MAJOR PROJECT REPORT

DESIGN OF
COMPOUND DIE SET
WITH HYDRAULICPRESS

SUBMITTED TO: Mechanical

Engg. Deptt.

SUBMITTED BY:-

Ramkaran
Sanjay Singh
Gurpreet
Deepak Kumar

[3709349]
[3709356]
[3709318]
[3709313]

SELECTION OF PROJECT
We engineering students have certain skills, traits and motives. Our
psychological make up tells us what traits and motives we posses, thus
giving the solution to the problems of different nature and magnitude at
different time being encountered.
The project activity is essentially a person oriented work which initially
itself is a big task to identify, explore and then selection of the same.
After exploring the sound technical know how and skills we are possessing,
the environmental set up in workshop, the availability of the resources, the
manufacturing process involved, the expert guidance and help which can be
sought, complexity of technology, economy of production and time schedule
of completion of task. We finally select project title COMPOUND DIE
AND HYDRAULIC PRESS FOR WASHER CUTTING.
This project involves intensive to extensive exposure to a no. of common
types of manufacturing operations to be done on the job such as turning,
drilling, cutting, threading etc. thus further increasing the technical knowhow skill of we people.
This project emphasizes the trouble and problem being encountered at
various levels of its production, from the procurement of material to
operations and processes in giving final practical shape to the product;
resulting us to know the difficulties being faced on the actual production
floor of an industry.

WHAT WE HAVE INNOVATED IN THIS PROJECT

We are designing a hydraulic press for small scale industry which gives
better production because as Compared to other press like electric their
cost of maintenance and equipment is high .
Whereas hand operated press creates lots of fatigue in workers as
worker have to give force by his hand and as well as feed.
But in foot operated die we can apply foce by legs and feed by hand that
is why this type of press will be useful in small scale industries.

INTRODUCTION
Press working may be defined as a chip less manufacturing process by
which various components are made from sheet metal. This process is
known as cold stamping. The machine is used for press working is
called a press. The main features of the press are: a frame which
supports a ram or a slide and a bed, a source of mechanism for
operating the ram Inline with and normal to the bed. The ram is
equipped with suitable punch. A stamping is produced by the
downward stroke of the ram when the punch moves towards and into
the die block. the punch and die block assembly is generally termed
as a die set or simply as the die press working operation are usually
done at room temperature.
A die is a specialized tool used in manufacturing industries to cut, shape
and form a wide variety of products and components. Like molds and
templates, dies are generally customized and uniquely matched to the
product they are used to create. Products made with dies range from
simple paper clips to complex pieces used in advanced technology.

COMPOUND DIES:-

It performs two or more cutting operations during one stroke of the press
at one station only. In order to do this both the upper and lower members
of the die set carry punching and blanking elements which are directly
opposite to each other.

WASHER BY COMPOUND DIE

PRESS OPERATION:-

The sheet metal operation done on a press may be grouped into two
categories, cutting operation and forming operation. In cutting operation
the work piece is stressed beyond its ultimate strength. The stress caused
in the metal by the applied force will be shearing stress. In formatting
operation the stress are below the ultimate strength of the metal. In this
operation there is no cutting of the metal but only of the contour of the
work piece is changed to get the desired product. The stress included in
the metal during the bending and drawing operations is tensile and
compressive and during the squeezing operation these are compressive.
Below we give the definition of the various press operation:-

A) Blanking:- Blanking is the operation of cutting a flat shape from

sheet metal. The article punched out is called the blank and is the
required product of the operation. The hole and metal left behind is
discarded as waste. It is usually the first step of series of operations

B) Punching (piercing):- It is a cutting operation by which

various shaped holes are made in sheet metal. Punching is similar
to blanking except that in punching the hole is the desired product,
the material punched out to form the hole being waste

Advantages of metal stamping:

Sheet stamping is an advanced technique of mechanical working. It has
got the following option:
1. Small weight of fabricated part.
2. High productivity of labour.
3. High efficiency of technique as regards the fabrication of items of
diversified shape.
4. High volume, low cost production.
5. Predictable strength character stick.
6. Uniformity in parts.
7. Low cost material.
8. Less labour consuming.
All the above advantages have made stamping very attractive to a host
of industry, particularly to automotive, aircraft, electrical engineering
and other.

PRESS WORKING EQUIPMENT:

We will use a foot operated press using a lever advantage.

Lever : A lever is a mechanism that can be used to exert a large force

over a small distance at one end of the lever by exerting a small force over
a greater distance at the other end of the lever.

In general the effort force can be expressed as

Fe = Fl dl / de

(1)

where
Fe = effort force (N, lb)
Fl = load force (N, lb) (note that weight is a force)
dl = distance from load force to fulcrum (m, ft)
de = distance from effort force to fulcrum (m, ft)

Requirements of press tool design:

The press tool design should suit the type of production it will be used
for, that small batch, large batch, or mass production. The press tools
should meet the following requirements:
1. The dimensional accuracy and surface finish of stamping should
conform to the drawing and specification.
2. The working parts of the tool must be adequately strong, durable
and
easily replaceable when worn out.
3. The die should ensure described hourly output, easy maintains,
safe
operation and reliable fastening in the press.
4. The die should be designed in such a way that far as possible
standards components are used for its manufacture.Asfew
special
parts as possible should be used in its design.
5. The scrap in the stamping operation must be kept as a minimum
by
suitable designing the strip layout. The percent utilization of the
material is given as:
Percentage material utilization = total area of blank cut / area of uncut
strip *100
Normally the value of this factor is 70 to 80%.

Press tool components:

The press tool components may be divided into the following types:
1. Working components, which participate in the shaping of parts:
dies, punches and their section.
2. Structural components, which serve for joining the working
components to one another and to press: upper shoe, lower shoe
and shanks.
3. Guiding components, which sure accurately alignment of the
upper shoe with the die in operation: guideposts and
bushing.Guide post can also facilitate tryout of the press.
4. Feeding components, which feed the stock strip or blanks to the
stamping station.
5. Locating and locking components, which provide for an
accurate positioning of the stock or the blanks in the die and fix
it in the places while the operation is performed?
6. Stripping components, which strip and remove the blanks and
the scrap from the working components after the operations is
over: strippers push off pins, knockouts.

Press tool components

PRESS WORKING TERMINOLOGY:-

A simple cutting die used for punching and blanking operation is shown.
The definitions of the main component of the die and press are given:-

1) Die set:- It is unit assembly which incorporates a lower and upper

shoe, two or more guideposts and guidepost bushings

2) 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 consisting of a pair of mating members for producing work in
a press.

3) Die block:- It is a block or a plate which contains a die

cavity.
4) Lower shoe:- The lower shoe of a die set is generally mounted
on the bolster plate of a press. The die block is mounted on the
lower shoe. Also, the guide posts are mounted in it.

5) Punch:-

This is the male component of the die assembly, which is

directly or indirectly moved by and fastened to the press ram or

slide.

6) Upper shoe:- This is the upper part of the die set which
contains guidepost bushings.

7) Punch plate:- The punch plate or punch retainer fits closely

over the body of the punch and holds it in proper relative position.

8) Back up plate:- Back up plate or pressure plate is placed so that

the 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.

9)

Stripper:- It is a plate which is used to strip the metal strip

from a
cutting or non cutting punch or die. It may also guide the sheet.

10) Knockout:- It is a mechanism, usually connected to and

operated by the press ram, for freeing a work piece form a die.

11) Pitman:- It is a connecting rod which is used to transmit

motion
from the main drive shaft to the press slide.

12) Shut Height:- It is the distance from top of the bed to the
bottom
Of the slide, with its stroke down and adjustment up.

13) Stroke:- The stroke of a press is the distance of ram movement

from its up position to its down position. It is equal to twice the
crankshaft throw or the eccentricity of the eccentric drive. It is
constant for the crankshaft and eccentric drives but is variable on
the hydraulicpress.

Working of a cutting die:

The punch holder is fastened directly to the ram of the punch press and
the die shoe is fastened to the bolster plate of the press. Guide post may
be used as to better align the punch holder with the die shoe. These three
main components constitute what is known as the die set. a die set can be
had two guide post located at the rear of the die set ,diagonally ,one at
the back and in the front of the die set , or with four guide post ,one in
each corner of the die set .
The lower ends of the guide post are press fitted into the die shoe. At
upper end, the guide posts have a slip fit with the guide bushing which
are press fitted into the punch holder. With this, the guide posts have a
free movement in the bushings. The punch is fastened to the punch holder
and the die block is fastened to the die shoe. The punch is aligned with
the opening in the die block. Since both the punch and die block act as
cutting tools they are hardened.
The cutting action takes places during the downward movement of the
punch into the die block. After the cutting action, the elastic recovery in
the strip material takes places. Due to this the size of the blank increases
and that of the hole in the strip decreases. So at the end of the cutting
action, when the punch starts to move upward the scrap strip cling to the
punch and the blanks get clogged in the die opening. To remove the scrap
strip from the punch surface a stripper is used to avoid clinging of the
blank in the die opening; the walls of the die opening are tapered.

The usually happens with thin blanks which have been treated with a
lubricant. To help the blanks free itself from the punch face, pushes off
pins are provided which are fitted into the punch body.
The most popular design is a straight, round plunger with a sliding fit in
the punch body. It is held in the places by a light compression spring and
a set screw. If at the end of body, a pilot is to be provided, then the pushoff pin is located off center. When the space available for a comparisons
spring is insufficient, a flat spring is used.
In the case of very small punches no space is left to provide the push-off
pin. In such cases, the sticking of the blank to the punch face may be
avoided by changing the shape of punch bottom. With this, the oil seal or
vacuum created by the oil films is broken and tendency of the blank to
stick to the punch face is greatly decreased. The drawback of this method
is that the blank gets distorted. Due to this method is suitable for
punching operations.

Principle of metal cutting:The cutting of sheet metal in press work is a shearing process. The cutting
action is explained with the help of fig. the punch is of the same shape as
of the die opening except that it is smaller on each side by an account
known as clearance. As the punch touches the material and travels
downwards, it pushes the materiel into the die opening. The material is
subjected to both tensile and compressive stresses as shown in fig.
Stresses will be highest at the edges of punch and die and the materiel
will start cracking there. The various steps in the rupture or fracture of the
material can be written as: stressing the material beyond its elastic limit,
plastic deformation, reduction in area, fracturing starts in the reduced area
and becomes complete. if the clearance between punch and die is correct,
the cracks starting from the punch and die edges will meet and the rupture
is complete as shown in fig. If the clearance is too large or too small, the
cracks do not meet and a ragged edge results due to the material being
dragged and torn through the die.

DESIGN
Clearance:
As is clear in the previous article, the die opening must be sufficiently
larger than the punch to permit a clean fracture of the metal. This
difference in dimensions between the mating members of a die set is
called clearance. The clearance is applied in the following manner:(i)

When the hole has to be held to size, i.e., the hole in the sheet
metal is to be accurate(punching operation),and slug is to be
discarded, the punch is made to the size of hole and the die
opening size is obtained by adding clearance to the punch size.

(ii)

In blanking operation, where the slug or blank is the desired

part and has to be held to size, the die opening size equals the
blank size and the punch size is obtained by subtracting the
clearance from the die-opening size.

It is the amount of clearance per side of the die opening. The clearance is
a function of the kind, thickness and temper of the work materiel, harder
materials requiring larger clearance than soft materials, the exception
being aluminium. The usual clearance per side if the die, for various
metals are given below in terms of the stock thickness, t:
For brass and soft steel, c = 5% of t
For medium steel,
c = 6% of t
For hard steel,
c = 7% of t
For aluminium,
c = 10% of t
The total clearance between punch and die size will be twice these fig.
these clearance are blanking and piecing operations.

Minimum diameter of the piercing:

To punch a hole the compressive punch should be at least equal to the
force necessary to fracture the material. The hole which will be punched
under the condition will be smallest. If is the shear strength of the work
material is the compressive strength, d is the smallest hole diameter to
be pierced and t is the stock thickness, then smallest hole diameter to be
pierced and t is the stock thickness then
Piercing pressure

= dt

Strength of pressure = /4
dt = /4d
d = 4t/

It is assumed that = 2then

d = 2t
The minimum diameter of a hole can be punched is twice the stock
thickness. In the actual practice smaller holes than this are prcised
successfully, showing to what extent the punch may be loaded without
failure.

Cutting forces and force by our foot transmitting to shank:In cutting forces as the punch in its downward movement enters the
material it need not penetrate the thickness of the stock in the order to
affect complete rapture of the part. The distance which the punch enters
into the work material to cause rapture to take place is called penetration
and is usually given as the percentage of the stock thickness.
The percent penetration depends upon the material is cut and also stock
thickness. When a hard and strong material is being cut to very little
penetration of the punch is necessary to cause fracture. With softer
material, the penetration will be greater. For example, for soft aluminum,

it is 60% of t for 0.15%carbon steel is annealed; it is 38%of t. The

percentage penetration depends upon the stock thickness, being smaller
for thicker sheet and greater for thinner sheet.

The maximum force F is Newton needed to cut a martial is equal to the

area to be shared times the shearing strength is N/mmfor the material.
For a circular blank of the diameter D mm and of thickness t, mm the
cutting force will be given as
Formula:
F1 = pi* t * Newtons

(for piercing)

Where is shearing stress = 60N/mm2.

P is perimeter of steet to be pierced or blanked.
t is thickness of sheet = 0.5 mm
F1 = 3.14x 10x0.560
=942 N
F2 = pit Newtons
= 3.14 x 20x0.5x60
= 1884 N
F = F 1 + F2
= 942 + 1884
= 2826 N

Force we can apply by our foot is normally 400 N. By our lever we can
increase effort by 5 times.
As load = effort (50/10)
So load applied upward = 2000N
Now this force is sent upward and here we have one more lever of effort
length 20cm and load length 5 cm
We will fet force at punch =20004= 8000N
So because of our lever mechanism we will get a increased effort of
8000N.
Hence we can easily cut our material to make washer easily using this
mechanism.

BOLSTER PLATE:
It have dimensions (20020012) mm. The sides are to be machined on
milling Machine and the surface on surface grinder. After that two holes
of dia 22.0 mm and 12.0 mm are drilled throughout on vertical
drilling machine. Then hole size of 6.8 mm is made and tapped with m8
tap.

Die Block: It is taken of dimensions (15015015) mm. The sides are to be

machined on milling m/c and the surface on surface grinder. Two holes of
20.0 mm and 10.0 mm are drilled throughout on vertical drilling
machine. Drilling and Roaming is done to make hole size of 6.8 mm (4
No.s) and tapping is done with m8 tap set

Stripper plate: Stripper plate has dimensions (15015010). A plate of (150404) mm

is made on vertical milling machine. Two holes of 20.0 mm and 10.0
mm are made on vertical drilling machine. Drilling and Reaming is done
to make hole size of 6.8 mm (4 No.s).

Punch holding plate: It will have dimensions of (20020015.5) mm. 4 holes of 14.0 mm
are drilled throughout on vertical drilling machine. 12 holes are drilled of
5.0 mm and tapped with m6 tap.

Top plate :Top plate will have dimensions (20020020.0) mm. 4 hole of 8.5 mm
are drilled throughout m20 square threads are made in the centre for the
screw movement.

Piercing Punch: The material for the piercing punch has length 51mm and 40.2 mm. We
will Face 0.5 mm from both sides. Turn a length of 50 mm to make dia 40
mm. Turn the rod up to a length of 40 mm length and make 10.0 mm.
then drill 4 hole of 5.0 mm and tapping is done with m6 tap.

Blanking Punch: We will take a rod of length 51 mm and 55.2 mm. face 0.5 mm from
both sides. Turn the rod up to length 55.0 mm to make 50.0 mm. Turn
up to a length of 45 mm and make 20.0. Turn up to a length of 5.0 mm
to make 10.0 mm. Drill 4 hole of 5.0 mm and tapping is done with m6
tap.

Lever : We will take a 4*4 bar of length 700 mm. towards the effort we will take
600 mm . whileat the bar going to punch we will take lenth 100mm with
respect to fulcrum. Fulcurum will be at 600mm from the rope drive
coming from pulley.

RAW MATERIAL ESTIMATION COST

Density of mild steel=7861 kg/m3
Cost of mild steel=Rs. 40/kg
Mass= volume density
( 1 ) Bolster plate:Total volume =LBH
= 20220221= 856884 mm =0.85710-4 m3
Mass of bolster plate
m = 0.857786110-4
=6.74 kg
Cost of Bolster Plate = 6.74 X 40 = Rs. 270
( 2 ) Die Block:Total volume V =LBH
=15215216
=369664 mm3
=3.710-4 m2
Mass of die block m =VS
=3.710-4 7861
=2.91kg
Cost of Die Block = 2.91 X 40 = Rs. 117
( 3 )Stripper plate:Total volume V=LBH
=15215211
=254144mm3

2.54 X 10-4 m3

Mass of stripper plate:m=VS=2.5410-4 7861=2.0 kg

Cost of Stripper Plate = 2 X 40 = Rs. 80

(4) Punch holding plate:Total volume V= LBH

=20220221
=856884mm3
= 8.5710-4 m3
Mass=VS
=8.5710-4 7861
=6.74 kg
Cost of Punch Holding Plate = 6.74 X 40 = Rs. 269.6
(5) Top plate:Total volume V= LBH
=20220221
=856884 mm3
=8.5710-4 m3
Mass=VS
=8.5710-4 7861
=6.74kg
Cost of Punch Holding Plate = 6.74 X 40 = Rs. 269.6

(6) Guide post:Total volume V= /4 d2 l

= /4 142 232
=35695.52mm3
= 3.5710-5 m3

Mass=VS
=3.5710-5 7861
=0.28kg
Cost of Guide Post = 0.28 X 40 = Rs. 12
Cost of 4 Guide Posts = 12 X 4 = Rs. 48

(7) Blanking punch:Volume of rod V = /4 d2 l

= /4 522 55
= 116745.2mm3
= 1.210-4 m3
Mass

= VS
= 1.210-5 7861
= 0.94kg

Cost of Blanking Punch = 0.94 X 40 = Rs. 38

(8) Piercing punch:Volume of rod V = /4 d2 l
= /4 422 52
= 72006.48mm3
= 7.210-5 m3
Mass

= VS
= 7.210-5 7861
= 0.6kg

Cost of Piercing Punch = 0.6 X 40 = Rs. 24

(9) Screw:-

Volume of rod V = /4 d2 l
= /4 322 150
= 120576mm3
= 1.2010-4 m3
Mass = VS
= 1.2010-4 7861
= 0.948kg
Cost of Screw = 0.948 X 40 = Rs. 38

10) Aluminium Sheet:

Total volume V = LBH
= 1220400.8
= 39040 mm3
= 3.910-5 m3
Mass

= VS
= 3.910-5 2700
= 0.105kg

Cost of Aluminum Plate = 0.105 X 40 = Rs. 16

11)lever1:
Total volume = LBH
=6003030
=510000mm3 = 5.110-4 m2
Mass = VS
= 5.1 10-4 7861
= 4 kg
Cost of plate = 4 40 = Rs.160

12) Lever2:Total volume = LBH

=2503030
=150000mm3 = 1.510-4 m2
Mass = VS
= 1.5 10-4 7681
=1.1kg

Cost of pulley = 1.1 40

= Rs.44

14)

Foot Platform:-

Total volume = 25015020

=750000mm2
= 7.510-4 m2
Mass = 7.510-47681
= 5.7 kg
Cost = 5.740
= Rs. 228

15)

Table:-

Total volume = 650300100 + 422500

= 19500000 + 8000
= 19508000mm2
Mass = 19.5 kg
Cost = 19.5*40
=780
Total estimated material cost =Rs. 2382

REFERENCES

BOOKS:
Production technology by P.C. Sharma
Production technology by O.P.Khanna
Production technology by B.S.Raghuwanshi
Workshop technology by S.k.Garg

WEB:
www. google.com
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