1.

Introduction
In a manufacturing organization, a job to be manufactured spends most of the
time in moving and waiting. For reduction of this moving and waiting time of jobs/parts,
it is necessary to have proper layout and proper scheduling procedure. The manufacturing
of the any product deals with different parameters such as the overall arrangement of the
various facilities, equipments, material, manpower, materials handling, service facilities,
and passage required to facilitate efficient operation of production system of the plant
within the area of the site selected previously. In this whole report we are dealing with
the manufacturing of different types of dies.
Manufacturing touches the every part of the universe. While manufacturing the dies the
important to know the manufacturing process is the most significant one how to adopt the
path to manufacture the die.

The word “DIE” in itself means the complete press tool in its entirety, with all the
punches, die buttons, ejectors, strippers, pads, and blocks, simply with all its components
assembled together. The DIE is an ideal tool that can produce large quantities of parts
that are consistent in appearance, quality, and dimensional accuracy. It is a press tool
capable of cutting the metal, bending it, drawing its shape into considerable depths,
embossing, coining, finishing the edges, curling, and otherwise altering the shape and the
outline of the metal part to suit the wildest imaginable design concepts. Manufacturing
methods for picture frames, chandeliers, door and wall hardware, kitchen sinks, pots and
pans, window frames, and doors were gradually replaced by more practical and less
costly techniques.

In today’s practical and cost-conscious world, sheet-metal parts have already

replaced many expensive cast, forged, and machined products. The reason is obviously
the relative cheapness of stamped, or otherwise mass-produced parts, as well as greater
control of their technical and aesthetic parameters. That the world slowly turned away
from heavy, ornate, and complicated shapes, and replaced them with functional, simple,
and logical forms only enhanced this tendency. Manufacturing methods for picture

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frames, chandeliers, door and wall hardware, kitchen sinks, pots and pans, window
frames, and doors were gradually replaced by more practical and less costly techniques.
When evaluating a part for die production, the most restrictive aspect to be considered is
the cost of the tooling. To build a metal stamping die is a costly process, involving many
people, many machines, and several technologies. For that reason, the demand for tooling
must first be economically justified. [2]
A correct evaluation of the problem must be performed on the basis of:
• Availability of the appropriate press

• The equipment’s running speed

• The length of production shifts

• Scheduling for the needed time interval

Dies and its Types:

Die:
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.
Types of dies:
The dies may be classified according to the type of press operation and according to the
method of operation.
(A) According to type of press operation:
According to this criterion, the dies may be classified as cutting dies and forming dies.
1: Cutting Dies:
These dies are used to cut the metal. They utilize the cutting or shearing action.
The common cutting dies are: blanking dies, perforating dies, notching dies, trimming,
shaving and nibbling dies.
2: Forming Dies:
These dies change the appearance of the blank without removing any stock.
Theses dies include bending, drawing and squeezing dies etc.

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(B) According to the method of operation:
According to this criterion, the dies may be classified as : single operation or simple dies ,
compound dies , combination dies , progressive dies , transfer dies and multiple dies.
1: Simple Dies:
Simple dies or single action dies perform single operation for each stroke of the
press slide. The operation may be one of the operation listed under cutting or forming
dies.
2: Compound Dies:
In these dies, two or more operations may be performed at one station. Such dies
are considered as cutting tools since, only cutting operations are carried out. Figure
shows a simple compound die in which a washer is made by one stroke of the press. The
washer is produced by simulation blanking and piercing operations. Compound dies are
more accurate and economical in production as compared to single operation dies.

Fig. no: 1.1 - Compound Die

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3: Combination Dies:
In this die also, more than one operation may be performed at one station. It is difficult
from compound die in that in this die, a cutting operation is combined with a bending or
drawing operation, due to that it is called combination die.

Fig. no: 1.2 - Combination Die

4: Progressive Dies:
A progressive or follow on die has a series of operations. At each station, an operation is
performed on a work piece during a stroke of the press. Between strokes the piece in the
metal strip is transferred to the next station. A finished work piece is made at each stroke
of the press. While the piercing punch cuts a hole in the stroke, the blanking punch blanks
out a portion of the metal in which a hole had been pierced at a previous station. Thus
after the first stroke, when only a hole will be punched, each stroke of the press produces
a finished washer.

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 Fig. no: 1.3 - Progressive Die

5: Press Working Terminology:

A simple cutting die used for punching and blanking operation as shown:

Fig. no: 1.4 - Press Terminology

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1. Bed:
The bed is the lower part of the press frame that serves as a table to which a Bolster plate
is mounted.
2. Bolster Plate:
This is a thick plate secured to the press bed, which is used for locating and supporting
the die assembly. It is usually 5 to 12.5 cm thick.
3. Die Set:
It is unit assembly which incorporates a lower and upper shoe, two or more guide parts
and guide part bushings.
4. Die Block:
It is a block or a plate which contains a die cavity
5. Lower Shoe:
The lower shoe of the die set is generally mounted on the bolster plate of a press. The die
block is mounted on the lower shoe, also the guide post are mounted on it.
6. Punch:
This is male component of a die assembly, which is directly or indirectly moved by and
fastened to the press ram or slide.
7. Upper Shoe:
This is the upper part of the die set which contains guide post bushings.
8. Punch Plate:
The punch plate or punch retainer fits closely over the body of the punch and holds it in
proper relative position.
9. Back up Plate:
Back up plate or pressure plate is placed so that intensity of pressure does not become
excessive on punch holder. The plate distributes the pressure over a wide area and the
intensity of pressure on the punch holder is reduced to avoid crushing.
10. Stripper:
It is a plate which is used to strip the metal strip from cutting a non-cutting Punch or die.
It may also guide the sheet.

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6. Equipment for Sheet-metal Forming
For most general press working operations, the basic equipment consists of mechanical,
hydraulic, pneumatic, or pneumatic-hydraulic presses with a wide variety of designs,
features, capacities, and computer controls. Typical designs for press frames are shown in
Fig. The proper design, stiffness, and construction of such equipment is essential to the
efficient operation of the system and to achieving a high production rate, good
dimensional control, and high product quality. The traditional C-frame structure has been
used widely for ease of tool and work piece accessibility, but it is not as stiff as the box-
type pillar or the double-column frame structure (Fig. 16.60f). Furthermore, accessibility
has become less important due to advances in automation and in the use of industrial
robots and computer controls.
Press selection for sheet-metal forming operations depends on several factors:
1. Type of forming operation, the size and shape of the dies, and the tooling required.
2. Size and shape of work pieces.
3. Length of stroke of the slide, the number of strokes per minute, the operating speed,
and the shut height (the distance from the top of the bed to the bottom of the slide with
the stroke down).
4. Number of slides. Single-action presses have one reciprocating slide. Double action
presses have two slides, reciprocating in the same direction. They typically are used for
deep drawing-one slide for the punch and the other for the blank holder. Triple-action
presses have three slides; they are typically used for reverse redrawing and for other
complicated forming operations.
5. Maximum force required (press capacity and tonnage rating).
6. Type of mechanical, hydraulic, and computer controls.
7. Features for changing dies. Because the time required for changing dies in presses can
be significant (as much as a few hours) and thus affect productivity, rapid die-changing
systems have been developed. Following a system called single-minute exchange of die
(SMED), die setups can be changed in less than 10 minutes by using computer-controlled
hydraulic or pneumatic systems.

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 (g)
Fig. no: 1.5 -Schematic illustrations of types of press frames for sheet

Because a press is a major capital investment, its present and future use for a broad
variety of parts and applications should be investigated. Versatility and multiple use are
important factors in press selection, particularly for product modifications and for making
new products to respond to continually changing global markets. [2]

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Problems in previous die manufacturing :

1.Vibrations
The most common problems
• High noise
• Uneven wear and chipping
• Corner damage
• Short toollife
• Bad surface finish

2. Chip jamming
 Critical in full slotting especially in long chipping materials. Can cause corner
damage,edge chipping and breakage. Recutting of chips reduces toollife.

3. Unacceptable workpiece/surface
 Geometrical and dimensional tolerances Surface finish and burr generation
4. Tool breakage or chipping
 Often caused by overloading of tool or chip jamming.

5. Smearing and build up edge

 Especially austenitic materials, titanium and aluminum
6. High wear
 Mostly due to unfavourable cutting conditions or very abrasive materials

Fig.no:1.6 Previous perforated sheet

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Defects in sheet:

 Defects resulting from the melting practice such as dirt, slag and blow
holes.

 Ingot defects such as pikes, cracks scabs, poor surface and segregation.

 Defect due to faulty forging design.

 Defects of mismatched forging because of improper placement of the metal

in the die.

 Defects due to faulty design drop forging die.

 Defects resulting from improper forging such as seams cracks laps. etc.

 Defects resulting from improper heating and cooling of the forging part.

Fig.no:1.7 Defects in sheet

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 1.1 Problem statement
The problems of current project are:
 Heating of engine.
 Poor Ventilation.
 Weight and cost.

1.2 Objectives
 Understanding the manufacturing of die.
 Understanding pattern making process.
 Selecting a casting process to manufacture die.

1.3 Scope
 The dies will be in actually used in production line of front grill when they will be
manufactured.
 Cost of the project is minimized, by using pattern material as thermocol. Thermocol
is the material which melts easily in casting process. Allowance is taken as minimum
range.

1.4 Methodology
Total three dies are to be manufactured since sheet metal working operation cannot
be produced on single process. Because in single process the stresses produced are
higher and leads to reduced life and early failure of product.

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1.4.1 Processes:

 Work Order no.4077,4078,4079  Pre fitting.

 Design Release.  CNC Machining.
 Pattern Making.  Spotting.
 Casting.  Heat Treatment.
 Raw Material.  Fitting.
 Standard Material.  Die Ready For Tryout.

Fig. no: 1.8 - Forming

Fig. no: 1.9 – Piercing

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 Fig. no: 1.10 - Blanking

1.4.2 Pattern making:

A pattern is a model or the replica of the object (to be casted). It is embedded in

moulding sand and suitable ramming of moulding sand around the pattern is made.
Pattern can be said as a model or the replica of the object to be cast except for the various
al1owances a pattern exactly resembles the casting to be made. It may be defined as a
model or form around which sand is packed to give rise to a cavity known as mold cavity
in which when molten metal is poured, the result is the cast object.
An error in dimension or design, not easily seen on a drawing, becomes apparent when
the pattern is taking shape. The patternmaker is thus very often responsible for alteration
in design to suit drawing office errors, and also to improve the mouldability of a casting.
Although a casting of difficult design can be made successfully under strict supervision,
such close attention may not be available when a repeat of the casting is required; this
results in dissatisfaction. There is also the designer's weakness for artistic lines and
curves, due to his unfamiliarity with manufacturing methods. Considerable expense in
pattern construction is often incurred this way. [5]
A pattern prepares a mold cavity for the purpose of making a casting. Runner, gates and
risers used for introducing and feeding molten metal to the mold cavity may sometimes
form the parts of the pattern. The first step in casting is pattern making. The pattern is a
made of suitable material and is used for making cavity called mould in molding sand or

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other suitable mould materials. When this mould is filled with molten metal and it is
allowed to solidify, it forms a reproduction of the, pattern which is known as casting. [8]

Fig: 1.11 - Upper punch die

Fig: 1.12 - Lower punch die

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 Fig. no: 1.13 – Thermocol Patterns

The following factors affect the choice of a pattern:

1. Number of Castings to be produced.
2. Size and complexity of the shape and size of casting.
3. Type of molding and castings method to be used.
4. Machining operation.
5. Characteristics of castings.

1.4.3 Casting processes can be classified into following four categories:

A. Conventional Molding Processes
1. Green Sand Molding
2. Dry Sand Molding
3. Flask less Molding

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B. Chemical Sand Molding Processes
1. Shell Molding
2. Sodium Silicate Molding
3. No-Bake Molding

C. Permanent Mold Processes

1. Gravity Die casting
2. Low and High Pressure Die Casting

D. Special Casting Processes

1. Lost Wax
2. Ceramics Shell Molding
3. Evaporative Pattern Casting
4. Vacuum Sealed Molding
5. Centrifugal Casting

E. Green Sand Molding

Green sand is the most diversified molding method used in metal casting operations.
The process utilizes mold made of compressed or compacted moist sand. The term
“green” denotes the presence of moisture in the molding sand. The mold material consists
of silica sand mixed with a suitable bonding agent (usually clay) and moisture.

 Advantages
1. Most metals can be cast by this method.
2. Pattern costs and material costs are relatively low.
3. No Limitation with respect to size of casting and type of metal or alloy used.

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 Disadvantages
Surface Finish of the castings obtained by this process is not good and machining is
often required to achieve the finished product.

F. Sand Mold Making Procedure

The procedure for making mold of a cast iron wheel is shown in figure.
 The first step in making mold is to place the pattern on the molding board.
 The drag is placed on the board.
 Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.
 Molding sand is then riddled in to cover the pattern with the fingers; then the drag is
completely filled.
 The sand is then firmly packed in the drag by means of hand rammers. The ramming
must be proper i.e. it must neither be too hard or soft.
 After the ramming is over, the excess sand is leveled off with a straight bar known as a
strike rod.
 With the help of vent rod, vent holes are made in the drag to the full depth of the flask
as well as to the pattern to facilitate the removal of gases during pouring and
solidification.
 The finished drag flask is now rolled over to the bottom board exposing the pattern.
 Cope half of the pattern is then placed over the drag pattern with the help of locating
pins. The cope flask on the drag is located aligning again with the help of pins
 The dry parting sand is sprinkled all over the drag and on the pattern.
 A sprue pin for making the sprue passage is located at a small distance from the
pattern. Also, riser pin, if required, is placed at an appropriate place.
 The operation of filling, ramming and venting of the cope proceed in the same manner
as performed in the drag.
 The sprue and riser pins are removed first and a pouring basin is scooped out at the top
to pour the liquid metal. [9]

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 Then pattern from the cope and drag is removed and facing sand in the form of paste is
applied all over the mold cavity and runners which would give the finished casting a
good surface finish.
 The mold is now assembled. The mold now is ready for pouring. [4]

Fig. no: 1.14 – Sand Moulding Process

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G. Cleaning of Castings
After the solidification of the casting, the mould is knocked out and solidified
casting is taken out of the moulding sand. At this juncture the cast product is attached
with risers, and gates. Many times the moulding sand also get adhered to the casting as
some of the sand gets fused with the molten metal. The cleaning of castings refers to the
removal of gates, risers and sand. Also, cleaning may involve machining or abrasive
finishing of the cast product. The cleaning operations usually performed on a casting are
given below:
1. Removal of gates, in-gates, riser, feeder etc.
2. Surface cleaning
3. Trimming
4. Finishing

H. Removal of gates, in-gates, riser, feeder etc.

There are various methods of removal of unwanted metallic parts from the solidified
cast product. In case of brittle material, the gates, risers, and feeder can be removed by
impact force. this is usually done in shakeout or knock out devices. Other processes that
may be used to cut off the metallic parts include, band saws, grinding machine, shearing
machine, cutting torches, etc. [8]

I. Surface cleaning
As the temperature of molten metal is usually high, sand particles near the surface of
the casting gets fused and adheres to the surface of the casting. the cleaning of the
surfaces both interior and exterior thus becomes necessary. There exist several methods
to remove the adhered sand from the castings. Some of the most common methods of
removal of sand are tumbling, and sand or metallic shot blasting. Tumbling is done in a
barrel like machine called as tumbling mill which helps to remove the sand by rubbing
action of the cast parts with each other. Whereas, in blasting, abrasive particles are
thrown on the surface of the casting in a carrying medium. Air is the most common
medium used in this process. Sometimes, metallic shots are thrown on the surface of the

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castings to remove the unwanted material. Blasting processes include air blasting,
centrifugal blasting, hydro-blasting etc. Other methods to clean the cast surface include
wire brushing, and buffing.

J. Trimming
Trimming operations involves the removal of fins, gates and risers appendages,
metallic chaplets, etc. These unwanted material is removed by using hammer and chisel
called as chipping process, or by pneumatic chipping hammers or by the use of grinders.

K. Finishing
The finishing at this stage refers to the final cleaning. The castings after the
removal of gates, risers, fins, chaplets, adhered sand is washed and then depending upon
the requirements of the end product final finish is provided by machining, polishing,
buffing, chemical treatment etc.

L. Inspection of Castings
Inspection of castings is done to ascertain various characteristics. Generally the
inspection of castings is carried out to ascertain the required surface finish, dimensional
accuracy, various mechanical and metallurgical properties and soundness. Various tests
used for inspection of castings are:
1. Measurement of the final dimensions
2. Measurement of Surface finish
3. Destructive testing
4. Non-destructive testing

M. Measurement of the final dimensions

The casting dimension can be measured through various calipers or gauges. The
final dimension obtained is compared with the design dimension and dimensional
accuracy can be calculated.

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N. Measurement of surface finish
The surface finish of a casting can be measured by perthometer, roughness tester,
and by using profilo-meter. Usually Root mean square values are measured.

O. Destructive testing
As the name of the test suggests destructive, the casting sample is prepared after
cutting the final casting such types of tests are required to measure mechanical and
metallurgical properties of the product. Mechanical tests include tensile strength
measurement, toughness measurement, and hardness measurement. Metallurgical tests
include dendrite arms spacing, type of structure obtained, and shrinkage cavities.

P. Non-Destructive testing
The various methods employed in this category of test are:
1. Visual inspection: is carried out to check the final appearance of the casting. Major
cracks, swells, tears etc. may be detected by this method.
2. Radiographic inspection: radiography is used to identify and measure the internal
defects in the casting. Generally X-rays are used to identify the internal defects in
castings.
3. Magnetic particle inspection: this test is not applicable to non-ferrous alloys. This test
is conducted to determine and locate the structural discontinuity and subsurface defects in
castings.
4. Pressure testing: It is employed to locate leaks in a casting or to check the overall
strength of a casting in resistance to bursting under hydraulic pressure. It is carried out on
tubes and pipes.
5. Fluorescent penetrates: the fluorescent penetrate is sued to locate the minute’s pores
and cracks in the final castings. [8]

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1.4.4 MACHINNING:

(A) 2D MACHINING:
When casting procurement is done in the machine shop the next process is to
finish the casting to final dimension. Generally the allowance of 10mm is given on each
side. Therefore proper machining should be ensured in order to develop a good die. For a
die its base is of utmost important as it is going to be stalled on press.Where the stamping
will be ensured correct only when it will be correctly mounted. Also the next machining
operation followed will be correct if die base is correct as of every next process will use
base as reference. In die manufacturing for machining base is to be taken as reference
datum, hence it is machined first. As casting involves various allowances, it might have
errors in heights so the bed height is adjusted by adjusting its four corner on the bed. The
bed height is ensured to be correct. Error once accumulated will lead to error in whole
die. For 2D machining the die is stalled over the RAMBAUDI CNC MACHINE as
shown in below fig.

Fig. no: 1.15– Base Machining

Once the bed is machined through milling machine it is reversed and horizontal and
vertical faces are machined. Faces are now machined as this process is carried out in

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either horizontal or vertical plane since known as 2D machining.3D machining is when
surfaces are cut which lie on different planes and which may be other than the three
major planes of the milling machine. 3D machining requires all three axes of the mill to
be able to move simultaneously. Depending on the profile required, slot drills, bull nose
or ball ended cutters are used for 3D finish machining. Slot drills or end mills can be used
for roughing. Manual creation of NC code for 3D machining is not a realistic option. The
mathematics involved is formidable and a code listing is likely to have many tens of
thousands of lines. 3D machining can take a very long time even on fast, modern
machines and especially if a high quality finish is required. A ball-ended cutter leaves
parallel rows of cusps over the cut surfaces. To reduce the height of these cusps, the
parallel passes of the tool must be closer together. If the distance between passes is
halved, the machining time doubles. The diameter of the ball ended cutter comes into the
equation too: the smaller the diameter, the greater the number of tool passes. 3D
machining takes much longer machining time than 2D machining: it can easily run into
hours. For this reason it is a good idea to machine materials where high feed rates can be
used: for example, high density closed cell rigid modeling foam or modeling wax.
However, the highest feed rates do not give the shortest machining time. This is because
acceleration/deceleration control is applied to machine movements. [11]

Fig. no: 1.16 - After base machining

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(B) 3D MACHINING:

3D machining is when surfaces are cut which lie on different planes and which
may be other than the three major planes of the milling machine. 3D machining requires
all three axes of the mill to be able to move simultaneously. Depending on the profile
required, slot drills, bull nose or ball ended cutters are used for 3D finish machining. Slot
drills or end mills can be used for roughing. Manual creation of NC code for 3D
machining is not a realistic option. The mathematics involved is formidable and a code
listing is likely to have many tens of thousands of lines. 3D machining can take a very
long time even on fast, modern machines and especially if a high quality finish is
required. A ball-ended cutter leaves parallel rows of cusps over the cut surfaces. To
reduce the height of these cusps, the parallel passes of the tool must be closer together. If
the distance between passes is halved, the machining time doubles. The diameter of the
ball ended cutter comes into the equation too: the smaller the diameter, the greater the
number of tool passes. 3D machining takes much longer machining time than 2D
machining: it can easily run into hours. For this reason it is a good idea to machine
materials where high feed rates can be used: for example, high density closed cell rigid
modeling foam or modeling wax. However, the highest feed rates do not give the shortest
machining time.
This is because acceleration/deceleration control is applied to machine movements. [12]

Fig.no.1.17-3D profile machining

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 1.5 Organization of Dissertation
The work of the system will be carried out according to the following chart:
Table no. 1.3-Gantt Chart for the system.

Work July Aug Sept Oct Nov Dec Jan Feb Mar

System Approval

Allotment Letter
from the company

Company's
Sponsorship Letter

Literature Survey

Final Design,
Modeling and
Checking

Pattern Checking

Raw Material

Manufacturing

CNC Machining

Die Ready for Try

out

Final Report

Final Submission

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 2. Literature Review
1. Arash Behrouzi et al. had discussed Shape error due to elastic recovery of formed part
in unloading known as spring back, is one of the most important problems of tool design
in sheet metal forming processes. Many researches have been performed for proposing an
efficient method to decrease or compensate spring back error in sheet forming processes.

2. J. S. Colton et al. had discussed the demand for rapid, low-cost die fabrication and
Modification technology is greater than ever in the sheet metal forming industry. One
category of rapid tooling technology involves the use of advanced polymers and
composite materials to fabricate metal forming dies. In addition because the mechanisms
by which they fail are not fully understood, the dies are designed on the basis of
experience and intuition. This study investigates the failure of V-bending dies fabricated
from an easy-to-machine, polyurethane based, composite board stock Based on the
mechanical behavior of the die material, several failure criteria are proposed to predict
die failure mode and the corresponding die life

3. Peter Kostka et al. discussed the ability to predict different process Conditions in deep
drawing is essential for die face designers, tooling stamping & manufacturing engineers.
These predictions in turn affect the speed, accuracy and cost of the final produced
product. This paper briefly discusses the possibilities of controlling the blank holding
pressure distribution and shows some computer simulations done in DYNAFORM, with
the result being experimentally verified with tooling designed by the authors.

4. Radha Krishna Lal et. al 2017, studied the effect of ratio of die radius and thickness of
the sheet. Ratio of the die radius and thickness of the sheet verses spring back angle, are
plotted as shown in the figure. It is seen that after certain level the spring back effect
increases as the R/t ratio increases. In order to investigate the effect of die radius and
blank thickness on the spring back angle of flanging process, the following strategy was
employed. Two groups of FE simulation models are generated with the Identical R/t ratio
that range between 1.0 and 5.0.

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 Fig.no:1.18-Graph for spring back angle to R/t
5. Y. Marumo et al. has carried out the study regarding variation in the blank holding
force required for the elimination of wrinkling and the limiting drawing ratio with sheet
thickness. They found that blank holding force required for the elimination of wrinkling
increased rapidly as the sheet thickness decreased. When the sheet thickness was very
thin, the blank holding force was strongly influenced by the coefficient of friction. The
limiting drawing ratio decreased as sheet thickness decreased and it decreased rapidly
below 0.04 mm thickness. When the sheet thickness was very thin, the limiting drawing
ratio was strongly influenced by the coefficient of friction.

6. M. Ahmetoglu et al. have carried out the study of effect of process parameters such as
initial blank shape and the blank holding force on the final part quality (i.e., wrinkling
and fracture). During the initial experiments, it was found that the oval blank shape had
the worst formability, from a fracture point of view, among the three blank shapes (i.e.,
oval, oblong, and rectangle). The oval shape reduced the fracture limit of AA 2008-T4.
However, it caused smaller wrinkling heights in the flange along the sides of the
rectangular pan. Control of the (BHF) as a function of time improves the formability and
the quality of the final part. However, BHF control in time is not enough by itself. Since
the deformation characteristics are not uniform around the periphery of the rectangle, the
BHF has to be controlled as a function of location, too. Metal flow can be controlled by
using draw beads on the sides of the rectangle.

7.C.M. Choudhari et al 2013, have indicated that one of the reasons is the complex
casting process; the other isthe lack of theoretical guidance. In view of the reasons above,

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27
the current casting process is usually designedaccording to the designers' experience and
intuition. This has inevitably led to repetitions and readjustments inpractice, thus giving
rise to more scraps and higher cost.

8. B. E. Narkhede et al 2014, hav indicated The solidification of metals continues to be a

phenomenon of great interest to physicists, metallurgists, casting engineers andsoftware
developers. It directly affects the production cycle time, internal quality of castings and
material utilization (yield). Theprocess of casting solidification is complex in nature and
the simulation of such process is required in industry before it isactually undertaken. The
volumetric contraction accompanying solidification of molten metal manifests in defects
like shrinkagecavity, porosity, and sink. The simulations results were compared with the
experimental trial and the comparison was found to be ingood agreement.

9.Vishal Naranje et. al 2012 Cost estimation of sheet metal parts is a complex and time
consuming task that requires a great deal ofknowledge and experience. In today’s
competitive environment, early and accurate cost estimation has become vital for taking
important decisions such as material selection, production processes and mainly
morphological characteristics of the product.

10. Rashmi Dwivedi et. al 2016 Deep drawing is a common sheet metal forming process
used to manufacture complicated 3-D parts from thin sheet metals.In many industries,
Deep Drawing is a very important metal forming process. Deep drawing is complex
deformation affected by the geometrical and process parameters. Deep drawing process
optimization is a challenging task. This paper presents a review on the deep drawing
parameters and identifies directions for future research and the results of present study
were showing the successfully produced aluminium alloys cup.

11. Vinod Laxman Hattalli et. al 2016 This paper aims at scattering light on the recent
research and developments in the sheet metal forming processes over the last two
decades. Most of the literature available on sheet metal forming focuses on the

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parameters that influence the quality and economic factor of the final product. The
influence of process parameters based on geometry such as punch nose radius, blank
temperature, and blank holding force, tooling dimensions, blank thickness and punch
depth is significant. Similarly, the parameters based on the material properties like elastic
strength, yield strength, plasticity and anisotropy have as much influence as the geometry
based parameters. The literature raises the issue of defects in the formed parts.

12. Shailendra Kumar et. al 2007, The present paper describes an intelligent system
AUTOPROMOD developed for automatic modeling of progressive die. The proposed
system utilizes interfacing of AutoCAD and AutoLISP for automatic modeling of die
components and die assembly. The system comprises eight modules, namely DBMOD,
STRPRMOD, BPMOD, PPMOD, BBDSMOD, TBDSMOD, BDAMOD and TDAMOD.
The system modules work in tandem with knowledge-based system (KBS) modules
developed for design of progressive die components. The system allows the user firstly to
modelthe strip-layout and then utilizes output data files generated during the execution of
KBS modules of die components for automatic modelingof progressive die. An
illustrative example is included to demonstrate the usefulness of the proposed system.
System modules are implementable on a PC having AutoCAD software and thus its low
cost of implementation makes it affordable for small and medium sized stamping
industries.

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 3. Materials
 EDD(Extra Deep Drawing)-
EDDS is produced from vacuum degassed steel to achieve a very low-carbon
content. It is chemically stabilized with elements such as titanium and niobium
(columbium) during production to combine the remaining residual amounts of carbon and
nitrogen to make it "interstitial-free." Excellent uniformity and exceptional formability
characterize coated and uncoated sheet of this quality. The final product is excellent for
deep drawn parts in that the sheet exhibits a high resistance to thinning during drawing.
EDDS sheet is non-aging, thus coil breaks, strain lines and fluting during fabrication are
not encountered. [6]

 Weldability – Low-carbon level makes this a good welding candidate.

 Fatigue Performance – Relatively low yield, compared to other steels, makes this grade
more susceptible to fatigue than higher strength steels.

Denting – Relatively low yield strength, compared to other steels, may make EDDS more
susceptible to denting. For additional capabilities, please check our dent resistant steel.
 Applications – EDDS is used in applications where severe forming characteristics are
required. EDDS is typically found in door inners, dash panels, body side inners and floor
pans with spare tire tubs.

 GREY IRON CASTINGS – Gr: FG 260

This specification governs the quality requirements of Grey Iron Castings having a tensile
strength of 260 N/mm2.
 Grey Cast Iron (Gray iron) is so called because of the colour of the fracture face. It
contains 1.5-4.3% carbon and 0.3-5% silicon plus manganese, sulphur and phosphorus. It
is brittle with low tensile strength, but is easy to cast.

 Application: Suitable for general engineering purposes.

 Manufacture: The castings shall be cast from the metal melted or refined in any suitable
metallurgical plant other than an iron ore smelting furnace. All castings above five tonnes

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 shall be mould cooled. Under mould cooling process, the mould should not be disturbed
until the hottest portion of the casting cools down to 300*c.
 Heat Treatment: Castings shall be artificially aged (stress relieving) by heating in a
furnace to a temperature of 520 to 580*C (recommended), whenever specified. Test
pieces shall also be heat treated along with the castings they represent.
 Finish: All castings shall be properly fettled and dressed and all surfaces shall be
thoroughly cleaned. Whenever specified, the machined surfaces shall have the surface
finish as indicated in the drawing.
 Freedom From Defects: Castings shall sound, clean, free from defects such as porosity,
blow holes, sand inclusions, shrinkage’s, cavities, hard spots, cold shuts, cracks, etc.
which may adversely affect machining and utility of castings.
 Chemical Composition: The composition of iron is left to the discretion of the
manufacturer. (But limit of sulphur and phosphorus may be specified by BHEL, if
desired). In case of special castings, the detailed chemical composition shall be as agreed
between BHEL and the manufacturer.
 Mechanical Properties
 Tensile: The test pieces prepared in accordance with clause 11 shall show a tensile
strength of 260 N/mm2, minimum, when tested in accordance with IS:1608.
 Hardness (Brinell): Hardness shall be measured on actual casting at three different places.
The castings shall have a Brinell Hardness in the range of 180 to 230 HB, when tested in
accordance with IS 1500.

 MS(Mild Steel)-
 Mild steel is the most commonly used steel. It is used in the industries as well in the
different everyday objects we use. Even the pans and spoons of the kitchen are
sometimes made of mild steel. The main target of this article is to discuss about
different mild steel properties. The mild steel is very important in the manufacturing of
metal items. Almost 90% steel products of the world is made up of mild steel because it
is the cheapest form of steel. [6]

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 Mild steel is the most widely used steel which is not brittle and cheap in price. Mild steel
is not readily tempered or hardened but possesses enough strength.
carbon 0.16 to 0.18 % (maximum 0.25% is allowable)
Manganese 0.70 to 0.90 %
Silicon maximum 0.40%
Sulphur maximum 0.04%
Phosphorous maximum 0.04%
 Mildest grade of carbon steel or mild steel contains a very low amount of carbon - 0.05 to
0.26%

 EN8
 Applications: Automotive parts, Connecting rods, Studs, bolts, Axles, spindles, General
engineering components.
 Product Description: EN8 is an unalloyed medium carbon steel which is used in
applications where better properties than mild steel are required but where the costs do
not justify the purchase of a steel alloy. EN8 can be heat treated to provide a good surface
hardness and moderate wear resistance by flame or induction hardening processes. From
the automotive trade to wider general engineering applications, EN8 is popular steel in
industry.
Table no: 3.2- EN8 Chemical Composition (weight %)

C Si Mn P S
MIN 0.36 0.10 0.60
MAX 0.44 0.40 1.00 0.05 0.05

 Key features:
 Unalloyed medium carbon steel
 Reasonable tensile strength
 Can be flame or induction hardened
 Readily machinable
 Moderate wear resistance if heat treated

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 Availability :
 Round bar, square bar, hexagon and plate
 Engineering Steel
 Machinability:
 Good
 Weld ability:
 Heat treatment required if over 18mm to prevent cracking.
 Mechanical Properties (in "R" condition):
 Max Stress 700-850 n/mm2
 Yield Stress 465 n/mm2 Min (up to 19mm LRS)
 0.2% Proof Stress 450 n/mm2 Min (up to 19mm LRS)
 Elongation 16% Min (12% if cold drawn)
 Impact KCV 28 Joules Min (up to 19mm LRS
 Hardness 201-255 Brinell

 40Cr4

The 40Cr4 is alloy steel has a wide uses in engineering industry because of his geometric
properties, such as resistance corrosion, high flexibility, appropriate hardness, and its
ability to tolerate static and dynamic loads. And it is a very suitable in domestic uses and
in manufacturing some of automotive parts and in many engineering applications. In this
research a sample of 40Cr4 was selected, where heat treatment (Hardening and
Tempering) was carried out for him, this process was carried out at (870, 890) 0C
respectively, after that tempering process was carried out at 580 so as to remove the
internal stresses and to prevent carbides precipitation which occurs at a temperature of
(450-800) 0C for the 40Cr4 steel, also mechanical tests were carried out, which is MPI
and hardness tests using Brinell method, This paper also include the theoretical and
experimental research on heat treatment process carried out in industry in order to
improve mechanical property of 40Cr4. In general the experimental results showed that
the heat treatment leads to improve the mechanical properties such as tensile strength,

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 toughness, and hardness the best cases appeared at 880 0C.

 40Cr4 is an alloy steel consisting of an average amount of carbon 0.35-0.45%, Silicon

0.10-0.35%, Manganese 0.6-0.9%, Chromium 0.9-1.2%. It is most widely used as a
material for automobile component in industry as it possess the better mechanical
property such as high tensile strength, toughness, ductility and hardness. Heat treatments
or thermal treatment is heating processes usually takes place on 40Cr4 and keep them at a
constant temperature for an appropriate period of time depends to bring change to the
internal structure followed by a change in the natural and mechanical properties.
Required mechanical property of 40Cr4 is achieved by carrying an hardening heat
treatment (at 8900) process followed by tempering(at 5700) on 40Cr4.

 Hardening
 In this process, 40Cr4 is heated to a temperature higher than the upper critical
temperature heat and cooled
by water or oil or any convenient liquid, where the resulting a single phase solution
consists of a complex
Carbides such chromium carbide and iron carbide andmanganese carbide, this can lead to
form a supersaturated
solution, which will the saturated excessive carbon atoms be dissolved in the solution due
to the rapid cooling,
which will make crystal structure have a centred body prism-shaped (BCT).

 Tempering
 Where heating to lower than critical temperature is carried out and before austenite
reformation to allow again redeployment. This paper deals with heat treatments for a
40Cr4 alloy steel, which is carried out by heating it to temperature above upper critical
temperature and stay at this temperature for specified period of time, and then cooling it
by direct air, then process of tempering is carried out at 580 0C in order to remove
internal stresses. Heat treatments aim is to change the mechanical and physical properties

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 of metal, where soft stainless steel presence for example does not withstand stresses and
does not resist the wear by friction. Processes of Hardening and Tempering where used
and Normalising and annealing have been eliminated, that is because the alloying
additions and cooling rate in 40Cr4 steel lead to increase in BHN along with that also
increase the mechanical properties.

Table no: 3.3 - 40Cr4 chemical composition

Designation C Si Mn Cr

40Cr4 0.35-0.45 0.10-0.35 0.6-0.9 0.90-1.2

 D2
D2 steel is an air hardening, high-carbon, high-chromium tool steel. It has high wear and
abrasion resistant properties. It is heat treatable and will offer hardness in the range 55-62
HRC, and is machinable in the annealed condition. D2 steel shows little distortion on
correct hardening. D2 steel’s high chromium content gives it mild corrosion resisting
properties in the hardened condition.
If you need better machinability then consider A2 tool steel which has a chromium
content of 5% and is more readily machinable.

 Applications for D2 Steel:

Stamping or Forming Dies, Punches, Forming Rolls, Knives, slitters, shear blades, Tools
Scrap choppers, Tyre shredder

 Forging: Heat slowly and uniformly to 700°C then more rapidly to 900/1040°C. Do not
continue to forge D2 below 925°C. Reheat as often as necessary to maintain proper
forging temperature. After forging cool slowly. This is not an annealing process. After
the forging is cold, it must be annealed as described below.

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 Annealing: Heat uniformly to 843/871°C, then slow furnace cool at a rate of not more
than 10°C per hour. After annealing D2 a maximum hardness of 240 Brinell may be
achieved
 Hardening: D2 tool steel is extremely sensitive to overheating during hardening – do not
overheat.
Pre heat slowly to 750/780°C and soak. Continue heating to the final hardening
temperature of 1000/1030°C and allow the component to equalise. Quench in oil or cool
in air.
 Tempering: Heat uniformly and thoroughly to the desired temperature and hold for 25
minutes per cm of thickness. D2 can be double tempering at approximately 15°C below
the first tempering, after intermediate cooling to room temperature.

Table no: 3.4 - D2 Chemical composition

C Si Cr Mo V
1.50% 0.30% 12.00% 0.80% 0.90%

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 4. Calculation:

4.1 Bending force:

𝑲𝑳𝑺𝒕𝟐
F=
𝑾

Where,

F=Bending force

K= 1.2 (16 times metal thickness die opening)

L= Length (bending part)

S= Ultimate tensile strength (EDD)

t= thickness

W= width between contact points on die

𝟏.𝟐×𝟓𝟐𝟎×𝟑𝟓𝟒×𝟏𝟐
F=
𝟒𝟖𝟎

∴ F= 480 KN

4.2 Drawing force:

𝑫
P= 𝝅𝒅𝒕(𝑼𝑻𝑺)( − 𝑪)
𝒅

P= drawing pressure

d= Shell outer diameter

PCET’s- Nutan Maharashtra Institute of Engineering & Technology, B.E. (Mechanical)

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D= blank diameter=√𝑑2 + 4𝑑ℎ

t= Thickness

UTS= Ultimate tensile strength

C= Constant to cover friction and bending (0.6 to 0.7 for ductile material)

518.54
P=𝜋 ×480× 1 × 354 × ( − 0.7)
480

P= 202.96 KN

4.3 Cutting force:

𝑷=𝒕×𝑳×𝑺

P= Cutting force

t= thickness

L= length

S= Shear strength of material

For Blanking –

𝑃 =𝑡×𝐿×𝑆

𝑃 = 1 × 520 × 2.977

P=1548.04 KN

PCET’s- Nutan Maharashtra Institute of Engineering & Technology, B.E. (Mechanical)

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For Piercing –

𝑃 =𝑡×𝐿×𝑆

Here, L=perimeter

𝑃 = 1 × 15.70 × 2.977

P=46.73 KN

∴ For two holes

𝑃 = 46.73 × 2

P=93.477 KN

[13]

PCET’s- Nutan Maharashtra Institute of Engineering & Technology, B.E. (Mechanical)

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 5.Designs

1. Blanking Die

Fig.no:1.19 Blanking die (4077)

PCET’s- Nutan Maharashtra Institute of Engineering & Technology, B.E. (Mechanical)

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2. Forming Die

Fig.no:1.20 Forming die(4078)

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3. Piercing Die

Fig.no:1.21 Piercing die(4079)

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 6.Summary

We studied in this project:

1. We referred various research paper as per in literature review.

2. Methodology and plan of action.

3. Approximate time required for development of the part use in the project.

4. Process sheet.

5. Approximate cost report.

6. Calculation for the various components used in this project.

7. Mechanism used in this project and its calculation.

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 7. References

1. A Behrouzi, B M Dariani*, and M Shakeri – “A new approach for inverse analysis of

springback in a sheet-bending process ” Department of Mechanical Engineering,
Amirkabir University of Technology, Tehran, Iran The manuscript was received on 12
April 2008 and was accepted after revision for publication on 31 July 2008.

2. Y. Park Graduate Research Assistant J. S. Colton Professor-“Sheet Metal Forming

Using Polymer Composite Rapid Prototype Tooling” Fellow ASME The George W.
Woodruff School of Mechanical Engineering, Georgia Institute of Technology Oct 2015.

3.Peter Kostka, Peter Cekan –“Computer simulated & experimental verification of tolling
for progressive deep drawing” university of technology in Bratislva .

4. Radha Krishna Lal, Vikas Kumar Choubey, J. P. Dwivedi & Shravan Kumar –“Study
of factors affecting Springback in Sheet Metal Forming and Deep Drawing Process”
Department of Mechanical Engineering, Madan Mohan Malaviya University of
Technology, ICMPC 2017.

5. Y. Marumo*, H. Saiki, L Ruan-“Effect of sheet thickness on deep drawing of metal

foils” Department of Mechanical Systems Engineering, Kumamoto University, 2-39-1,
Kurokami Kumamoto, 860-8555, Japan,Oct 2007.

6. Prakash Sonis, N. Venkata Reddy, G. K. Lal –“On Multistage Deep Drawing of

Axisymmetric Components” Department of Mechanical Engineering, Indian Institute of
Technology, Kanpur, India Oct 2015.

7. C. M. Choudhari, B. E. Narkhede, S. K. Mahajan- “Casting Design and Simulation of

Cover Plate using AutoCAST-X Software for Defect Minimization with Experimental
Validation” Department of Production Engineering, Veermata Jijabai Technological
Institute, Mumbai,400019 India Technical Education, Maharashtra State 2014.

8. C. M. Choudhari, B. E. Narkhede, S. K. Mahajan-“ Methoding and Simulation of LM

Sand Casting for Defect Minimization with its Experimental Validation” Department of

PCET’s- Nutan Maharashtra Institute of Engineering & Technology, B.E. (Mechanical)

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Production Engineering, Veermata Jijabai Technological Institute, Mumbai,400019 India
Technical Education, Maharashtra State 2014.

9. Vishal Naranje, Shailendra Kumar, H.M.A Hussein-“A Knowledge Based System for
Cost Estimation of Deep Drawn Parts” Assistant Professor, Department of Technology,
University of Pune, Ganeshkhind, Pune- 411007 2014.

10. Rashmi Dwivedi,Geeta Agnihotri – “Study of Deep Drawing Process Parameters”

Research Scholar, Maulana Azad National Institute of Technology, Bhopal, 462003,
India 2016.

11. Vinod Laxman Hattalli, Shivashankar R. Srivatsa-“ Sheet Metal Forming Processes –
Recent Technological Advances” Dept. of Mechanical Engineering, BMS College of
Engineering, Bull Temple Road, Bengaluru, 560019, INDIA 2016.

12. Shailendra Kumar, Rajender Singh –“ An intelligent system for automatic modeling
of progressive die” Department of Mechanical Engineering, Hindu College of
Engineering, Sonepat, Haryana, India Department of Mechanical Engineering, CRSCE,
Murthal, Haryana, IndiaReceived 12 July 2006; received in revised form 13 April
2007;accepted 16 April 2007.

13. Books(Calculations)

1. Tool design / Donaldson, Cyrll

2. Elements of workshop technology Vol.- I / Choudhury, Hajara S K

3. Elements of workshop technology Vol.- II / Choudhury, Hajara S K

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