Thus, in the work, the effects of groove width and angle on CGP of commercially
pure Ni Sheets were investigated by experimental and numerical methods.
TABLE OF CONTENTS
1.INTRODUCTION:
The die consist of the die block and the punch and is used to
cut or shape sheet metal or similar materials. The die block is the part of that die
that consist a hole that has the same outline as the piece that is to be punched. The
punch fits into the hole in the die block, which is the part to which power is
applied for performing the cutting operation.
Die can be classified with respect to the basic operations that they performs such
as cutting die and sharpening die. The cutting dies are the simplest form. The
plain or blanking die is the type most frequently used. Depending on the shape of
the punch, the blank can have any shape.
Various combinations of punches and dies can be used to perform both the cutting
and sharpening operations. Double –action dies, plain drawing dies, redrawing,
gage and follow, and compound dies are just a few used in these operations. Two
concentric punches are used in the double –action die. An outer punch is used to
perform the operations of cutting and holding the blank. The inner punch is used
as a forming or drawing punch. The plain drawing die is in tented only for shallow
drawing since there is little or no pressure on the blank. Complicated sheet metal
are often made by the use of progressive dies. Dies clearances are checked with
the die makers square. Heat –treating a die requires exceptional skills and
judgement.
1.1.INTRODUCTION OF DIES:
1
The die block is the part of the die that consist a hole that has the same outline as
the piece that is to be punched. The punch fits into the hole in the die block it is
part to which power is applied for performing the cutting operations. The
hardened and tempered die block does the actual cutting. The stripper plate in the
die block strips the stock from the punch on the releasing stoke. The guide strips
merely guides the stocks , and the gage pin is used to gage the location of the
holes punched in the stock.
In some die designs, the part of the punch are integral in one piece, but they are
separate pieces united by suitable in others designs. The shank attaches the punch
to the ram of the press, and the collar of the punching block takes the thrust.
1.2.TYPES OF DIES
Cutting dies
Shaping dies
Combined cutting and shaping dies
The cutting dies are the simplest forms of dies. The part that is cut out can have
any shape, depending on the shape of the punch.
2
1.3.CUTTING DIES
1.3.1.PLAIN DIE:
The plain die is the important and most frequently used type of die.
Depending on the shape of the punch, the blank can have any shape. The die is
used to punch a given shape from sheet metal in one continues cutting operations.
The material can be either stock or a blank obtained from a preceding operations.
Sometimes the blank punched from the stock is the part to be used, or it can be
only waste material, and the punched stock is the portion that is to be used. The
typical sequence of operations of a plain die in punching sheet metal. A strip of
sheet metal or stock is placed between the die and the stripper plate. On the
downward stroke, the punch “punches out “the blank from the stock and the stock
is held down by the stripper plate to prevent lifting on the upward stroke of the
punch. It several punches are combined for blanking several pieces
simultaneously, they are called multiple dies.
Fig.1.3.1.Plain die
3
1.3.2.SELF-CENTERING DIES:
The dies is used chiefly for punching holes. The stock must be centred
punched at the points where the holes are required and then placed under the
punch so that the conical point’s registers with the centre punch the mark on the
stock.
Fig.1.3.2.Self-Centering Dies
1.4.SHAPING DIES
4
Some sheet metal parts that required shaping. As will be noted, some
of these are combines with cutting or punching. These may be separate operations
or combined, depending upon the particular job.
A typical die used to bend to the desired shape is the plain bending die.
The contour of the punch and die determined the final shape of the stocks. The
springiness of the stock or material is an important factor in this type of die
operation. In pending stock to irregular shapes, an allowance must be made for
this factor in shape of die so that the work is bend slightly beyond the required
angle or shape. The allowance is necessary to compensate for the backward spring
of the stock when it is released from the die.
1.4.2.CURLING DIE:
Ordinary the maximum diameter of the bead that can be formed is 3/16 inch for
tinplate and sheet iron. An extra large bead can be obtain without cracking the
metal by annealing the metal.
Fig.1.4.2.Curling Die
1.4.3.WIRING DIE:
6
1.4.4.BULGING DIE:
Fig.1.4.4.Blulging Die
7
1.5.COMBINATION PUNCHING AND SHAPING DIES
Two concentric punches are used in this type of double action die.
An outer punch is used to perform the operation of cutting and holding the blank.
The inner punch is a forming or drawing punch. In actual operation, the cutting
blanking punches first descends to cut a blank.
When the blank has been cut, the punch forces the blank on to
top of the die and presses it against the annular ring with enough pressure to
prevent wrinkling. Then, it is allowed to recede into the forming part of the die
during the drawing process. Then, the inner or drawing punch descends to
perform the drawing operation and finish the shell. The drawing dies usually
employ a punch to shape or draw the work, and, in some instances, a second
drawing operations is perform on work from the drawing die.
1.5.2.PLAIN-DRAWING DIE:
The plain draw is intended only for shallow drawing because there
is no pressure holder on the blank to prevent its wrinkling. A drawing punch with
a diameter equal to the diameter of the hole minus twice the thickness of the blank
or stock. The die hole is tapered slightly. The blank fits in the recess at the top of
the die. After the drawing operations is completed, the bottom edge of the die
strips the shell from the punch on the upward stroke.
8
Fig.1.5.2.Plain Drawing Die
1.5.3.RE-DRAWING DIE:
During the downward stroke of the punch, the drawn shell is forced
thoroughly the restricted opening. The squeezes the shell to a smaller diameter.
As the perimeter is reduced, the excess metal in the shell is squeezed lengthwise.
Therefore, the shell is lengthened by the redrawing operation.
After the redrawing operation is completed, the work piece is stripped or removed
from the punch by the stripping edge. Redrawing dies are sometimes called
reducing dies because the redrawing die operation reduces the diameter of the
9
work. If consist able elongations is desired, the work is passed thoroughly a
number of redrawing dies.
Fig.1.5.3.Re-Drawing Die
10
1.5.5.COMPOUND DIE:
This type of die is constructed with a die in the upper punch and
a punch in the lower die. That is, it contain two punches and two dies. By the
combined action of two punch and the two dies, blank are formed to the desired
shape for which die is designed. Compound dies are different from plain and
follow dies in that the basic punch and die elements are combined so that both the
die, as well as strippers plates or ejectors.
In actual die operation, the upper die descends and follow the die in the basic
punch and die element are combined so that both the upper and lower members
contain the equivalent of a punch and die.
In actual die operation, the upper die descends and depress the stripper plate. As
the downward movement is contains the blank is cut from the stocky by the
telescoping action of the upper and lower dies, the lower die acting as a punch.
Both dies function as punch as well as external punch, and lower die act an inner
punch. At the same time that the blank is cut, the punch pierces a central hole in
the upper elements. As the ram ascends, the blank is forced out of the upper
element by the ejector, and the stripper plate pushes the work off the lower die.
The metal punched from the hole falls thoroughly the opening in the lower die.
Fig.1.5.5.Compound Die
11
1.5.6.MISCELLANEOUS DIES:
12
Fig.1.5.6.Miscellaneous Dies
13
CHAPTER 2
2.FORMING PROCESSES
2.1.TENSILE FORMING
Tensile forming involves those processes where the primary means of plastic
deformation is uni - or multiaxial tensile stress.
Stretching, here a tensile load is applied along the longitudinal axis of the
workpiece
Expanding, where the circumference of a hollow body is increased by
tangential loading
Recessing, where depressions and holes are formed through tensile loading
14
2.2.COMBINED TENSILE AND COMPRESSIVE
FORMING
This category of forming processes involves those operations where the primary
means of plastic deformation involves both tensile stresses and compressive
loads.
2.3.BENDING
This category of forming processes involves those operations where the primary
means of plastic deformation is a bending load.
2.4.SHEARING
This category of forming processes involves those operations where the primary
means of plastic deformation is a shearing load.
15
CHAPTER 3
3.PRESS TOOLS:
Blanking Tool
When a component is produced with one single punch and die where the
entire outer profile is cut in a single stroke the tool is called a blanking tool.
Blanking is the operation of cutting flat shapes from sheet metal.
The outer area of metal remaining after a blanking operation is generally
discarded as waste.
Size of blank or product is the size of the die & clearance is given on punch.
It is a metal cutting operation.
16
in blanking metal is obtain after cutting is not a scrap or it is use able.
3.2.PIERCING TOOL
Piercing tool
Piercing involves cutting of clean holes with a resulting scrap slug. The
operation is called die cutting and can also produce flat components where the
die, the shaped tool, is pressed into a sheet material employing a shearing action
to cut holes. This method can be used to cut parts of different sizes and shapes
in sheet metal, leather and many other materials.
Cutoff tool
Cut off operations are those in which a strip of suitable width is cut to length in
a single operation. Cut-off tools can produce many parts. The required length of
strip can be cut off for bending and forming operations using this tool.
17
3.4.PARTING OFF TOOL
Partings are similar, in that a discrete part is cut from a sheet or strip of metal
along a desired geometric path. The difference between a cutoff and a parting is
that a cutoff can be nestled perfectly on the sheet metal, due to its geometry.
With cutoffs, the cutting of sheet metal can be done over one path at a time and
there is practically no waste of material. With partings, the shape can not be
nestled precisely. Parting involves cutting the sheet metal along two paths
simultaneously. Partings waste a certain amount of material, that can be
significant.
3.5.TRIMMING TOOL
When cups and shells are drawn from flat sheet metal the edge is left wavy and
irregular, due to uneven flow of metal. Shown is flanged shell, as well as the
trimmed ring removed from around the edge. While a small amount of Material
is removed from the side of a component in trimming tool.
Fig.3.5.Trimming Tool
3.6.SHAVING TOOL
Shaving removes a small amount of material around the edges of a previously
blanked stampings or piercing. A straight, smooth edge is provided and
therefore shaving is frequently performed on instrument parts, watch and clock
18
parts and the like. Shaving is accomplished in shaving tools especially designed
for the purpose.
3.7.FORMING TOOL
Forming is the operation of deforming a part in curved profile. Forming tools
apply more complex forms to work pieces. The line of bend is curved instead of
straight and the metal is subjected to plastic flow or deformation.
3.8.DRAWING TOOL
Drawing tools transform flat sheets of metal into cups, shells or other drawn
shapes by subjecting the material to severe plastic deformation. Shown in fig is
a rather deep shell that has been drawn from a flat sheet.
Fig.3.8.Drawing Tool
This type of Press tool is used to perform only one particular operation therefore
classified under stage tools.
3.9.PROGRESSIVE TOOL
A progressive tool differs from a stage tool in the following respect: in a
progressive tool the final component is obtained by progressing the sheet
metal or strip in more than one stage. At each stage the tool will progressively
shape the component towards its final shape, with the final stage normally being
cutting-off.
19
3.10.COMPOUND TOOL
The compound tool differs from progressive and stage tools by the arrangement
of the punch and die. It is an inverted tool where blanking and piercing takes
place in a single stage and also the blanking punch will act as the piercing die.
3.11.COMBINATION TOOL
In a combination tool two or more operations such as bending and trimming
will be performed simultaneously. Two or more operations such as forming,
drawing, extruding, embossing may be combined on the component with
various cutting operations like blanking, piercing, broaching and cut off takes
place- it can perform a cutting and non cutting operations in a single tool.
20
CHAPTER 4
4.GENERAL PRESS TOOL CONSTRUCTION
The general press tool construction will have following elements:-
Shank: It is used to locate the press tool in press for alignment purpose.
Top Plate: It is used to hold top half of the press tool with press slide.
Punch Back Plate : This plate prevents the hardened punches penetrating
into top plate.
Punch Holder: This plate is used to accommodate the punches of press tool.
Punches : To perform cutting and non cutting operations either plain or
profiled punches are used.
Die Plate: Die plate will have similar profile of the component where cutting
dies usually have holes with land and angular clearance and non cutting dies
will have profiles.
Die Back Plate: This plate prevents the hardened Die inserts penetrating into
bottom plate.
Guide Pillar & Guide Bush : Used for alignment between top and bottom
halves of the press tools.
Bottom plate: It is used to hold bottom half of the press tool with press slide.
Stripper plate: it is used to strip off the component from punches.
strip guides: It is used to guide the strip into the press tool to perform the
operation.
21
Fig.4.General Press Tool
4.2.STRIPPING FORCE
Stripping force will be usually 10 to 20 % of cutting force
4.3.PRESS FORCE
Press force will be cutting force with stripping force Press Force = Cutting force
+ Stripping force
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CHAPTER 5
5.1.LUBRICANTS:
When working with German silver or copper stock, a thin coat pf sperm oil can
be used. Lard oil can also be used on these material sheet cavity which the
lubricants and passing it through a pair of rolls.
Clean soap and water is recommended as a lubricant for drawing brass and
copper. For aluminium stock, lard oil, tallow, or Vaseline is recommended.
23
5.2.MATERIALS FOR DIE MAKING:
In most instances, a good grade of tool steel is used for making punches
and dies. The steels should be free or harmful impurities. Sometimes, the body of
the die can be made of cast iron with an inserted steel bushing to reduce the cost
of material. An advantage of this type of construction is that an insert can be
replaced when it is become worn. Soft steel that has been case hardening does not
change it form can be corrected readily because the interior is soft.
The simple design can be used to illustrate the operations necessary to make the
opening in a blanking die. The large circular ends A and B should be bored out
with a drill of the same diameter.
Then, several small holes can be drilled to outline the intermediate part
of the design. Alternative small holes should be drilled first. Then, the remaining
holes should be drilled so that the entire metal section C can be removed
from the design without difficulty.
The blanking die must have a clearance. Clearances is the taper given the
walls of the holes in a die; the large end of the hole is at the bottom of the die.
This permits the punched blanks to fall out of the die. The die having no clearance
is compared with a die having an exaggerated clearance.
24
Several method can be used to obtain the clearance. If there were, no
clearance is the punch blank would remain stuck in the die block. The blank is
free to fall out of the die block if the die has clearance.
In drilling to the outline of the die design, the clearance can be obtained
by inserting a prop or thin strip of metal beneath the block on the side farthest
removed from the hole that is to be drills. The tilts the dies block so that the drilled
hole will be inclined from the vertical at an angle to the clearance angle AOB.
The holes can be drilled at angle of 90⁰ to the face of the die block and
then reamed from the bottom with a tapered reamer to provide the clearance
angle. The opening at the bottom can also be made larger by filling the die
opening to the scribble lines.
5.4.DIES:
The die may be defined as the female part of a complete tool for
producing work in a press. It is also referred to a complete tool consists of a pair
of mating members for producing work in a press. Die construction: Here the
blank punch cum piercing die is mounted on the bottom of the bottom plate,
25
which is bolted with machine bed. Blank die and piercing punch are mounted on
the top plate, which is mounted on the press ram. A knockout is placed between
blank, die and piercing punch, which is used for to eject the component from the
die. A stripper plate is held with blank punch. The process of tool making calls
for a high level of keenness and qualifications. It is important for the maker to
produce tools that are of acceptable standards and which are suitable for the task
they are meant for. It is not possible to achieve this unless one is competent
enough and has the necessary skills to produce high quality tools. There are rules
and regulations that are often followed when creating tools to ensure that the
products are of the quality that is needed. If a maker disregards the rules, chances
are that products made will not be suitable. With poor quality tools, the
manufacturing industry will not give out its best and this can affect a whole
economy. In the days when tools were handmade, several machines had to be
used to polish them up.
The purpose of this was to give the tools a finer finish and increase the quality.
However, the process of producing quality tools has been made easier and
International Journal of Advances in Mechanical and Civil Engineering,
ISSN:2394-2827 Volume-2, Issue-1, Feb.-2015 Design And Manufacturing Of
Progressive Press Tool 21 faster due to the introduction of more efficient
machines. There are numerically controlled machines that are used to make tools
more easily. Tool making machines can grind, mill and polish up the tools within
a very short time. This is a very positive development from the time-consuming
hand making process. For any maker of tools to be able to come up with good
products, he should be able to have the image of the required product in mind.
Only when you understand what is needed can you develop it accordingly.
Therefore, additional knowledge such as computer literacy and the ability to use
computer technology to come up with better tools is required.
26
CHAPTER 6
Certain steels have a very low rate of expansion and contraction in hardening and
are very desirable for test plugs, gages, punches and dies, for milling cutters, taps,
reamers, hard steel bushings and similar work.
It is recommended that for forging these steels it be heated slowly and uniformly
to a bright red, but not in direct flame or blast. Harden at a dull red heat, about
1,300 degree fahrenheat.
A clean coal or coke fire, or a good muffle-gas furnace will get best results. Fish
oil is good for quenching although in some cases warm water will give excellent
results. The steel should be kept moving in the bath until perfectly cold. Heated
and cooled in this way the steel is very tough, takes a good vutting edge and has
very little expansion or contraction which makes it desirable for long taps where
the accuracy of lead is important.
6.1.PROPERTIES
Code : 100MnCrW4
C Si Mn Cr V W
0.95 0.25 1.10 0.60 0.10 0.60
Steel Properties : Cold work tool steel. Very high resistance to cracking High
machinability, medium
28
29
6.1.1.STRENGTH:
6.1.2.HARDNESS
Hardness of a material indicates its resistance to get indented that is not temporary
(i.e.; it persists even after the load conditions are removed, as opposed to the
strength that is an indication of its performance only when the load is applied),
and carbon is also the primary hardening element in steel. The Rockwell method
measures the hardness of OHNS Tool Steel to be in the range of 64 RC to 58 RC
(this is the most commonly used measurement technique).
6.1.3.TOUGHNESS:
6.1.4.BRITTLENESS
30
6.2.APPLICATION:
All press cutting tools & punching tools for thinner materials.
Small tools of complicated design for reforming, bending & drawing. Small
plastic & rubber moulds.
Working tools, sizing and stamping tools. Machine knives for cellulose, paper
and pulp, and metal working industries, gauges, plastic moulds, thread rolling
tool, blanking tools.
31
CHAPTER 7
7.LITERATURE REVIEW:
32
The design of die is variable according to the aim it is intended
to fulfil. However, the design of the press involves certain common principles
and steps; those should be followed in order to have an efficient and acceptable
outcome. Many researchers have conducted researches on designs of dies for
sheet metal components.
33
CHAPTER 8
W = w + loss
Upper die
Loss = 0.6kg
Lower Die
Loss = 0.07kg
34
3. Holes and cavities:
4. Angle of V groove:
α = 55°
5. Clearance:
Clearance = 5mm
35
CHAPTER 9
36
37
38
CHAPTER 10
39
40
CHAPTER 11
11.CONCLUSION
41
CHAPTER 12
12.REFERENCES
42