 4 lists mechanical properties of the various qualities of carbon steel
sheet.
Types of drawing
Redrawing
Reverse drawing
1) Using the single-draw drawing technique it is possible to produce a drawn part from
a blank with a single working stroke of the press (Fig).
36
37
38
Sheet steels and other sheet metals with higher strengths and better formability have
recently become available.
Other metals and alloys that can be deep drawn include aluminum and aluminum alloys,
copper and alloys, some stainless steels, and titanium.
Low-carbon sheet steels are the materials that are most commonly deep drawn and are
commonly used, for example, in the Automotive industry. Materials such as 1006 and
1008 steel have typical yield strengths in the range of 172 to 241MPa (25 to 35 ksi) and
elongations of 35 to 45% in 50 mm (2 in.). These materials have excellent formability
and are available cold or hot finished in various quality levels and a wide range of
thicknesses. Table 4 lists mechanical properties of the various qualities of carbon steel
sheet.
39
40
Spring back:
Variation of bend-stresses causes spring back after drawing. The largest tensile stress
occurs in the outside surface metal at the bend. The tensile stress reduces toward the centre of
the sheet thickness and becomes zero at neutral axis.
The pie shaped sketch in figure depicts the changing tensile and compressive stresses in
the bend zone. Since the tensile stresses go from zero at point O on the neutral axis to a
maximum value at point X on the outside surface, the stress-strain curve developed is the
standard tensile test may be used for analysis of drawing.
The metal nearest the neutral axis has been stressed to values below the elastic limit. The metal
creates a narrow elastic band on both sides of the neutral axis, as shown in above figure. The metal
farther away from the axis has been stressed beyond the yield strength, however, and has been
plastically or permanently deformed when the doe opens, the elastic band tries to return to the original
flat condition but cannot, due to restriction by the plastic deformation zones. Some slight return does
occur as the elastic and plastic zones come to equilibrium, and this return is known as spring back.
41
The spring back forces about point O as created by the elastic metal are also depicted. Actually,
plastically deformed metal has a very small elastic return characteristic, which adds to the spring back.
Overcoming Spring back: Several methods are used to overcome or counteract the effects of spring
back. These are
1. Over drawing
2. Bottoming or setting
3. Stretch drawing
The sheet metal is often over bent an amount sufficient to produce the desired degrees of bend or bend
angle after spring back. Over drawing may be accomplished by using cams, by decreasing the die
clearance, or by setting the punch and die steels at a smaller angle than required in the case of a V-die.
When the clearance is reduced below the sheet metal thickness, the burnishing action wipes the metal
against an undersize punch or die steel. Over drawing is illustrated in following figures.
Bottoming or setting consists of striking the metal severely at the radius area. This places the metal
under high compressive stresses that set the metal past the yield strength. Bottoming is accomplished by
placing a bead on the punch at the bend area. In a Wiping die or U-die, the pad must bottom against the
shoe or backing plate so that the punch may set the metal at the bend. I t would be useless to bottom
against the flat areas of sheet metal, since they are not stressed and do not cause spring back. Also,
bottoming against these larger areas would require extremely high press tonnage.
Bottoming must be carefully controlled when adjusting the press ram or the forces
involved will rise at a rapid rate. Also, if two blanks are accidentally placed in a drawing die
that bottoms, press or die breakage may result.
Stretch drawing consists of stretching the blank so that all the metal is stressed past the yield
strength. The blank is then forced over the punch to obtain the desired contour. Very little spring back
occurs due to this pre-stressing before drawing. Only relatively large radii are bent by this method,
since sharp radii would take the pre-stressed metal beyond the ultimate tensile strength. The sheet metal
must be uniform in strength. Stretch drawing is most frequently done with a special hydraulic machine
rather than a die in a press.
42
When permissible, locate the burr side toward the inside of a form (or bend). Z dies and the like,
which produce reverse bends in a single operation, are excepted from the rule.Important! In the above
rule the emphasis is on the works when permissible. This is because the burr side of the piece part is
often predetermined in accordance with the functional requirements of the piece part in relation to the
end product. In such a case, the burr side is specified on the piece part drawing. It is then the normal
obligation of the die maker to examine his die design drawings and verify that the die he is about to
make will produce the piece part to specification. A burr side specification on the part drawing
supersedes the possible deleterious effects of the burr on drawing or forming dies.
Edge condition of the work piece is known to be a factor, which can affect the degree of drawing
possible for a given type of material. Smooth edges permit more severe drawing than rough edges. The
burr side of a blank is contiguous to the break, and therefore, if the burr side is on the outer surface of
the bend (tension side), the stock material will be more susceptible to the initiation of edge fractures in
the bend area. While it is true that this condition is primarily concern of the product engineer, the die
maker should recognize it also. In some cases where drawing is relatively severe, burr side location can
be difference between fracturing and not fracturing. In doubtful cases, the burr side effect on the bend
should be verified in advance, in order to assure compatibility of the cutting and forming (drawing)
operations.
43
44
DESIGN CALCULATIONS
Blanking calculations :
Shearing force for blanking operation:
Shear force F= (K*L*T*S)/1000 TONS
K =1.2 for normal clearance
L = perimeter of the blank = 188.4 mm
T =thickness of the stock strip = 1 mm
S =shearing strength of mild steel = 21 kg/sq.mm
Shearing force = (1.2*188.4*1*21)/1000 TONS
= 4.7 TONS
45
46
Piercing Calculations:
Shearing force for piercing operation:
Shear force F= (K*L*T*S)/1000 TONS
K =1.2 for normal clearance
L = perimeter of the hole = 78.5 mm
T =thickness of the stock strip = 1 mm
S =shearing strength of mild steel = 21 kg/sq.mm
Shearing force = (1.2*78.5*1*21)/1000 TONS
= 2.6 TONS
47
= 0.75(14)
= 10.5mm
48
Drawing calculations :
Shearing force for drawing operation:
Shear force F= (K*L*T*S)/1000 TONS
K =1.2 for normal clearance
L = perimeter of the hole = 78.5 mm
T =thickness of the stock strip = 1 mm
S =shearing strength of mild steel = 21 kg/sq.mm
Shearing force = (1.2*78.5*1*21)/1000 TONS
= 1.2 TONS
49
50
STRIP LAYOUT
Strip layout plays an important role especially in the case of the design of the press tool.
Strip decides the economic utilization of the work piece and helps in the decrease of cost of the
job and reduction in the production time by increasing the number of components.
First method:
Length of the stock strip = 684 mm
Width of the stock strip = 115 mm
Area of the stock strip = 684*115 = 78660 sq.mm
Number of blanks obtained = 22
Area of one blank = 2826 sq.mm
Area of 22 blanks = 22*2826= 62172 sq.mm
Stock strip efficiency = area of all blanks obtained/ area of the stock strip
= 62172/ 78660 = 0.79 = 79%
51
Before Blank
52
Second method:
length of the stock strip = 684 mm
width of the stock strip = 64 mm
area of the stock strip = 684*64 = 43776 sq.mm
number of blanks obtained = 11
area of one blank = 2826 sq.mm
area of 11 blanks = 11*2826 = 31086 sq.mm
stock strip efficiency = area of all blanks obtained/ area of the stock strip
= 31086/43776 = 0.71 = 71%
53
COST ANALYSIS
COMPUND DIE
Amount in Rs
Conventional milling
12
100
1200
Grinding
10
100
1000
10
100
1000
320
1600
Lathe turning
100
600
Cylindrical Grinding
200
600
Total cost
6000
Other cost
Allen screw, dowel pins, high tension rubber material are purchased from markets,
including the raw material for making the die and the heat treatment of the material has been
charged = Rs 3000
Total cost of the compound die = 6000 + 3000
= Rs9000
54
CONCLUSIONS
1)
The Bearing cup can be manufactured in 3 operations namely blanking operation, drawing
operation, piercing operation. If we use unit dies, the total cost will be more and the time taken
to manufacture will be more. So a compound die is used to manufacture the product where all
the operations are performed in one stroke of the press.
2)
3)
The Compound die is used in the batch operation of 6000 units of bearing cup.
4)
After the batch production of 6000 units, then the compound die is sent for machining so
that it can be used again for the next batch production.
5)
6)
The life of the compound die can be increased by machining the vital parts of the
compound die which are the punch and the die.
7)
The impact plate which is placed between the bottom bolster and punch holder is replaced
if necessary to improve the die life. Also the high tension rubber material can be replaced if
required.
55
APPENDIX
DRAWINGDIE
56
DRAWINGPUNCH
57
BEARING CAP
58
BEARING CAP
59
60
61
STRIPPER PLATE
62
63