Design of Press Tool With Its Defects

DESIGN ANALYSIS OF PRESS TOOL WITH ITS DEFECTS AND REMEDIES

CONTENTS 1.

Introduction……………….……………………….……... ......5

2. Literature survey ………………………………….…………. 11 3. Design & its analysis ……………………………………… .....13 4. Elements of press tool ……………….………………………..17 5.

Conclusion.…………………… ………………........………… 23

6.

References.……………………..………………………………24

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ABSTRACT ABSTRACTPress tools are used to produce a particular component in large quantity, out of sheet metals where particular component achieved depends upon press tool construction and its configuration. The different types of press tool constructions lead to different operations namely blanking, bending, piercing, forming, drawing, cutting off, parting off, embossing, coining, notching, shaving, lancing, dinking, perforating, trimming, curling etc. Generally, metals having thickness less than 6mm is i s considered as strip. Blanking is one of the s heet metal operations where we produce flat components of prerequisite shape. In Blanking the required shape periphery is cut and cut-out piece is called blank. The press tool used is for blanking operation is called as blanking tool, if piercing operation, it is piercing tool and so on based on operation that we perform. The application of press operations is widely used in many industries like food processing, packing, defence, textile, automobile, aircraft and many apart from manufacturing industry. In this connection an attempt is made on to learn the press tool design, materials, manufacturing used for press tool and calculations involved in it. In this work, a real time design of a simple blanking press tool and manufacturing of a prototype is made along with analysis where the output is a circular piece having diameter of 20mm. The press machine is of mechanical type. Tool making is one of the trades, which requires a detailed study, structural analysis and process planning before proceeding with any practical work. The success of any tool largely depends on the process analysis and design anal ysis of the tool. A systematic approach in tool making is therefore very essential. This project report mainly enlightens the various aspects of “Press Tool”. This report gives brief information about the design analysis and overview of a “PRESS TOOL” which serves the need for mass production of sheet metal component. KEYWORDS: Blanking, Die Design, Manufacturing, and Analysis;

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CHAPTER 1. INTRODUCTION 1.1 INTRODUCTION Press tool is a device that aids production of large quantity of similar sheet metal component to the required shape, size and dimensional accuracy. The component may be flat blank (Blanking tool) or formed one one (Drawing tool, Forming or Bending Bending tool). A press tool consists mainly of die and punch, which are suitably shaped to get article of desired shape. The sheet metal strip is pierced on the die and the t he punch is then lowered under a heavy pressure. The metal is thus pressed between punch and die and the article of desired shape is obtained. For preparing article with wide range of shape, pressing is to be carried out in different stage. Press tools are useful when a large number of similar articles are to be produced.

Fig. 1.1 PRESS TOOL 1.2 TYPES OF PRESS TOOLS  Progressive tool  Compound tool  Combination tool  Fine blanking tool 5|Page


1.3 TYPES OF PRESS TOOL OPERATIONS PRESS W ORKING OPERATIONS (SHEET METAL)

CUTTING

BENDING

FORMING

DRAWING

BLANKING

BENDING

STRETCH FLANGING

CYLINDRICAL CUP DRAWING

PIERCING

FLANGING

SHRINK FLANGING

RECTANGULAR SHELL DRAWING

NOTCHING

HEMMING

REVERSE FLANGING

IRREGULAR SHAPE DRAWING

TRIMMING

HOLE FLANGING

LANCING

Embossing/ Form Beads

JOGGLE

1.3.1. BLANKING: Stamping having an irregular contour must be blanked from the strip. Piercing contour must be blanked from the strip. Piercing, Embossing and various other operations may ma y be performed the strip prior to the blanking station.

Fig. 1.3.1

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1.3.2. PIERCING : Piercing tools pierce holes in previously BLANKED, Formed or Drawn parts. It is often impractical to pierce holes while forming because they would become distorted in the forming operation. In such cases they are pierced in i n a piercing tool after forming.

Fig. 1.3.2 1.3.3. CUTT OFF : Cut off operations are those in which strip of suitable width is cut to length. Preliminary operations before cutting off include Piercing, Notching and Embossing. Although they are relatively simple, cut off tools can produce many parts.

Fig. 1.3.3 1.3.4. BENDING : Bending is defined as shaping the material around straight axis which extends completely across material. Metal flow is uniform in this operation.

Fig. 1.3.4

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1.3.5. FORMING : Forming tools apply more complex forms to work pieces. The line of bend is curved inside of straight and the metal is subjected to plastic flow or deformation. Metal flow is not uniform in this operation as Bending.

Fig. 1.3.5 1.3.6. DRAWING : Drawing operation transform the flat sheets of metal into cups, shells or other drawn shapes by subjecting the material to severe plastic deformation.

Fig. 1.3.6 1.3.7. TRIMMING : When cups and shells are drawn from flat sheet metal the edge is left away and irregular due to uneven flow of metal. This irregular edge is trimmed in a trimming die.

Fig. 1.3.7

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1.3.8. SHAVING : Shaving is a secondary operation usually flowing punching In which the surface of the previously flowing punching in which the surface of the previously cut edges is finished smoothly to accurate dimensions. There is little clearance between punch and edge and only a thin section of the edge is removed from the edges of the pieces.

Fig. 1.3.8 1.3.9. EMBOSSING : It is shallow forming operation in which the material is stretched over a male die and caused to conform to the male die surface by a female die surface. It results depressed detail on one side and raised detail on opposite side of the work piece.

Fig. 1.3.9 1.3.10. COINING : Coining is the process of pressing material in a die so that it flows into the spaces in the detail on the die face.

Fig. 1.3.10 1.3.11. CURLING : A curling die rolls the raw edges of the sheet metal into a roll or curl. The purpose is to strength than the raw edges provide protective edges and improve the appearance of the product.

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Fig. 1.3.11

1.3.12. NOTCHING : It’s one of the cutting operations, in which in which material cut at the edges of the blank.

Fig. 1.3.12 1.3.13. BROCHING : It’s one of the cutting operations, in which in which series of teeth or serrations are cut across the t he blank.

Fig. 1.3.13 1.3.14. LANCING : It’s one of the operations, in which it includes it includes both cutting and non-cutting operation that’s one side bending with two or more side cutting.

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CHAPTER 2. LITERATURE SURVEY High rate production industries generally use press machines. Thickness can vary significantly, although extremely small thicknesses are considered as sheet and above 6mm are considered as plate. Thickness of the sheet metal fed in between is called its gauge. Sheet metal is simply fed in between the dies of press tool for any press operation to perform. The reciprocating movement of punch is caused due to the ram movement of press machine. The press machine may be of electrical type, mechanical type, pneumatic type, manual type and hydraulic type. In today’s today’s practical and cost conscious world, sheet metal parts have already replaced many expensive cast, forged and machined products. The common sheet metal forming products are metal desks, file cabinets, appliances, car bodies, aircraft fuselages, mechanical toys and beverage cans and many more. Due to its low cost and and generally good good strength and formability characteristics, low carbon steel is the most commonly used sheet metal because high carbon composition gives high strength to the material. The other sheet metals used are aluminium and titanium in aircraft and aerospace applications. The purpose of this paper is to examine the causes for these seemingly contradictory results. An attempt will be made here to review the previous studies to look into future possibilities of various die designs. The various authors considerations are taken into i nto account with their presents in building up the work and their statements are as follows: Mr. Amit D. Madake et.al.[1] He states that sheet-metal s heet-metal die is an inseparable inseparabl e constituent of the development process of any given automotive or consumer appliance. In most of the cases, this accounts for a high proportion in the tooling needs of the large size and structural member in any automotive like the chassis and the BIW. K.Kishore Kumar et.al.[2] explains that before converting raw materials to a finished product we need an accurate design of the the product and also data required for manufacturing. manufacturing. If the design is not accurate then defects will occur in the manufactured product, small mistakes in designing a product makes the manufactured product useless so more amount time is allotted for designing new product. Gasper Gantar et.al.[3] states that the selection of most appropriate design and technological solutions to produce certain mould should capture technical performance economic issues as well as environmental impacts occurred during the mould life cycle. An approach is presented to support the selection select ion of alternative mould design solutions in the t he early design stage. Sachin Ramdas Jadhav et.al.[4] He explains sheet metal forming problems are t ypical in nature since they involve geometry, boundary and material non-linearity. Drawings part involves many parameters like punch and dies radius, clear ance, lubrication, blank holding force and its trajectories etc. So designing the tools for part drawing involves a lot of trial and error procedure. Vishwanath M.C. et.al.[5] He states that in this work the use of a software namely Pro/E for designing a progressive die to manufacture cup for the oil filter has been incorporated. A progressive die is a multiple station s tation die. In this work authors have designed a progressive die which has two stages of operation. The former operation is piercing and is followed by blanking. T. Z. Quazi et.al.[6] prescribes a model investigation the effect of potential parameters influencing the blanking process and their interaction. The blanking process optimization carried out by using Design of Experiment (DOE), Finite Element Method (FEM) with ANSYS 11 | P a g e


Package, Simulation with ABAQUS-Explicit software, Blank soft Software and Neural Network Amol Totre et.al.[7] refers about forming processes employed in high volume production, blanking is one of the most widely used separation techniques. Still, analysis of blanking is mainly based on phenomenological phenomenological knowledge. Samadhan D. Bhosale et.al.[8] His aim is to apply the quality tools to find out the root causes of the quality problems related to manufacturing of mechanical seal. The modes of defects on production line are investigated through direct observation on the production line and statistical tools like Check sheets, Histogram, Pareto analysis, Cause and Effect diagram etc. are used in enhancing the process by continuous monitoring through inspection of the samples. Jai Hindus S et. al.[9] He assists assi sts the die designer to design press pres s tool dies for the online maintenance in the press itself and to reduce the tool failure due to the dynamic actions of the press tool in the press.

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CHAPTER 3. DESIGN & ITS ANALYSIS 3.1 TOOL DESIGN CONSIDERATION A designer is a person who furnishes the drawings of the tool. He must have a very good knowledge regarding the manufacturing of the tool, selection of materials and other necessary designing aspects. The die design should suit the scale of production, as it will be used for small or large lot or mass production. Press tools should meet the following requirements. 1. The accuracy and surface finish of stampings should confirm to the drawing and specification. 2. The working part of the die must be adequately strong, durable in operation and easily replaceable when worn-out. 3. The tool should ensure the required hourly output, easy maintenance, safe operation and reliable fastening on the press. 4. The die should be designed preferably of standard items, using as less parts as possible. 5. The scrap should be kept in minimum. 3.2 DESIGN OF PRESS TOOL INVOLVES THE FOLLOWING STEPS 1. Determination of the force. (Press tonnage) required for the operation. 2. Selection of press for requisite force, work piece size and shape. 3. Determination of shut height of the tool. 4. Calculating the die thickness and margin (minimum cross section) 5. Designing of locating elements. 6. Selection of hardware items. 7. Selection of pillar dies set. 8. Deciding punch length and mounting. 3.3 TOOL DESIGN PROCEDURE STUDY OF COMPONENT The first step in the design procedure is to define the problem in a clear and simple statement of the functional needs. The tool design will receive the part print, information on which tool is needed, what the capabilities of the tool must be, the type of the press on which tool is used, the number of parts to be produced and pertinent information concerning the part. CONCEPT DESIGN The research and sketches should be combined to one or two attentive design solution, which may consist of rough working showing the side and top view if needed. The best selected and reworked and the final design decided upon. DESIGN CONSIDERATION Before start in any design some major considerations are required to be made which can solve majority of the problems while designing the press tool, moulds, jigs and fix tures. MANUFACTURING MANUFACTURING PROCESS In any design, manufacturing process should be easy, simplified and majority of the operations should be carried out in house. By considering this point we made our tool as simple as possible for manufacturing. MAINTENANCE Last but never the least is very much necessary to think about the maintenance, if due to any reason some parts break down, it should be easily manufactured in short time so that ideal times is reduced and that t hat care to be taken during designing.

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3.4 THE FOLLOWING DESIGN POINTS SHOULD BE CONSIDERED CAREFULLY 1. Controlling location of the scrap strip. 2. Guidance should be extended at least two scrap width in front of first station. 3. The type of stripper used. 4. Channel clearance should be accurate to allow the strip st rip to move freely. 5. Location of figure and stage stoppers. 6. Die block should be longer and wide enough so that the location of the holes will be at least 7. one and half times the thickness of the die block away from the edge. 8. Dowel should be safe in non-cylindrical location such that sections or parts may be mounted 9. in one position only. 10. Counter bore in the die block, the tapered hole in the die shoe and the reamed holes in the die 11. shoe must be made from 6-9 mm deeper than needed to allow for grinding of die block. 12. Choose the die set, so that when the die block is mounted, it can be ground without removing 13. it from the die shoe. 14. Small profile punch should be guided in the stripper plate. 3.5 TOOL DESIGN CALCULATIONS The strip layout is presented in Fig:8. The calculation is done on strip to find out the following steps 1. % of strip used =(Area of component x 4)/Length of strip x width of strip 2. Shear force = (KxLxTxS)/1000tons) = (1.5x2x3.141x10x0.5x420)/1000 (1.5x2x3.141x10x0.5x420)/1000 =1.97 tons Where, K =1.1 to 1.5 (constant based on clearance) L= length of cut in mm T= thickness of cut in mm S= Shear strength of material in kg/mm2 3. Stripping force = 10%of shear force = 0.2 ton 4. Net force = Shear force+ Stripping force = 1.97+0.2 =2.2 ton

Fig: 8 Strips

Fig: 9 Blank

5. 6. 7. 8.

The blank is shown in Fig: 9 and the calculations for it is done as follows Press tonnage = 1.2 1.2 x Total force = 1.2 x 2.2 = 2.64 tons Thickness Thickness of of die plate = 3 Shear force= 4.2cm x10=42mm Thickness of punch holder = 0.5 x td =0.5x5 = 25mm (td = thickness of plate selected) Similarly by substitution td values we get 9. Thickness of bottom plate = 1.5 x td = 7.5mm 10. Thickness of top plate = 1.25 x td= 6.25mm 11. Thickness of stripper plate = 0.5 x td= 2.5mm 12. Cutting clearance = C x S x (TMax)/10 = 0.05mm 0.05mm S= Sheet metal thickness Tmax= Based on material property (Max Stress bearable)=1000 N/mm2 13. Cutting clearance = 4% of sheet thickness 14. Black punch size = Size of Blank die-2c 14 | P a g e


15. C=6% of thickness of wall 16. Cutting force = π x D x t x Fs =3.14x0.5x20x2.2= 69 N 3.4 DESIGNING SCRAP – STRIP STRIP LAYOUT In the design of blanking parts from strip material, the first step is to prepare blanking layout, that is, to layout the position of the work pieces in the strip and their orientation with respect to one another. While doing so, the major consideration is t he economy of material. Another important consideration in strip layout is the distance between the blanks and the strip edge and distance between blank to blank. To prevent the scrap from twisting and wedging between the punch and the die. The distance must increase with material thickness. A general rule of thumb is to keep this distance equal to from 1 to 1.5times the material thickness. The following figure 3.4 are e xample of strip layouts.

Fig 3.4 A – Front Front scrap Bridge thickness B – Bridge (space between parts and strip edge, and part to parts) the distance from a point on one part to the C – the corresponding point on the next part. H – Part Part width l - Length of part W – Width Width of strip Scrap recovery at end Y – Scrap N – Number Number of blanks – thickness thickness of strip t – L – Length Length of strip

B= 1.25t, when C is less than 2inch = 1.5t, when C is more than 2inch C=l+B W = H + 2B A = t + 0.015H Y =L – =L – Nc Nc +B N = L – L – B B /C

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3.4.1 PERCENTAGE OF UTILIZATION Strip layout is important to have economy of press tool operation. Scrap strip layout gives an idea on the positioning of various punches, stops and pilots. It ensures the ideal location of blanks in the stock strip. Several trial t rial layouts have to be made to confirm the maximum percentage of utilization of stock strip. The goal should be to have at least 75% utilization. The percentage of stock used to calculated by b y the formula: % of utilization = Area of one blank X 100 /Lead X Width

Where, Lead = Length of component + Bridge thickness Width= Breadth of component + 2 X Bridge thickness 3.4.2 EXAMPLE 1: FOR STRIP LAYOUT CALCULATION

Fig 3.4.2 (a) Length of part = 20mm : Breadth of part = 10mm Thickness of part =1.5mm Bridge thickness = one times of sheet thickness taken = 1.0 X 1.5 = 1.50mm Width of strip W = H + 2B = 20 + 2 X 1.5 =23mm Front scrap “a” = t + 0.015H = 1.5 + 0.015 X 20 = 1.8mm C =l + B = 10+1.5 =11.5mm

Fig 3.4.2 (b)

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CHAPTER 4. ELEMENTS OF PRESS TOOL

Fig. 4.1 4.1 ELEMENTS OF PRESS TOOL 4.1.1. TOP PLATE It is the top portion of the complete tool, which holds the top assembly or complete tool through the punch holder. Material: C45 or CI. 4.1.2. BOTTOM PLATE It is also called as die shoe or bolster plate, its main function is to provide a rigid foundation and base to the assembly. It assembles the fixed half of the tool. Material: C45 or CI. 4.1.3. STRIPPER PLATE This plate is also called as guide plate. This plate helps in stripping operation. It not only strips the strip from the punch but the main function of this plate is to guide the punch accurately which maintains the alignment between punch and die. Hence the plate is made with same care as die plate. It is made out of mild steel. In some cases, this guide plate is also made of tool steel. A channel is milled in the plate which will guide the stock strip. 4.1.4. GUIDE PILLAR These are cylindrical pins known as guide pins or guide pillars. These provide accurate alignment to the die set. One end of the pillar is given press fit in the base plate with H7/p6 tolerance. The other portion, which is sufficiently long, provides guide for top plate for easy sliding. Material: EN-36 HRc: 54-56 4.1.5. GUIDE BUSH These are mounted to the top plate, which provide smooth sliding contact between pillars and top plate. Material: EN-36 HRc: 60-62. 17 | P a g e


4.1.6. BALL CAUGES In progressive press tools the punch and die should align very accurately to provide equal clearance on all sides of the die. In such causes ball cages are used. Ball cages contain ball bearings inserted within them, which provide the sliding movement. movement. Material: Aluminum or Brass 4.1.7. PILOTS In progressive press tools the function of pilots is to position the stock strip accurately and to bring it into proper position positi on (Registering) for successive blanking, piercing, bending or other press operations. Mechanically fed strip normally under fed and pull forward in the same direction with the feeding motion by the pilots, because any mechanical feeding mechanism utilizes a unidirectional locking device which prevents any back feeding of the s trip. 4.1.8. DIE The female member of the tool in which openings are made for the punch to enter in them is termed as die. It includes well supporting and actuating part of the tool. It also includes cutting profiles, bending die insert, pushers, stoppers, strip guides etc. Material: HCHCR (D3) HRC: 60-62 4.1.9. PUNCH This is most important element of the tool. It is the cutting element of the tool. Punch gives the whole size and the shape on the component. This is made out of high carbon high chromium steel material (D3). [T215 CR12 W90]. Punches are hardened and tempered to 58-60 HRC. Material: HCHCR, OHNS HRC: 60-62 4.1.10. PUNCH HOLDER This plate is also called as punch plate all the punches are accurately held in this plate. This plate should be thick enough to accommodate punch shoulder and keep the punches perpendicular. It is made out of HCHCR (D2). Hardness: Hardness: 56-58HRC. 4.1.11. DIE PLATE In this plate all die inserts held accurately. accurate ly. This plate thickness as same as die inserts insert s thickness .This plate made out of HCHCr (D2). Hardness: 56-58hrc 4.1.12. STRIP GUIDE In progressive press tool there becomes a requirement of feeding the stock strip along a particular path for each ea ch operation to take place. Thus strip guides are used to guide the long stock strip in the required path for each operation can be carried out properly. The strip guide combines of two material strips or parallel blocks, which are screwed and doweled on the die surface in alignment with the die parameters. It is one of the important elements of the progressive tools with fixed as well as floating stripper. Material:D2 HRC: 56-58 4.1.13. STOPPERS Stoppers are installed on the dies to arrest the feedings movement of the strip, to the requirement. Material: D2 HRC: 52-56 4.1.14. LIFTERS Lifters are assembled in die plate with a close running fit. These are spring actuated to hold and lift the strip. Material: D2 HRC: 52-56 4.1.15. DOWELS Dowels hold the parts in perfect related alignment by absorbing side pressure and lateral thrust. Dowels always should have case hardening.

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4.1.16. SCREWS In assembly process the parts of tool are held together rigidly by socket head cap screws. Also screws fastened the assembly. Screws are available in standard size. 4.2 MATERIAL SELECTION FOR DIFFERENT ELEMENTS Bottom plate plate St-42 St- 42 Top plate plate St-42 St- 42 Die Die plate HCHCR HCHC R (D2) Punches Punches HCHCR HCHC R (D3) Back plate plate Case Cas e hardened hardened Punch plate HCHCR HCHC R (D2) Stripper Stripper plate plate HCHCR (D2) Gui Guide plate Case Ca se hardened Guide Guide pillar pillar Case ase hardened harde ned Auxili Auxiliar ary y guide guide pil p illar lar O HN HNS S Pilot STD Dowel STD Lifters OHNS 4.3 TYPES OF FITS ASSOCIATED WITH PRESS TOOL SL No. 1

TOOL ELEMENTS Blanking punch and Stripper

TYPE OF FIT Running Fit

2 3

Piercing punch and Stripper Guide pillar with Bottom plate

Running Fit H7/p6(press fit)

4

Guide pillar with Guide bush

H7/g6(sliding fit)

5 6 7

Punch with Punch holder Pilot with Stripper Direct pilot with punch

H7/k6(Light key fit) H7/g6(sliding fit) H7/p6(press fit)

8

Pilot with punch holder

H7/k6(Light key fit)

9

Dowels with Stripper plate

H7/m6(Medium drive fit)

10 11

Dowels with Die plate Dowels with Bottom plate

H7/m6(Medium drive fit) H7/m6(Medium drive fit)

12 13 14

Dowels with Top plate Dowels with Punch holder plate Punch back plate(for Dowels screws)

H7/m6(Medium drive fit) H7/m6(Medium drive fit) Running fit

15 16

Lifter with Die plate Guide bush with Top plate

H7/p6(Light key fit) H7/p6(press fit)

17 18

Adjuster and slot in PHP plate Punch and die

H7/g6(sliding fit) Cutting clearance fit

and

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4.4 DEFECTS AND REMEDIES The various Defects or problems that are reducing are given below,

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4.5 ASSEMBLY We have now come to final stage of manufacturing of the tool. Assembly of a tool means seating the parts of the tool in their respective position to get the required work. This is the critical stage of tool manufacturing. Any fault committed during machining of parts will be highlighted and may cause problem during try-out. t ry-out. Assembly of tool may be divided into two groups, 4.5.1 BOTTOM HALF  Firstly, we made chamfer and oil stoned to all elements of bottom half of tool  Lifters are placed to back plate and die plate  Die plate and back plate is aligned properly to their proper positions according to their  reference position to the Bottom plate by dowelling.  Finally, the Die plate, Back plate and Bottom plate is fastened by means of screws. 4.5.1 TOP HALF  Firstly, we chamfered and oil stoned to all elements of Top half of the tool.  All punches and pilots are grouped in Punch holder to their proper position and get  entered into their relative positions in Bottom half.  Proper alignment is done to top half of the tool with respect to its Bottom half.  Springs are provided for proper ejection of the component.  Finally the top half is get clamped by means of screws only after knowing the perfect  alignment between two half of the tool, and then the tool get moved to tryout and then  to inspection and finally to dispatch of the components with approval by the quality. 4.6 CARE OF TOOL The sliding is as should be lubricated (pillars and bushes, pushers & lifters). The impact leads to damages of die and punch and the press experiences heavy load of the blank is not lubricated. The ‘Die Maker’ is expected to detect faults of the press tool resulted from poor workmanship and from wrong mounting and adjustments. To do so, he must know the courses of faults and the methods of remedy. • Wrong installation of the tool will source in many defect ed finished products. An immediate indication in the wrongly mounted tool is a unilateral friction of the guide pillars. • Bright surface of the cut at one side of the part witness an inadequate clearance. • Rapid blunting of the cutting edges of the punch and die at that area the fault is normally due to misaligned bed, this can be detected by releasing the fastening of the lower shoe and measuring the clearance between the tool and the press bed by a feeler gauge. 4.7ADVANTAGES OF PRESS TOOL 1. Speed production – Progressive Progressive die metal stamping is based on the continuous feed of material through the different different die stations of a tool. The nature of the process allows you to create more parts in a shorter period of time when compared with traditional fabrication or machining. For high volume volume parts, progressive stamping provides the lowest cycle times per part. 2. Less Scrap Material – Progressive – Progressive stamping is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal to produce your desired end part shape. The vast majority of material is used, hence, less scrap is produced. Progressive Die Metal Stamping may provide the most cost effective material option for manufacturing your parts. 3. Quicker Setup – When compared to traditional fabrication or machining, the setup time may be much less for the progressive stamping progressive stamping process. process. What is achieved in multiple Setups and processes during traditional fabrication traditional fabrication and machining, machining, may be

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performed in one operation if Progressive Die Stamping is utilized. util ized. This reduction in Setup and processing will result in a more cost effective piece part. 4. Create More Geometries with a Single Process – Progressive Progressive Die Metal Stamping allows you to create parts with many geometries within a single tool. This video This video shows a single part progressing through a die. All required geometries of the part are achieved in one Progressive Die operation. 5. Longer Runs – The continuous material feed used in the progressive die stamping process allows for long runs. Longer runs between material changes and tooling and tooling adjustments mean your parts can be produced in a much shorte r time. 6. High Repeatability – The The hard tooling hard tooling die designs allow for high volume runs without die degradation. This means that part quality remains high and there are fewer failed parts. All of the factors above contribute to reducing the overall cost 7. Lower Cost per Part – All of your part. part. Using progressive die stamping allows you to create robust parts in the most cost effective and expeditious manner. manner. We look forward to helping you save money on your next project! 4.8 DISADVANTAGES OF PRESS TOOL 1. Higher mount of force and energy is required for metal forming process compared to other manufacturing methods. 2. The components with cross holes cannot be produced easily using metal forming process. 3. The initial capital cost is higher

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CHAPTER 5. CONCLUSION 5.1 CONCLUSION In course of this project I have gained a great deal of confidence and knowledge in the way of tool manufacturing. The work has gone in detail in all the analysis methodically. The tool can also be designed and manufactured without any these analyses, but the success and the economics of the tool is not assured. I have executed my very best to achieve the required results, as far as the tool is concerned. This project has paved a new way for me to tap the knowledge that lies in the waste field of Press tools. I learned many aspects such as cooperating and adjusting myself with other fellow crew working on this tool. And the strong positive guidance given by our guides during solving of problems is really commendable; hence the success of the design analysis of the tool is assured.

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CHAPTER 6. REFERENCES 6.1 REFERENCES [1] Mr.Amit ,D.Madake, Dr.Vinayak, R.Naik, Mr.Swapnil, S.Kulkarni, "Development of a SheetMetal Component with a Forming Die Using CAE Software Tools (Hyper form) For Design Validation and Improvement", International Journal of Modern Engineering Research (IJMER) , Volume 3, Issue Iss ue 3, May-June, 2013 , pp-1787-1791,ISSN: 2249-6645. [2] K.Kishore Kumar, Dr. A.Srinath, M.Naveen, R.D.pavan kumar, "Design of progressive dies", International Journal of Engineering Research and Applications (IJERA), ISSN: 2248-9622, Volume 2, Issue 3, May-Jun 2012, pp.29712973. [3] Gasper Gantar, Andrej Glojek, Mitja Mori-BlazNardin, MihaelSekavcnik, "Resource Efficient Injection Moulding with Low Environmental Impacts", Strojniski Vestnik-Journal of Mechanical Engineering, 59(2013)3,copy right 2013,Journal of Mechanical Engineering, All rights reserved.DOI:10.5545/sv-jme.2012.661 reserved.DOI:10.5545/sv-jme.2012.6 61 pp:193-200. [4] Sachin Ramdas Jadhav, Sunil Hiraman More, Swapnil S. Kulkarni," Die Design for Formed Component using inputs from FEA for determining the most suited values for the Design or Process parameter", International Journal of Advanced Engineering Research and Studies E-ISSN2249 – 8974 8974 /April-June,2014/95-98. [5] Vishwanath M.C, Dr. Ramni, Sampath Kumar L ,"Design of progressive draw tool", International Journal of Scientific and Research Publications, Volume 3, Issue 8, August 2013 ,1 ISSN 2250-3153. [6] Prof. T. Z. Quazi, R.S.Shaikh, "An Overview of Clearance Optimization in Sheet Metal Blanking Process", International Journal of Modern Engineering Research (IJMER) Volume 2, Issue.6, Nov-Dec 2012, pp-4547-4558 ISSN: 22496645. [7] Amol Totre, Rahul Nishad , Sagar Bodke, An Overview Of Factors Affecting In Blanking Processes" International Journal of Emerging Technology and Advanced Engineering, (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013). [8] Samadhan D. Bhosale, S.C.Shilwant, S.R. Patil ," Quality improvement in manufacturing processes using SQC tools" International Journal of Engineering Research and Applications (IJERA), ISSN: 2248-9622 Vol. 3, Issue 3, May-Jun 2013, pp.832-837. [9] Jai hindus S."Design and development of stamping dies for online maintenance" Vol. 9, No. 4, APRIL 2014, 2014, ISSN 1819-6608,ARPN 1819-6608,ARPN Journal of Engineering and Applied Sciences,©2006-2014, Asian Research Publishing Network (ARPN), All rights reserved. [10] Hairulliza Mohamad Judi, Ruzzakiah Jenal and Devendran Genasan "Quality Control Implementation in Manufacturing Companies Motivating Factors and Challenges" ISBN: 978-953-307-236-4 978- 953-307-236-4,, (2011). [11] Dr. Taylan Altan, Selection of die materials and surface treatments for increasing die life in hot and warm forging" Paper no 644-FIA Tech Conference, April 2011.

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Design of Press Tool With Its Defects

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