RIFT VALLEY UNIVERSITY

Bishoftu Campus

DESIGN AND MANUFACTURING OF

STAPLER BODY

Abdi Bedasa ……………………………………0002/13

RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
Table contents
Abstract…………………………………………………………………………………………II
1, Introduction…………………………………………………………………………………..1
- Disassembly of stapler…………………………………………………………………..2
2, literature review………………………………………………………………………………3
- Strip layout………………………………………………………………………………3
3, Calculations…………………………………………………………………………………..4
4, Problem description…………………………………………………………………………...6
5, stapler body die design…………………………………………………………………………6
6, result and discussion …………………………………………………………………………..7
Conclusion…………………………………………………………………………………………9
Reference…………………………………………………………………………………………10

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ABDI BEDASA ID NO 0002/13 FEB 2024
RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
Abstract - A stapler is most commonly used in day-to-day life. A stapler is made up of plastic, stainless steel
and zinc plated steel. These are most commonly material used to manufacture stapler. In this project, we are
created stapler body die. Because of most stapler are made in china, for Indian manufacturers we going to
design and manufacture stapler body die for stapler body. In this project, we are making progressive die for
stapler body, which will easily to manufacture, and due to using standard assembly parts, it is easy to replace
for maintenance.

Key Words: Tool Design, Strip Layout, Tonnage Calculation, Stapler Body Design, Final
Assembly, Math 1.

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ABDI BEDASA ID NO 0002/13 FEB 2024

 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
1, INTRODUCTION
Tool Design is a specialized phase of tool Engineering Tool - design function may be performed by a tool
Engineer in addition to these other duties in manufacturing, or they may be performed by a tool design
specialist who devotes his entire working time to tool design the word "tooling refers to the handwork
necessary to produce a particular product considerable amount of tooling is the result of work performed by
the tool designer Tooling as viewed by the tool designer, consist of a vast array of Cutting device, jigs
fixtures, dies, gauge, etc. used in normal production
1] Sheet-metal press working dies you all types of Sheet metal fabrication
2] Die Casting
3] Plastic molds
4] Forging die
Progressive Die:
The progressive die is used to perform two or more operations at different stages at one time. Every time the
Ram descend, the stock strip is advanced through a series of stations that perform one or more distinct die
operations on the work piece. Thereafter a complete work piece is produced with each stroke of the ram.
Have you ever wondered how simple objects, like a stapler, work? This report is how I reverse engineered a
stapler in order to answer that question. I started out by taking the stapler completely apart and analyzing how
each piece worked. I discovered the way the staple goes through the paper and what causes it to bend. I also
learned how the staples are forced towards the front of the chamber to be forced out. The stapler was
relatively easy to disassemble because most pieces just clipped to each other. After I took it completely apart I
measured each piece of the stapler with a caliper. I then looked to see what each material was made of and
how that affected the stapler. I discovered that the materials were mostly common metals or plastics. I
concluded that this was to keep the cost of making a stapler low so that the most profit could be made. They
did not use plastic for all of the pieces though because some of them needed to be able to withstand pressure.
Some pieces also needed to be able to stay firm and not bend so that the staples would go into the paper
properly. The pieces mostly just clipped together so this made me think that the size of each piece cannot be
off or else the pieces will not fit together properly and the stapler will not be effective.

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ABDI BEDASA ID NO 0002/13 FEB 2024
RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
Disassembly of Stapler

Disassembly of the stapler was much easier than it seemed. There were only 4 screws to be taken off
using a screw driver and the rest of the pieces just snapped apart. The first thing I did was unscrew all of the
screws. They held the bottom of the stapler to the top of the stapler and when I removed them I was able to
separate the stapler into two parts, the base and the head. The only part of the base that was very important
was the “anvil” which bends the staples.

Figure 1: stapler

The head of the stapler was all held together with a rod that went through each piece and allows the
stapler to move up and down. After removing the rod the top cover was able to be taken off. Attached to the
top cover was a metal piece which forces staples out of the magazine and through paper.

After removing the top cover all that remained was the magazine holding the staples. Inside the
magazine there was a coil that held the follow block which holds the staples forward, and the spring which
makes the staples stay down. This left only the staples which were stuck together tightly in a row.

ABDI BEDASA ID NO 0002/13 FEB 2024

 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS

Figure 2: Assembly of stapler

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2. Literature Review

Figure-3:Strip Layout
Strip Layout:
In this strip layout, there are six-station where different types of operations are performed and they are as
follows
Station 1: Piercing operation:
This operation consists of simple hole punching.it differs from blanking in that punching is the scrap (cut
out blank) and the strip is the work piece. In the first station, there are four piercing operations performed with
different sizes of diameter 4 mm and diameter 6 mm, and a hole is made.
Station 2: forming Operation:
This operation consist of stampings requires accuracy; dies employing pressure pads are often designed. The
pressure pad helps to hold the stock securely during the forming and eliminates shifting of the blank. The
pressure can be applied to the pad by springs or by the use of an air cushion. When springs are used, they can
be located directly under the pad and confined in the die shoe. This operation is used to formed the shape of
closing stapler pin
ABDI BEDASA ID NO 0002/13 FEB 2024
 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
Station 3: Piercing Operation:
In the third stage, there is a piercing operation performed cutting the half shape of the component due to
less cutting force
Station 4: Piercing Operation:
In the fourth stage, there is a piercing operation performed cutting the shape of the component.
Station 5: Bending Operation:
Bending is the uniform straining of material, usually flat sheet or strip metal around a straight axis, which
lies in the neutral plane and is normal to the length-wise distortion of sheet or strip. In four stages there are
two bending operations performed on the head of a nail cutter.

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Station 6: Cutoff Operation:

A cutoff operation separates the work material along a straight line in a single line cut. In the sixth stage of
operation where the components are cutoff and the operation is completed.
3. Calculation
Tonnage:
Cutting forces:
The force required to penetrate the stock material with the punch is the cutting force.
F=SPT
Where, F=Cutting Force
S=shear strength of stock material
P=Perimeter or Length of Cutting Edge
T=Thickness of Material
In this case, the material we used is stainless steel
S=5.1118 ton/squre.cm
P=300mm=30cm
T=2mm=0.2cm
F=SPT
F=5.118 x 300 x 0.2
F=19.045≅24 tons
As per standard, we can used 24 tons capacity. Machine can be used because 24 tons is the standard machine.
2] Scrap: strip layout for blanking, A scrap-strip

ABDI BEDASA ID NO 0002/13 FEB 2024

 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
Layout having insufficient stock between the blank, will results in a weakened strip, subject to breakage and
thereby causing miss feed
T=specified thickness of the material
B=1.25t where c is less than 64mm
B=1.5t where C is more than 64mm
T=1mm
B=1.5 x 1=1.5mm
C=88.5+1.5=90mm
3] Die sets selection:
In this case, the die sets selected four pillar all set standard die set. Due to progressive die and more amount
stage of operation. As per company standard.

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4] Punch Design:
From the equation
P=SLT
Where, P=pressure
S=shear strength
L=blanked perimeter
T=thickness
P=51.118 kgs
L=300mm
T=2mm
P=51.118 x 300 x 2
P=19.45 ton
The value is well the 24-ton capacity of the select press 5]
spring:
In this case we used solid stripper plate can be used for the job
We are using four-pillar system we are using a yellow spring of 50mm diameter. Pressure can be
sustain=250kg Maximum pressure. We are using four spring.
6] Bending Operation:
First Bending:
B= (A/360) x 2 /π x (IR+Kt)
Where,
ABDI BEDASA ID NO 0002/13 FEB 2024
RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
B=Bend allowance in mm.
A=Bend angle in degree.
IR=Inside radius of bend in
mm. t=metal thickness
K=0.33 where IR is less than
2t 1] Bending:
B=A/360 x 2π x (IR+KT)
B=45/360 x 2π x (3.0212+0.50)
B=3.065mm \

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4. Problem Description:
The objective of this project is to make mold 3D to understand the bending of the component. To create a
strip layout where there will be no problem during running at high speed. To reduce wastage of components
due to increase in the cost of raw material.
5. Stapler Body Die Design
Solid work mostly commonly used for sheet metal because it easy to use and widely used in other company
solid work used to developed parts or make new part easy and fast

Figure 4 : Top view

ABDI BEDASA ID NO 0002/13 FEB 2024

 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS

Figure -5: Front view

Figure -6: Side view

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Figure -7: 3D view

6. Result and Discussion
General sheet metal die consists of different parts. Each part is important in its respect and has a different
function to perform. The following is the list of parts with their basic functions.
Top Plate:
This is the top most commonly used plate. The top plate is attached to the machine. Where they are used for
aliment of plate. This plate is connected to shank where the middle part is connect to press Size – 685 x 344 x
44
ABDI BEDASA ID NO 0002/13 FEB 2024
 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
Material – (C-45)
Heat treatment no heat treatment required Machine:
Shaping machine
Milling machine
Jig boring machine or drilling machine
Surface grinding
Tolerance: ±0.1
Punch holder support housing-
The plate is used for holding the punch in the die with help of riveting or applying the bolting system and
dove pin is used for aliment of plate
Size – 495 x 234 x 66
Material – (C-48)
Heat treatment - no heat treatment required
Machines:
Shaping machine
Milling machine
Jig boring machine or drilling machine
Wire cut electric discharge machine
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Thrust plate-
This plate is for bolts the plate in their will to miss aliment of plate and punch. Due adding this plate there
will less chance of bolts, dowel pin and guide pillar Size – 495 x 234 x 7
Material – (C-45)
Heat treatment – no heat treatment required Jig boring machine or drilling machine
Machine- shaping machine Wire electric discharge machine
Milling machine Surface grinding

Punch plate-
The punch plate where the punch pass through plate the burn does not attached to it and remove from its it
always contact with punch
Size – 495 x 234 x 45
Material – (C-45) Milling machine
Heat treatment – HRC 62 to 65 Jig boring machine or drilling machine
Machine- shaping machine Wire electric discharge machine
ABDI BEDASA ID NO 0002/13 FEB 2024
 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS
Surface grinding Tolerance-
Lapping operation
Die housing plate-
In this plate, punch plate attached to die housing plate for allayment of work of press
Size – 495 x 234 x 45
Material-C-45
Heat treatment - no heat treatment required Jig boring machine or drilling machine
Machines:
Wire electric discharge machine
Shaping machine Surface grinding machine
Milling machine Tolerance-
Bottom plate-
The bottom is attached to base of machine, which is used for clamping from down side and removal of scrap
from the bottom
Size – 75 x 75 x 11 Jig boring machine or drilling machine
Material – (C-45) Surface grinding
Heat treatment – no heat treatment required Lapping operation
Machine- shaping machine Tolerance-
Milling machine
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8. CONCLUSION
This study applied to redesigned stapler body die. The new design of stapler body die makes the
construction easy and can be manufacture in India. Feeder system enables the no chances of misleading and
error of the pitch. Less material wastage, make the proper utilization of material and increases productivity.

Figure 8: Assembly Stapler

ABDI BEDASA ID NO 0002/13 FEB 2024
 RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS

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REFERENCES
1] Masahiro Kimura1*, Hironori Tanaka1 , Motoki Hato1 , Satoshi Taniwaki1 , Yasuyuki Shibata1 , Kotaro
Mizuno1 , Nobuo Ochi1 , Yoichiro Mori , Takaya Nagasaki1 , Shuhei Ueno1 and Yuki Eguchi, Evaluation
of a New Stapler with Unique Surface Gripping Technology 18(9): 1-6, September,2021
2] Israel dunmade, lifecycle assessment of a stapling machine, international journal of engineering &
technology 4(1):12 oct, 2020
3] Reverse Engineering of a Stapler By Bailee Facemyer Foundations of Engineering Mr. Hendricks
September 9, 2013
4] International Research Journal of Engineering and Technology (IRJET) Volume: 08 Issue: 10 | Oct
2021
5] Yoichiro Mori , Takaya Nagasaki1 , Shuhei Ueno1 and Yuki Eguchi, Evaluation of a New Stapler with
Unique Surface Gripping Technology 18(9): 1-6, September,2021

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RIFT VALLEY UNIVERSITY BISHOFTU CAMPUS

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ABDI BEDASA ID NO 0002/13 FEB 2024