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DESIGN AND FABRICATION OF

GROOVE PRESS TOOL


ABSTRACT

Tool design is the process of designing and developing the tools,


methods, and techniques necessary to improve manufacturing efficiency and
productivity. It gives industry the machines and special tooling needed for today
is high-speed, high-volume production. It does this at a level of quality and
economy that will ensure that the cost of the product IS competitive. Since no
single t001 or process can serve all forms of manufacturing, tool design is an
ever-changing, growing process of creative problem solving. The main objective
of tool design is to lower manufacturing costs while maintaining quality and
increased production.

The design of groove dies is of great importance to the evolutions


of microstructure and mechanical properties of the material during CGP
(Constraint groove Pressing).

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

S.No TITLE PAGE NO.


1. 1. INTRODUCTION 1
1.1. INTRODUCTION OF DIES 1
1.2. TYPES OF DIES 2
1.3. CUTTING DIES 3
1.3.1. PLAIN DIE 3
1.3.2. SELF CE NTERING DIE 4
1.4. SHAPING DIE 4
1.4.1. PLAIN BENDING DIE 5
1.4.2. CURLING DIE 5
1.4.3. WIRING DIE 6
1.4.4. BULGING DIE 7
1.5. COMBINATION PUNCHING AND 8
SHAPING DIES
1.5.1. DOUBLE ACTION DIE 8
1.5.2. PLAIN DRAWING DIE 8
1.5.3. RE DRAWING DIE 9
1.5.4. GANG AND FOLLOW FIE 10
1.5.5. COMPOUND DIE 11
1.5.6. MISCELLANEOUS DIE 12
2. 2. FORMING PROCESSES 14
2.1. TENSILE FORMING 14
2.2. COMINED TENSILE AND COMPRESSIVE 15
FORMING
2.3. BENDING 15
2.4. SHEARING 15
3. 3. PRESS TOOLS 16
3.1. BLANKING TOOL 16
3.2. PIERCING TOOL 17
3.3. CUTOFF TOOL 17
3.4. PARTING OFF TOOL 18
3.5. TRIMMING TOOL 18
3.6. SHAVING TOOL 18
3.7. FORMING TOOL 19
3.8. DRAWING TOOL 19
3.9. PROGRESSIVE TOOL 19
3.10. COMPOUND TOOL 20
3.11. COMBINATION TOOL 20
4. 4. GENERAL PRESS TOOL CONSTRUCTION 21
4.1. CUTTING FORCE IN PRESS TOOL 22
4.2. STRIPPING FORCE 22
4.3. PRESS FORCE 22
5. 5. DIE MAKING OPERATIONS 23
5.1. LUBRICANTS 23
5.2. MATERIALS FOR DIE MAKING 24
5.3. DIE MAKING PROCESSS 24
5.4. DIES 25
6. 6. TOOL STEEL OHNS 27
6.1. PROPERTIES 27
6.1.1. STRENGTH 30
6.1.2. HARDNESS 30
6.1.3. TOUGHNESS 30
6.1.4. BRITTLENESS 30
6.2. APPLICATIONS 31
7. LITERATURE REVIEW 32
8. CALCULATION 34
9. CONCEPTUAL DESIGN 36
10. DESIGNED AND FABRICATED DIE TOOL 39
11. CONCLUSION 41
12. REFERENCE 42
CHAPTER 1

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:

A Die is a tool intened to cut or shape sheet metal or similar materials.


Basically , the die proper consist of the die block and the punch.

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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 OR PUNCHING DIES:

Many types of dies are required to handle the large variety


of cutting and shaping operations encountered in general practices. Dies can be
classified with respect to the operations that they perform

 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.

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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

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1.3.2.SELF-CENTERING DIES:

A self-centring is provided with a small conical point. So


that it does not require a gage pin for locating holes punched in the stock.

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

Shaping dies are used to change the shape of the stock.


They do no cutting. The term punch, strictly speaking, is a misnomer because it
does not operate as a punch in shaping operations. The punch is used to press the
stock against the die to bend the stock to the desired shape.

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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.

1.4.1.PLAIN BENDING DIE:

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.

Fig. 1.4.1.Plain Bending Die:

1.4.2.CURLING DIE:

Curling die is a special form of pending die in which part of the


stock is bent to form circular beads around edge of drawn cylindrical parts the
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progressive operation in curling veal around a cylindrical vessel the curling punch
force a metal outward to increase the circumference at the edge of a metal. The
metal crack if it is over stretched. The stretching action of the metal increases as
the diameter of the vead increases.

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:

The wiring die is modification of curling die in which provision is


made up of curling the edge of the work piece over a wire. The shape of punch is
same as for the curling die, but the die proper construct to float on spring.

The preparation for the wiring operation a ring of wiring is placed in


position around the projecting edge of the piece. The punch as it descends, the
coil the edge of the work piece around the wire successive steps.

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1.4.4.BULGING DIE:

The basic principal of operation of the bulging die depend on


the expensive action of the springy materials placed under pressure. A rubber disc
is subjected to a pressure by a descending plunger. In typical operation, the work
piece consisting of a shell drawn upright is placed directly above the mushroom
plunger. As plunger descends, the rubber disc is expanded outward to expand or
“bulge the shell into curved champers formed by the punch and bulging die a
cylindrical projection is formed as work enter and transvers the annular space
after the progressive die operation is completed, the work piece is obtain similar
types of work, such as covers or lids for some kind of cans or c containers, can
be formed on the bulging die.

Fig.1.4.4.Blulging Die

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1.5.COMBINATION PUNCHING AND SHAPING DIES

Various combinations of punches and dies can be used to


perform both the cutting and shaping operations. This is illustrated in the double
action die.

1.5.1.DOUBLE ACTION 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.

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Fig.1.5.2.Plain Drawing Die

1.5.3.RE-DRAWING DIE:

The redrawing die performs a second operation on a work piece that


comes from the drawing die. A second drawing operation is performed, which
reduces the diameter of the metal and increased its length. In other words a cup
or shell already formed from the stock is redrawn. The redrawing die is similar to
the drawing die in that the recess at the top of the die fits the shell that is to be
drawn instead of being made to fits a blank that is to be drawn. A redrawn die
with the shell in position for the redrawn operations.

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

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work. If consist able elongations is desired, the work is passed thoroughly a
number of redrawing dies.

Fig.1.5.3.Re-Drawing Die

1.5.4.GANG AND FOLLOW DIES:

A gang dies is one which two or more punches are combined in


a single punching head. As many holes as there are mounted, punches can be
punched simultaneously in a single operation. A follow die is modified gang die
in which several successive operations are performed progressively.

Fig.1.5.4.Gang and Follow Dies

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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

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1.5.6.MISCELLANEOUS DIES:

Numerous dies are made for various purpose. In


addition to the dies already describe, numerous others dies should be mentioned.
A burnishing die is constructed slightly smaller at the bottom than the top. Since
the bottom of the die is a little smaller than the top, the works receives a high
finish as it is forced downward through die. A combined die can be used to
perform combinations of operations in a single stroke. The blank can be cut. As
the stroke progress, the edge can be turned down, and the piece drawn into
required shape. A trimming die is used to remove excess metal, it is designed so
that the excess metal is removed from the edges or ends of various drawn and
formed work piece. The fluid dies are designed for forming fancy hollow ware
form soft metals by means of hydraulic pressure.

The shell that is to be formed is filled with liquid and enclosed


within the die. Then, means of a plunger, a hydraulic pressure can be applied to
force the shell outward against the contour of the enclosing wall of the dies. A
perforating dies are multiple die. Many small-diameter punches can be grouped
together to form the multiple die. A reducing die is a type of redrawing die. It is
designed to reduce only a portion of the shell instead of the entire length, as in
regular redrawing die.

Three independent movements can be made by the triple actions


die. It can be used to perform such operations as cutting or blanking, drawing and
stamping or embossing. Frequently a part cannot be made in a single operation
but required several. Often, these are made in such a way that the materials is
removed through in a series operations. These are known as progressive dies.
The work piece in the centre the various stages the flat strip at the bottom to the
finished piece at the top. The work is moved up one stage automatically with each
stroke of the press.

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Fig.1.5.6.Miscellaneous Dies

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CHAPTER 2

2.FORMING PROCESSES

Forming processes tend to be categorised by differences in effective stresses.


These categories and descriptions are highly simplified, since the stresses
operating at a local level in any given process are very complex and may involve
many varieties of stresses operating simultaneously, or it may involve stresses
which change over the course of the operation.

Compressive forming involves those processes where the primary means of


plastic deformation is uni- or multiaxial compressive loading.

 Rolling where the material is passed through a pair of rollers


 Extrusion where the material is pushed through an orifice
 Die forming, where the material is stamped by a press around or onto a die
 Forging, where the material is shaped by localized compressive forces
 Indenting, where a tool is pressed into the work piece.

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

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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.

 Pulling through a die


 Deep drawing
 Spinning
 Flange forming
 Upset bulging

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.

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CHAPTER 3

3.PRESS TOOLS:

Whenever sheet metal or other material is worked on a


press, press tools are used. Press tools are special tools custom built to produce a
component mainly out of sheet metal. Press tool is of stampings include cutting
operations (shearing, blanking, piercing, etc.) and forming operations (bending,
drawing, etc.) Sheet metal items such as automobile parts (roofs, fenders, caps,
etc.), components of aircrafts, parts of business machines, household appliances,
sheet metal parts of electronic equipment’s. Press tools manufacture precision
parts required for homological industry etc.

CLASSIFICATION OF PRESS TOOLS


3.1.BLANKING TOOL

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.

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in blanking metal is obtain after cutting is not a scrap or it is use able.

 The size of the blank depends on the size of the die.


 So the size of the die opening is equal to the blank size.
 Clearance is given to the punch.

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.

3.3.CUT OFF TOOL

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.

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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

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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.

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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.

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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.

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Fig.4.General Press Tool

4.1CUTTING FORCE IN PRESS TOOL


In general cutting force (CF) can be calculated using formula: CF =L x S x
ζmax

cutting force will be in Newton(N) Where, L = Cut length in mm,(perimeter of


profile to be cut) Ex: 40 mm square to be cut will have cut length of 160 mm

S = Sheet metal thickness in mm,

ζmax = Maximum shear strength of sheet metal MPa

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.DIE MAKING OPERATIONS:

The choice of a suitable lubricant, selection of the proper material,


and layout of the die are all-important operation’s that must be considerable in
die making.

5.1.LUBRICANTS:

Although some shops do not use a lubricant for working sheet


metal, a lubricant is recommended for best results. A heavy animal oil can be
used for cutting steel and brass. Lard oil can be used, but it is more expensive. A
mixture of equal parts of oil and black lead can be used for drawing steel shells.

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.

Then, several sheets can be lubricants lightly by passing them through


the rolls before the supply of lubricants on the rolls is exhausted. This is also good
method for lubricant’s work that is to be drawn because the thin coating of oil
will disappear during the drawing the operations, and cleaning or pad is
objectionable for applying lubricants because the coating of oil is usually too
thick are required cleaning after the operation has been finished.

Clean soap and water is recommended as a lubricant for drawing brass and
copper. For aluminium stock, lard oil, tallow, or Vaseline is recommended.

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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.

Internal strains or stresses are setup in steel during the manufacturing


process. In diemaking operations, the stresses must be relived before the die is
brought to its final size, or they will cause distortion. The presence of stresses
cannot be determined in the steel beforehand, but the die maker can relieve the
stresses in the steel by annealing after the die has been roughed out.

5.3.DIE MAKING PROCESS:

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.

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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.

Usually, a clearance angle of 1⁰ to 2⁰ must be provided. The die-


makers can be used to check for uniform clearance around the die opening. The
die makes square differs from the real square in that the angle of the blade with
the stock of the square is 92⁰ (90⁰+ 2⁰) to provide for the clearance angle. The
blade is very narrow for accessibility to small opening.

Surplus metal is removed from the large dies by machining. It can be


removed from the smaller dies with a sharp, cold chisel after drilling. Clearances
should not extended entirely upward to the cutting edge of the die; it should
extends only to with in about ⅛ inch of the edge. This is because the die opening
would be increased by sharpening, not because of the cutting action of the die.

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.

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CHAPTER 6

6.TOOL STEEL OHNS

OIL HARDENING NON-SHRINKING DIE STEEL

An ideal type oil-hardened steel, which is economical and dependable for


gauging, cutting and blanking tools as well as can be relied for hardness and good
cutting performance. It is used for make Blanking and stamping dies, Punches,
Rotary shear blades, Thread cutting tools, Milling cutters, Reamers, Measuring
tools, Gauging tools, Wood working tools, Broaches, Chasers.

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

Din - material - no. : 1.2510

Code : 100MnCrW4

Comparable Standards : A ISI : 01


27
Equivalent Brands :

Bohler German Japan Poldi Metal (EWK)Thyssen


No. Ravne Edelstahlwerke
Tew
(DEW
K460 2510 SKS3 StabilK OW4, Thyrodur2510
Merilo EX

Chemical composition : (Typical analysis %)

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

toughness and resistance to wear. Dimensional stability at heat treatment.

Physical Properties : Thermal conductivity W/ ( m . K) 200◦C/30

Density g/cm3 200C 7.85

28
29
6.1.1.STRENGTH:

Strength of a metal determines the extent to which it may deform when


load is applied on it. Strength can be measured based on various parameters, such
as the maximum ability to take strain, resistance to wear and tear, impact
handling, or how the material performs when subjected to frequently changing
load conditions. Strength generally increases as the carbon and manganese
content increases. Given the high percentage of both of those, OHNS Tool Steel
is strong.

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:

Toughness of a material determines whether it can be subjected to shock


conditions, and the extent to which it may undergo deformity in shape but still
not snap. If subjected to a proper treatment process, O1 Tool Steel tends to be
very tough.

6.1.4.BRITTLENESS

As opposed to toughness, brittleness measures whether a material will


snap instead of getting deformed, when load is applied. Alloy steels like O1 Tool
Steel are less brittle than cast or pig iron because of the presence of magnesium.

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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:

The design of die is variable according to the aim it is


intended to fulfil. But 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. This works can be broadly classified considering the
area to be applied as; food sector, automotive, aerospace, agricultural, medicine,
electronics, etc. The researchers found that it is relevant to give attention on die
design literatures that are dedicated to blanking and bending of sheet metals, some
of these works are discussed as follows. ‘Design of Blanking and Piercing Press
Tool for Manufacturing Washers of M12’, (K.Kishore Kumar, May 2012).

The methodology involved in the work includes manual design of


parts for press tool components followed by 3D modelling with CREO software.
One of the draw-back that is observed on that work is that the researcher did not
validate or taste the manual design for functionality using simulation software or
any other techniques. Another literature found relevant is ‘Press Too Design and
Analysis for 49 Lever 5 Stage Tool’, (H.Ameresh and P.Harishankar, July 2013).
This work involves design of punching and bending tools used to manufacture 49
lever component used in thermostats. In this work manual design of die
component was performed by following the standard calculation steps. Then the
outcomes of the design were modelled in CREO software and imported to
ANSYS for validation of the design under the given load conditions. The
limitation that was observed, the validation of the design was performed on an
imported model to ANSYS, Which was initially modelled in CREO. This may
result in simulation errors due to the 3D model information transformations error.

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.

A simple blanking tool is designed only when the piece


part has internal details (pierced holes). If the piece part is to be produced by the
combination of blanking and piercing operations. We should design altogether
different types of tool. One way of doing things is to perform the piercing in one
station then the strip is advanced to another station where the blanking is carried
out maintaining its relative position with the previously pierced hole. As the
processing progresses from station to station to tool is known as “Progressive
tool”. The word tooling refers to the hardware necessary to produce a particular
product.

The most common classification of tooling are as follows

1) Sheet metal press working tools.


2) Moulds and tools for plastic moulding and die-casting.
3) Forging tools for hot and cold forging.
4) Jigs and fixtures for guiding the tool and holding the work piece.
5) Gauges and measuring instruments.
6) Cutting tools such as drills, reamers, milling cutters broaches,
taps, etc.

33
CHAPTER 8

8.CALCULATION FOR DIE:

TO CALCULATE BLANK SIZE:

1. To calculate Loss of Die Weight:

W = w + loss

where, W = Weight of Die material

w = Net weight of die

Weight of Die steel W = 4.49kg

Upper die

Net Wt of Die, w = 3.89kg

Loss = W-w = 4.49-3.89 = 0.6kg

Loss = 0.6kg

Lower Die

Net Wt of Die = 4.24kg

Loss = W-w = 4.49-4.42 = 0.07kg

Loss = 0.07kg

34
3. Holes and cavities:

Maximum depth of cavity (h) = d,

h = 1.5d if a radius allowed at the bottom

where, d = size of diameter of the hole

Max depth of cavity, H = 8mm

4. Angle of V groove:

α = 55°

5. Clearance:

Clearance = 5mm

35
CHAPTER 9

9. CONCEPTUAL DESIGN (CATIA-2D MODEL)

36
37
38
CHAPTER 10

10. DESIGNED& FABRICATED DIE TOOL

39
40
CHAPTER 11

11.CONCLUSION

The demands of modern industry for maximum productivity at


minimal cost are a challenge to the tool designer. Preformed materials like OHNS
materials can greatly reduce tooling costs by eliminating many machining
operations. Whenever practical, preformed materials, such as drill rods, structural
sections, pre-machined bracket materials, tooling plate, and precision-ground flat
stock, should be specified in the design. Blanking and stamping dies, Punches,
Rotary shear blades, thread cutting tools, etc., are should made by using OHNS
steels for low budget and efficient tool makings.

41
CHAPTER 12

12.REFERENCES

1. Design of Jigs, fixture and Press tools.


Author: C.Elanchezhian
2. Tool Design.
Author: Doanldson,LeCain,Goold.
3. Manufacturing Technology-I.
Author: Dr.G.K.Vijayaragahavan.
4. Jig and Fixture Design - 5th Edition
Author: Edward.G.Hoffman.
5. OHNS Steel Material Properties and Applications.
Source: http://saajsteel.com/

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