Beruflich Dokumente
Kultur Dokumente
PROJECT REPORT ON
Die Maintenance Study and Chip-Dent Reduction
TraineePrakul Bansal
Details of the Trainee:Name of Trainee Fathers Name Date of Birth Course Name & Trade Name of Institute / Collage Session Name of Guide (if any) Referred by Permanent Address E mail Contact No. Previous project details (If any):Project Name Name of the Organization Duration Details related to current project:Project Name Dept. / Section Training Duration Die Maintenance Study and Chip-Dent Reduction Press Shop 8th June to 20th July Production of Goods Trucks and Buses Ashok Leyland, Alwar 1 month 3/530, KALA KUAN, ALWAR Grvchaudhary01@gmail.com +91-7206108388 GAURAV CHAUDHARY Mr. RAM GOPAL CHAUDHARY 01-08-1991 B.Tech, Mechanical Engineering NIT KURUKSHETRA 2012-13 Mr. Harsh Vardhan
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Acknowledgement
Gratitude is the hardest of emotions to express often one doesnt find adequate words to convey the feeling of gratefulness. There were many people whom I would like to thank for their support. I sincerely feel that credit of this work could not be narrowed down to any one individual, by which I have achieved its completion. Words will not suffice to express my deepest feeling of sincerest gratitude to my revered Mentor Mr. Harsh Vardhan for his guidance, constructive criticism and inspiring attitude resulting in the successful completion of my Project. Some persons certainly have more capacity to help others and I should not loose any opportunity to extend my feeling of profound gratitude to Mr. Rakesh, Mr. Dipin, Mr. Mandeep, Mr. Puneet, Mr. Deepak, Mr. Abhishek, Mr. Shiv Narayan for unstinted encouragement which inspired me to do better. I wish to acknowledge the sincere co-operation and moral support rendered to me by HR Department. In the end it would not be out of place to express sincere thanks to my Parents for their moral support and encouragement.
(__________) Dated
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This is to certify that GAURAV CHAUDHARY a student of National Institute of Technology, Kurukshetra has undertaken a summer training project on Die Maintenance Study and Chip-Dent Reduction under my guidance and mentorship. I assure all the contents, research work, analysis, and interpretations are genuine attempt on her/his part. This is also to certify that this project is neither submitted nor published else where.
I have ensured that this summer training report does not contain any information which will be detrimental to the interest of the company.
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Table of Contents
Sr. 1. 2. 3. Company profile Executive Summary Project 1:- Study of Die Maintenance a. Background of project work Repair Tools and Use of Standard Hand b. Tools c. Remedy Procedures for Press Die d. Die Design 4. Project 2:- Chip-Dent Reduction a. Background of project work b. Problem identification c. Situation analysis using 7 QC tools d. Countermeasure proposal 59-60 61-64 65 66 23-31 32-40 41-50 51-58 Description Page No. 6-15 16-22
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HONDA PRODUCTS
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HSCI PRODUCTS
Updated as on 2010
The driving force behind Hondas growth was the leadership of its founders Mr. Soichiro Honda and Mr. Takeo Fujisawa. philosophy. The most valuable legacy which our founders gave to our company is Honda This Honda Philosophy will continue to serve as the basis of our daily business action and judgment for all companies and associates within the Honda Group. It is critical that Honda Philosophy be fully understood, respected, shared and translated into action by every Honda associate around the world. HONDA PHILOSPHY The Honda Philosophy expressed in this illustration shows the Company Principle, Management Policies and the Honda Way based upon the fundamental beliefs of Respect for the Individual and The Three Joys :
COMPAN Y
COMPANY PRINCIPLES PRINCIPL
ES
Initiativ e
All associates are encouraged to take initiative while understanding that they must take responsibility for the results of those actions
Equalit y
Trust
The relationship among associates at HSCI to be based on mutual trust
All associates are treated fairly and equal opportunities given to each individual.
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MANAGEMENT POLICIES
anagement Policies
Company standards for carrying out Daily Operations are based upon the
Proceed always with ambition and youthfulness. Respect sound theory, develop fresh ideas and make the most effective use of time. Enjoy work, and encourage open communications. Strive constantly for a harmonious flow of work. Be ever mindful of the value of research and endeavor.
5S
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KAIZEN
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The companys product range includes Honda Jazz, Honda City, Honda Civic and Honda Accord which are produced at the Greater Noida facility with an indigenization level of 77%, 76%, 74% and 28% respectively. The CR-V is imported from Japan as Completely Built Units. Hondas models are strongly associated with advanced design and technology, apart from its established qualities of durability, reliability and fuelefficiency.
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GREEN PLANT
The new plant is modeled on the lines of Hondas latest global plants with great emphasis on environment protection and safety. Zero Discharge Plant
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Plantation of 20,000 trees in 1st year. Maximum usage on Natural Lighting for energy saving and healthy environment.
ASSOSIATES
The new plant employed 250 associates in the starting which has reached up to 700 in the present year.
SUPPLIERS CLUSTER
The suppliers cluster is spread over 150 acres having space for 8 critical and bulky part suppliers. Proximity to the HSCIs car plant and use of most updated techniques and features by these suppliers will make the overall process of car production more efficient.
PLC
RPSC supplies blanks as raw material as per PRT system controlled by Production Control Department. The blanks are stored and preserved press dept. end and loaded on the press line according to the plan. The blanks are processed in dies depending upon the number of operations and converted into parts. The parts are packed in trollies according to their packing standard after going through check on conveyer by online quality inspector. The repair parts are shifted to H/W area for repair and N/G parts put in red coloured scrap bin. The OK parts trollies are stocked at Trolley stock area. The PLC dept. receives the OK quality parts from trolley stock area according to dispatch plan. The parts are packed in PLC trollies from press production trollies according to their packing standard and delivered to GNU plant.
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Press dept. has sub dept. of Planning and Production, Quality Control, Machine Maintenance and Die Maintenance and New Model.
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Goggles
Ear Plugs
Nose Mask
Gloves
Arm Sleeves
Boot Cover
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Safety Shoes
2PS
2AP
3 10 12
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SRNO
1. 2. 3. 4. 5. 6. 7 8. 9.
Hood Skin Hood Frame Front Fender R/L Panel Roof Side Panel RH Side Panel LH Panel Rear Inside Front Floor Rear Floor
Hood Skin Hood Frame Front Fender R/L Panel Roof Side Panel RH Side Panel LH Panel Rear Inside
Rear Floor
10.
11.
12.
13.
14. 15.
DRAWING:
Drawing is a metal working process which uses tensile forces to stretch the sheet metal by which hollow shapes are formed.
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Die and punch are used in drawing operation. Drawing is usually done at room temperature, thus classified as a cold working process. The flow of material is controlled through pressure applied to the blank and lubrication applied to the die or the blank. If the form moves too easily, wrinkles will occur in the part. To correct this, more pressure or less lubrication is applied to the blank to limit the flow of material and cause the material to stretch or thin. If too much pressure is applied, the part will become too thin and break. Drawing metal is the science of finding the correct balance between wrinkles and breaking to achieve a successful part. Drawing leads to wrinkling and puckering at the edges where the sheet metal is clamped. This is usually removed by a separate trimming operation.
TRIMMING:
Trimming is the operation of cutting away excess metal in a flange or flash from a piece e.g. when holes are produced in a sheet manually, first circular blank is cut with a chisel and hammer. Then fine shapes are trimmed with the help of a sher or snip. This operation i.e. cutting by snip is called trimming.
There is no change in thickness. Good dimensional repeatability as well as close tolerances is possible with this process. Complex bending and re-strike operations can be accomplished using Cams in dies. Complicated flanges can be split in different operations.
Draw dies.
Trim and piercing dies, cam trim and pierce dies. Flange and Re-strike correction in forming dies. Blanking dies.
2. Preventive maintenance of dies Conducting weekly PM as per schedule Conducting monthly PM as per schedule Conducting yearly PM as per schedule
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Die opening procedure: Centralize the crane to the die centre Place all four noose of the crane rope in the rope slot of the top die. Lock the rope in the slot using die pins. Confirm that the die pins are locked rigidly Raise the crane hoist in inch mode. Once the top die is disengaged from the guide. Raise the hoist in rapid mode till there is a gap of ft between the die halves. Place the top die on the die cot wood. Do not place the die on floor without die cot wood.
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Die closing is a process of assembling the two halves of the die. Generally, the top die is assembled on the bottom die using a over head crane.
Die closing procedure: Centralize the crane centre to the top die centre Place all four noose of the crane rope in the rope slot of the top die. Lock the rope in the slot using die pins. Confirm that the die pins are locked rigidly Raise the crane hoist upto 2mt from ground level. Check the flow direction of the top and bottom dies are pointing towards same direction Move the top die to the center of the bottom die. Check if locators are hitting against the top die. Move the crane hoist down in inch mode till the gauides are engaged. Bring the hoist down till the distance block is touched. Remove the crane ropes from the slot
DIE WASHING
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Die Grinding
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Grinding is a highly skilled operation, where the required dimensions or form is achieved. It requires a tremendous amount of skill and concentration for grinding. Grinding is often a secondary or finishing operation. The quality of the ground surface depends on the selection of type of grinder and type of wheel. The next few pages illustrates how to finish a hexahedron block by grinding.
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Don'ts
Using damaged mounted wheels. Tighten the wheel with full force. Grind using undressed wheel. Blow off grinding dust using compressed air.
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Use
Finishing of counter and cutting edge. Finishing small counter, holes, cutting edges Rough finishing counter, cutting edge. Rough finishing small counter, cutting edge. Tightening and loosening socket bolts. Tightening and loosening socket bolts. Driving dowel pins, blocks, etc. Peening, Chisel, etc. Tightening ad loosening nuts. To replace offset Tightening, loosening cross recess screws. Tightening and loosening socket bolts. Holding, Gripping, cutting parts Cutting, chipping Tightening, loosening nuts Dowel pin pulling, driving Finishing contour Scribing lines General measurement Measuring clearances Measuring radius Tightening, loosening, socket bolts Holding, tightening, loosening round parts.. Clamping Parts Cutting steel, copper sheets
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Tap handle Die stock Flashlight Diamond file Dresser Oilstone Carbide cutter Emery paper Offset Emery wheel Buff Emery compound Copper Bar
Tapping holes Threading parts Working in dark areas Finishing hardened areas Dressing emery wheel Polishing contours, cutting edge Rough cutting with porter Polishing contours, general surface Rough cutting with angle grinder Finishing with porter Finishing with porter Rough polishing contour, general surface Die disassembly, driving large part
Description
Handling Pointers
Inspect and wear specified protective gears. Inspect conditions of tools. Set wrench fully into the bolt head Prevent over/under torquing
Cotton gloves
Do not use cracked tools or those worn in excess of 10% or oversize tools, check weld in the T handle. Use the proper size wrench and seat fully into the head. Check the weld of T handle wrench. Torque value will differ for bolt material and diameter.
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2. Tool Usage
3. Completion of operation
Check wrench for wear and crack. Clean and orderly arrange work area (especially oil) Refrain from using any damaged tools found.
4. Others
2. Tool Usage
Do not use gloves. Wear safety goggles if necessary. Do not use hammer with loose handle, missing wedge Do not use copper hammer with greater than 20% flared head Do not use hammer without an anti slip end. Do not use hammer with an oily hand.
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3. Completion of operation
Check condition of hammer head Replace or repair before using, or dispose. and handle. Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect and wear specified protective gears. Inspect conditions of tools. Prevent overtorquing or undertorquing . Check wrench for wear and crack. Clean and orderly arrange work area (especially oil)
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4. Others
Do not use wrench with worm opening(greater than 5%) or with cracks. Use proper tightening torque.
2. Tool Usage
3. Completion of operation
4. Others
Inspect and wear specified protective gears. Inspect conditions of tools. Do not hammer the screw driver. Check for loose handle. Check for cracked or chipped blade. Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect and wear
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Do not use tool with loose handle or with chipped, cracked, worn tip.
2. Tool Usage
3. Completion of operation
4. Others
specified protective gears. Inspect conditions of tools. 2. Tool Usage 3. Completion of operation Check for cracks, loose pin Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect and wear specified protective gears. Inspect conditions of tools. Caution for flying of broken chips. Check for cracks, loose pin Clean and orderly arrange work area.
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Do not use tool with excessively worn grip area or loose pin.
Wear cotton gloves and safety goggles. (However, do not wear gloves when using set chisel) Do not use tool with flared head, chipped or cracked point. Hardness of point shall be less than HRC 55.
4. Others
Inspect and wear specified protective gears. Inspect conditions of tools. When using the tool apply force in the direction of the adjusting slide. Do not use as a hammer. Check for cracks and looseness. Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect
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Do not use cracked tools or tool with loose adjusting screw or slide.
2. Tool Usage
3. Completion of operation
4. Others
Replace or dispose.
Pin Puller
Length of main unit shall be less than 300mm. Sliding weight hole diameter should be less than 15% of the diameter of the main unit slide. Flare of the main unit head section shall be less than 35%. Main unit and head shall be single piece. Normally, the pin screw end should not be welded.
2. Tool Usage
Caution, prevent pinching the finger. Check the condition of the pin puller welded bolt. Clean and orderly arrange work area. Refrain from using any damaged tools found. wear specified protective gears. Inspect conditions of
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3. Completion of operation
4. Others
tools. 2. Tool Usage Apply force only on the forward cutting strike. Work in a weld balanced attitude. When cutting edge becomes dull, clean the teeth with a wire brush. Check condition of handle and the crack stopper ring. Clean and orderly arrange work area. Refrain from using any damaged tools found.
hand which holds the tip. Do not use tool with loose handle or cracked handle.
3. Completion of operation
Wire brush
4. Others
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CAUSE
Blank holder pressure low Blank holder not level Blank holder not flat. Blank stock improperly positioned Blank holder pressure low Blank holder pressure too large Punch/Die radius too small
REMEDY
Adjust blank holder pressure Adjust blank holder Grind blank holder flat Adjust blank positioner Adjust blank holder pressure Adjust blank holder pressure Increase Die/Punch radius (observe part dimension) Adjust clearance C= t+ (2/10 6t/10) Adjust blank positioner Polish Adjust timing Defective stock
4.
Radial tear
Insufficient clearance between punch and die. Incorrect positioning of blank stock Scoring on the bead and die radius Incorrect slit timing Defective blank stock(work hardened) Defective blank stock Blank holder
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5. 6 Radial scratches Shiny spots on drawn surface 7. 8. 9. Drawn surface depression Inside scratches Streak depression along drawn surface (Starting mark)
pressure low due to unevenness Blank stock improperly positioned Scoring on the bead and die radius Insufficient clearance Improper shut height Improper die setup Excessive clearance
Polish Adjust clearance C=1.21.5t Adjust shut height Reset up Adjust clearance between punch and die. Polish Adjust die radius Polish Adjust bead (observe part) Adjust cushion Replace stock Reduce pressure increase bead pull force Correct bend surface Adjust cushion pressure Adjust bead Adjust slit timing
11 Line shift .
Groove scratches on flange holder and bead Insufficient ie radius Poor material slip property Bead lacks pull Excessive cushion pressure Defective blank stock Insufficient blank pull Defective die bend surface Improper cushion pressure Improper blank pull force (improper bead) Slit improperly timed
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13 Caused by . vacuum created during die separation 14 Develops . during pressing due to uneven distribution of stress during press operation. 15 Depression .. develops during processing due to insufficient pull on the material 16 Excessive . curvature develops during processing due to insufficient pull on the material.
Excessive shut height Insufficient material Insufficient cushion pressure Insufficient blank pull force (bead) Punch rise speed too high Improper air bleed hole size, quantity Uneven clearance Unbalance tension produced by the bead.
Adjust shut height Replace material Adjust cushion pressure Adjust bead Reduce punch speed. (double action) Change size, number, location of air bleed. Adjust stretch ratio Adjust oiling condition. Adjust clearance. Adjust location and height of the bead. Adjust processing and cushion pressure. Straightening process. (by use of jig during assembly) Reinforcement of bead. Adjust the blank holder pressure Repair of blank holder surface
Insufficient bead pull Insufficient blank holder pressure. Uneven blank holder surface Insufficient blank holder pressure Punch contour
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17 Irregular . spots formed by foreign objects on the die surface. 18 Crease . develops along the corner during drawing and bending due to concentration of stress 19 Condition that . develops on the inside surface of the sheet due to uneven distribution of stress.
Foreign objects on the die. Foreign objects on the blank stock. Burrs on sheared edge. Insufficient bead pull and blank holder pressure Excessive clearance
Clean the die. Clean the blank stock Remove burrs. Adjust bead shape and blank holder pressure Adjust clearance
Large die corner radius Excessive clearance Insufficient spring back allowance Insufficient blank holder and cushion pressure. Insufficient material Irregular radius on the die and punch surface Improper bead pull
Remedy due corner radius Adjust clearance Adjust spring back allowance Adjust blank holder and cushion pressure Use material of larger dimension
20 During initial . drawing phase the friction of the die caused excessive material stretch at the radius and subsequent increase in rigidity produced a
Improve he finish of the die and punch radii (smooth) Adjust the bead timing Increase the profile radius with consideration to blank holder contour, pressure direction.
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marked line.
CAUSE
Excessive clearance Insufficient clearance Primary cutter wear Protruding secondary edge. Punch and die off center Dull or worm punch Damaged or chipped cutting edge of punch Damaged or chipped cutting ede of die. Part not properly set in the die. Bushing surface too low. Incorrect drawing depth Stripper not set parallel. Loose punch Punch off center
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REMEDY
Hardface C= t*5/100~7/100 Adjust cutter edge clearance Hardface the cutter edge Grind secondary edge. Remedy die offset.
2.
3. 4. 5.
Edge condition different for sides. Material not sheared square Projection along the cutting edge. Depression along cutting edge Depression of the normally flat surface
Build up worm area by hardfacing Regrind or build up by hardfacing the punch cutter Regrind or build up by hardfacing the die cutter. Check the matching of the dies and make correction Install spacer and regrind height of bushing Adjust stripper Enlarge mounting diameter of the punch to provide good fit. Realign the punch
6.
7.
Punch breaks
8.
Scrap clogging
9.
Interference with reverse hold down Incorrect material or hardening Restriction of the hole. Scrap chute hole requires polishing Burrs Weak stripper spring or damage to the urethane Excessive cutting stroke causing part to bind Contour not matched between drawn part and trimming punch Punch and stripper contour not matched Damaged reverse holder spring
Adjust Change material or heat treat to proper hardness. Provide proper clearance Polish hole Lap punch and bushing Replace Adjust stroke
Match punch to the part contour Match stripper to punch contour Replace spring.
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Cause
Worn slide core Loose punch mount Incorrect secondary finish Incorrect clearance Clogged scraps Loose fixed cam Loose back up block Insufficient stroke.
Remedy
Adjust slide core clearance Correct mount to proper diameter Remedy Adjust clearance Match the punch, clean scrap escape hole Tighten bolt, install key Tighten bolt, install key Adjust stroke
2.
Blocked hole
CAUSE
Pilot hole too small. Ragged hole during pilot hole piercing Defective material Punch and die off center. Hole in part not aligned to the die. Incorrect burring hole bushing radius Improper drawing depth Improper burring
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REMEDY
Increase size of pilot hole so as to reduce the amount of burring Match the punch Adjust
2.
pilot shape.
part hole.
CAUSE
Binding in the curling groove Curling groove off center Punch and bushing misaligned Punch over hardened Worn guide
REMEDY
Polish groove Reposition curling groove by build up facing Align punch and bushing Temper to proper hardness Replace guide, post, bushing
2.
Broken punch
ESTABLISHING SHOT QUANTITY BASED ON MAINTENANCE INFORMATION:Durability of the dies will depend upon many factors such as shape of product, sheet thickness, die design, die material. Normally, it would be desirable to maintain die accuracy for each product by the respective process, or to perform control within the range that products of uniform quality (acceptable product quality) can be supplied. However, based
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on past experience with die repair, control is established for each process based on the number of press shots.
PERIODIC MAINTENANCE CYCLE:PROCES S Type, repair DRAW Normal Importan t Plating TRIM Normal Importan t PIERCE Normal Important SIDE CUT Normal Important BEND Normal Important 70,000 140,00 210,00 280,00 350,00 REMARKS Shots 0 0 0 0 Shots Shots shots shots Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Bead Wear countermeasure
Y Y Y
Y Y Y
Y Y Y
Y Y Y Y
dies for defects and damages In accordance with the maintenance procedure specified in the following attached sheets, and make any repairs as necessary. 2. Important Periodic Maintenance:- In addition to the periodic maintenance, look for areas of the steel die that indicate excessive wear from die aging, and perform the designated preventive maintenance. 3. Plating:- Check the hard chrome plated areas for the loss (peeling) of the plating as the result of polishing and galling. Perform repair by building up the worn surface with welding and then replating. Replating will restore excellent wear resistant
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property of the die (minimizing the depressions and scratches) and enable the continued production of quality products. Furthermore, the drawing property of the die is improved by the smoothness of the plated surface.
FEEDBACK:-
The information derived from the periodic maintenance provides valuable information on the characteristics of each die (die design inadequacies, repairs) which can be used in the design and manufacture of future steel dies.
KEEPING OF DIE MAINTENANCE AND REPAIR RECORDS:All the periodic maintenance record sheets, and repair and modification record sheets shall be kept in the file by parts (process) and in the order of maintenance performed.
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DIE DESIGN
1.
Draw die- The rolled steel sheet is formed into the shape of the die by applying a force perpendicular to the surface of the sheet.
Ref.
a. b. c. d. e. f. g. h. i.
Part Name
Die set Die Bead Balancer block Blank holder Punch Cushion Pin Pilot Guide
Function
To simplify the mounting of the die (some are made integral with the die) Forces the sheet stock to form around punch contour. Prevents wrinkles and distortion of press part, prevents slipping Used for adjusting the holding force of the die and blank holder. Used mainly for motorcycle. Maintains the blanked stock in place and holds the stock during drawing (prevents wrinkles) Forces the sheet stock into the die to form the shape. A component of the press which function as a support for the blank holder Performs the positioning of the stock sheet Performs the positioning of the blank holder to
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the die.
Inspection Points
Guide post Guide bushing Punch, Die, Blank Holder, guide, plate Guide plate mounting bolt Punch Die Die plating Die mounting bolt Bead Bead mounting bolt Ejector retainer pin Ejector spring Pilot pin Scrap chute box Upper/lower holder Hook hole Mounting bolts
Description of Inspection
Galling, wear, bend Galling, wear, crack Galling, wear Galling, wear Break, loosening Worn radius, galling Worn radius, galling Peeling Break, loosening Galling, crack, wear Break loosening Galling, deformation Break, bend Break, deformation, looseness Damage deformation Surface condition Screw thread war Break, looseness
Inspection Standard
0.1-0.2 0.1-0.2 0.05-0.1 0.05-0.1 None permitted 0.5max. 0.5max. None permitted None permitted Determine from Die and None permitted Not permitted Not permitted Not permitted Not permitted 60-70% contact 1mm max. Not permitted
Inspection Method
Micrometer, Inspection jig Cylinder gage Thickness gage Thickness gage Wrench Section gage Section gage Visual Wrench Part Wrench Visual Visual Visual Visual Straight edge Vernier caliper Wrench
Maintenance Method
Replace with new parts Replace with new parts Grind, Liner repair Grind, Liner repair Replace with new parts Weld build up worn spot Weld build up worn spot Plating Replace with new parts Weld build up worn spot or replace Replace with new part Replace with new part Replace with new part Replace with new part Replace with new part or repair Grind Machine new hole Replace with new parts
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2. STEEL SHEAR DIE ( Blanking, Trim, Pierce):Trim-pierce die For cutting off excess material
Ref. a. b. c. d. e. f. g. h. i. j. k. l. m. n.
Part Name Die set Dowel pin Stripper Guide bushing Stroke end pin Guide post Punch plate Spring ellipse (Spring urethane) Shoulder punch Bushing Die cutter Punch cutter Punch Scrap cutter
Function Upper die mounting plate (Some are made integral with the die) For the die positioning (accuracy 0.15-0.24) Holding the part in position, prevent part from lifting For aligning upper and lower die, to maintain die accuracy Die reference (normally 0.5mm clearance exists) For matching the upper and lower die, maintain die accuracy Shoulder punch mounting plate, maintains punch position Serve as auxiliary punch function. (When large force required in small space) Mate with the bushing and performs hole piercing Mate with Shoulder punch and performs hole piercing Mate with punch cutter and performs punching Match with die cutter and performs punching Serve as positioner for drawn parts
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Trim Die Periodic Maintenance Inspection Standard:No. Inspection Description of points inspection
1. 2. 3. 4. 5. 6. 7. Guide post Guide bushing Heel guide Wear plate Wear plate mounting bolt Male cutter, Flat Male cutter, Vertical Cut Male cutter head pipe Male cutter countered section Female cutter flat Female cutter vertical cut Female cutter head pipe Female cutter countered section Punch block mounting bolt Die block mounting bolt Punch Punch holder Bushing Bushing holder Ejector Ejector Spring Galling, Wear, Bend, Cracks Galling, Wear, Bend, Cracks Galling, Wear Galling, Wear Break, looseness Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Break, Looseness Break, Looseness Chip, wear, overcut, loose mounting Loose mounting, Galling Chip, Wear, Overcut, Loose mounting Loose mounting, Galling Damaged contour Break, bend, Deform
Inspection Standard
0.05-0.1 0.05-0.1 0.05-0.1 0.05-0.1 Not permitted Chip not permitted Clearance 0.05-0.08 of sheet thickness Sagging edge not permitted Overcut 0.52.0 + sheet thickness Chip not permitted Clearance 0.05-0.08 of sheet thickness Sagging edge not permitted Overcut .5-2.0 + sheet thickness Not permitted Not permitted Chip not permitted Edge sag Overcut = t + 0.5~2.0 Looseness 0.01 max Not permitted Not permitted
Inspection method
Micrometer, in inspection jig Cylinder gage Thickness gage Thickness gage Wrench Visual Thickness gage Check product shear edge Scale Visual Thickness gage Check product shear edge scale Wrench Wrench Visual Visual Vernier Calliper Cylinder gage Visual Visual
Maintenance Method
Replace with new part. Replace with new part. Repair wear Repair worn liner. Replace with new part Repair by weld build-up Repair by weld build-up Jig model repair Jig model repair Weld build up wear area Repair by welding Repair by welding Scale repair by welding Replace with new part Replace with new part Wear replace Repair by jig boring Weld build-up, Replace with new part Jig boring machining Repair by welding Replace with new part
8. 9. 10. 11.
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
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22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
Ejector Urethane Lifter Cylinder Knock out pin Knock out spring Scrape chut Upper/Lower holder Upper/Lower mounting bolts Hook hole Jig model
Break, Bend, Deform Deform, Bend, damage Air leak, Operating condition Malfunction Break, Bend, Deform Damage, Deform Surface condition Break, Looseness Screw thread condition Defective contour, Chip
Not permitted Not permitted Normal operation Deform not permitted Not permitted Not permitted 60-70% contact Not permitted 1mm max wear Not permitted
Visual Visual Test Stand Visual Visual Visual Straight edge Wrench Vernier caliper Visual
Replace with new part Replace with new part or repair Replace with new part or repair Replace with new part Replace with new part Replace with new part or repair Grind Replace with new part Drill new hole Repair or make new
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Steel Bending Die (Bend) & Steel Form Die (Restrike, Curling, Burring):Bend die is used to produce bend to the stock material with the die.
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Pierce/Burring die periodic maintenance Inspection Method:No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Inspection points Guide Post Guide bushing Punch Punch holder Bushing Bushing holder Burring punch Burring holder Burring bushing Burring holder Ejector Slit male cutter Description of Inspection Galling, wear, bend Galling, wear, crack Chip, wear, overcut, hole looseness Galling, Mounting looseness Chip, wear, mounting hole looseness Galling, mounting looseness Galling, wear, bend Mounting looseness, Galling Galling, wear Mounting looseness, Galling Contour damage Chip, galling, wear Inspection Standard 0.05-0.1 0.05-0.1 Chip not permitted Overcut = t+ 0.5~2.0 Looseness 0.01 max. Clearance t 0.05~0.08 Galling not permitted Looseness 0.01 max. Wear 0.05 max. Wear 0.05 max. Not permitted Determine from die and part sheared edge Determine from die and part sheared edge Determine from die and part sheared edge Not permitted Determine from die and part sheared edge None permitted None permitted Inspection method Micrometer, inspection jig Cylinder gage Visual Vernier Caliper Cylinder gage Visual Visual Cylinder gage Micrometer Micrometer Visual Maintenance Method Replace with new part Replace with new part Grind, Replace Jig boring Repair by welding, replace Jig boring Grind, Replace Jig boring Replace with new part Jig boring Repair by welding Repair by welding
13.
Repair by welding
14.
Blank holder
15. 16.
Visual
17. 18.
Wrench Visual
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19. 20.
0.5 max. Determine from die and part sheared edge None permitted Pin free from bend None permitted Not more than 1mm wear 60-70% surface contact None permitted
Vernier caliper
Ejector mounting bolt Knockout Knock spring Hook hole Upper, lower holder Upper mounting bolt
Break, loosening Malfunction Break, bend, deform Worn threads Flatness, irregular surface Break, looseness
Replace with new part Replace with new part Replace with new part Machine new hole Grind Replace with new part
E F E F F E F C E T C T O O N N A A P P P P E E A A R R A A N N C C E E :: A A F F T T E E R
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A P IA N I T, N D T TO RESOLVE CHIP-DENT PROBLEM TO E , N D INCREASE THE QUALITY T E IN S T C L WHAT IS CHIP DENT?I E S A R C OK PANEL L L CHIP EFFECT ON Y E APPEARANCE: V LOWER DENT PANEL A EFFECT ON IR AFTER PAINT, APPEARANCE: AFTER DENT IS S L PAINT, DENT IS IY CLEARLY UPPER DENT PANEL CLEARLY VISIBLE VISIBLE WHICH B WHICH AFFECTS OUR CHIP AFFECTS OUR L V CBU APPEARANCE CBU E I QUALITY W APPEARANCE S QUALITY H I IB HOW IT GENERATE: WHEN DURING DRAW OR TRIM OPERATION C L SOME DUST OR CHIP PARTICLE COMES ON THE DIE,GENERATE H E THE DENT A F W F H E I C C T H S EFFECT ON APPEARANCE: AFTER PAINT, DENT IS CLEARLY O VISIBLE WHICH AFFECTS OUR CBU APPEARANCE QUALITY A U F R F C E B C U T Hand Work Contribution, All Models May12 A S P P O E U - 59 A R R A EFFECT ON APPEARANCE: EFFECT ON AFTER PAINT, APPEARANCE: AFTER DENT IS PAINT, DENT IS CLEARLY CLEARLY VISIBLE VISIBLE WHICH WHICH AFFECTS OUR AFFECTS OUR EFFECT ON APPEARANCE: AFTER PAINT, CBU APPEARANCE CBU DENT IS CLEARLY VISIBLE WHICH AFFECTS QUALITY APPEARANCE OUR CBU APPEARANCE QUALITY QUALITY
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S. NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Part Name ROOF RR DR PNL L SPO L/H SPO R/H RR DR PNL R FR DR SKIN R HOOD SKIN FR DR SKIN L HOOD FRAME FR FNDR L RR DR SKIN L RR DR SKIN R FR FNDR R T/L SKIN FR DR PNL R FR DR PNL L FR FLOOR RR IN SIDE L RR IN SIDE R RR FLOOR T/L FRAME
ACTUAL 12.0 9.6 7.7 5.8 4.2 3.5 3.2 2.9 2.5 2.4 2.2 1.4 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
TARGET 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
Defect Wise
PART NAME HOOD SKIN TOTAL 108 DENT 54 DING 54 SCRATC H 0 OTHER S 0 RUST 0 SCRAP JAM 0 WRINKLE 0 BURR 0
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HOOD FRAME FR FENDER R FR FENDER L ROOF PANEL S P OUT R/H S P OUT L/H PANEL RR IN SIDE R PANEL RR IN SIDE L FR FLOOR RR FLOOR FR DOOR SKIN R FR DOOR SKIN L FR DOOR PANEL R FR DOOR PANEL L RR DOOR SKIN R RR DOOR SKIN L RR DOOR PANEL R RR DOOR PANEL L SPOI.LER SKIN SPOILER FRAME
0
0 54 134 80 66 0 0 0 0 45 44 0 0 18 30 0 0 0 0 525
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 SCRAP JAM 85
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 SCRATC H 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
85 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 85 OTHER S 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
TOTAL
TOTAL 2002
DENT 895
DING 525
WRINKLE 497
RUST 0
BURR 0
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ROOF PANEL S P OUT R/H S P OUT L/H PANEL RR IN SIDE R PANEL RR IN SIDE L FR FLOOR RR FLOOR FR DOOR SKIN R FR DOOR SKIN L FR DOOR PANEL R FR DOOR PANEL L RR DOOR SKIN R RR DOOR SKIN L RR DOOR PANEL R RR DOOR PANEL L T/L SKIN T/L FRAME
12.55 7.16 9.29 0.00 0.00 0.61 0.00 1.57 1.67 0.92 0.52 1.75 1.25 27.00 4.10 0.00 0.00
6.46 3.69 7.14 0.00 0.00 0.00 0.00 1.48 1.73 0.30 0.00 2.69 2.64 6.63 12.75 0.40 0.00
11.97 5.81 7.74 0.00 0.00 0.00 0.00 3.50 2.94 0.00 0.00 1.40 2.24 4.17 9.64 0.00 0.00
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