SEMINAR ON

DESIGN AND MANUFACTURING OF

BEARING CUP

L. DINESH REDDY

07241A0304

R. SHIVA KUMAR

07241A0319

B. THARUN VISHNU

07241A0323

INTRODUCTION
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Press Tool
Press Tool is a set of plates with a relief, or depth-based
design, in them. The metal is placed between the plates,
and the plates are pressed up against each other,
deforming the metal in the desired fashion.
There are different types of press machines:
Some of them are:C
C-type(
( ffixed
d type & open bbackk inclinable
l bl press))
Single action straight side press
Typical Hydraulic press

DIE
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A Die is an assemblage of parts used for producing

different sheet metal components.

The Die is also called press tool as the dies are used on
different types of presses based on the cutting forces
required for the component.

IIn this
h project a bl
blanking
k die,
d piercing die,
d drawing
d
die
d is
produced for production of bearing cap used to protect
from dust from bearings
g of a ceilingg fan.

There are different types of die to press relationships:-

Press Shut height

Capacity of press
Feed Height

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Materials used for making die sets:HCHC

Mild steel

Bearing cup
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Our Project lays emphasis on the design of sheet metal

dies for production of bearing cup used to protect the
b i
bearings
by
b preventing
ti the
th dust
d t tto enter
t .The
Th main
i
objective of the our project is to design a bearing cup
by the following operations:-

Blanking Operation
Piercing Operation
Drawing Operation

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3D--diagram of bearing cup

3D

3D view of bearing cup

Blanking operation
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Blanking: Blanking is used to produce

blanks
b
a s of
o desired
es e co
contour
tou and
a size
s e by
cutting them out of the stock strip. Blank
p
part
p
made byy
is the desired piece
Blanking operation.

Remaining after blanking is called as

scrap
scrap

Inverted top view of blanking and

piercing die plate

3D diagram in catia

Piercing operation
Piercing: This operation consists of
ssimple
p e hole
o e pu
punching.
c g. Itt differs
e s from
o
blanking in that the punching (or material
p and the strip
p
cut from stock)) is the scrap
is the work piece.
y Piercing is nearly always accompanied by
a blanking operation before, after or at
the same time.
time
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Top view punch and stripper plate

3D diagram in catia

Drawing operation
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A flat blank is formed into a cup

p byy
forcing a punch against the center portion
of a blank that rests on the die ring.
g

Top view of drawing die

3D diagram in catia

Die placed in open back

inclined press

Strip layout
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Strip
p layout
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plays
p y an important
p
role
especially in the case of the design of the
press tool.
p

Strip decides the economic utilization of

the work piece and helps in the decrease
of cost of the job and reduction in the
production time by increasing the number
of components.
components

Working

Design calculations
Blanking calculations :
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Shearing force for blanking operation:

Sh
Shear
force
f
FF= (K*L*T*S)/1000 TONS
K =1.2 for normal clearance
L = perimeter of the blank = 188
188.4
4 mm
T =thickness of the stock strip = 1 mm
S =shearingg strength
g of mild steel = 21 kg/sq.mm
g q
Shearing force = (1.2*188.4*1*21)/1000 TONS
= 4.7 TONS

Piercing Calculations:
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Shearing force for piercing operation:

Shear force FF= (K

(K*L*T*S)/1000
L T S)/1000 TONS

K =1.2 for normal clearance

L = perimeter of the hole = 78.5 mm

T =thickness of the stock strip = 1 mm

S =shearing
shearing strength of mild steel = 21 kg/sq.mm

Shearing force = (1.2*78.5*1*21)/1000 TONS

= 2.6 TONS

Drawing calculations :
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Shearing force for drawing operation:

Shear force F= (K*L*T*S)/1000 TONS

K =11.22 for normal clearance

L = perimeter of the hole = 78.5 mm

T =thickness of the stock strip = 1 mm

S =shearing strength of mild steel = 21 kg/sq.mm

Shearing force = (1.2

(1 2*78
78.55*1*21)/1000
1 21)/1000 TONS
= 1.2 TONS

Total tool calculations

Total force required
q
for the compound
p
tool=
y sshearing
ea g force
o ce for
o blanking
ba
g operation
ope at o +
shearing force for piercing operation +
q
for drawingg operation
p
total load required
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=4 7+2 5+1 2=8 4tons

=4.7+2.5+1.2=8.4tons

Cost analysis
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COMPUND DIE

Conventional milling

12

100

1200

Grinding

10

100

1000

Jig Boring, Drilling

and tapping

10

100

1000

CNC wire cut

320

1600

Lathe turning

100

600

Cylindrical Grinding

200

600

Total cost

Manufacturing time in hours

Manufacturing cost per hour

Amount in Rs

6000

Other costs
Allen screw, dowel pins, high tension
rubber
ubbe material
ate a are
a e purchased
pu c ase from
o
markets, including the raw material for
makingg the die and the heat treatment of
the material has been charged = Rs 3000
y Total cost of the compound die =
6000 + 3000
=Rs.9000
R 9000
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Conclusions
The Bearing cup can be manufactured in 3 operations
namely blanking operation,
operation drawing operation,
operation piercing
operation.
1)

2) The Compound die is used in the batch operation of

6000 units of bearing cups.
3) The
Th unit
it costt off th
the bbearing
i cup iis R
Rs 33.
4) The life of the compound die can be increased by
machining
h
the
h vitall parts like
l k punchh and
d the
h die.
d
p pplate which is pplaced between the bottom
5)) The impact
bolster and punch holder is replaced if necessary to
improve the die life.

References
Tool design
g byy Cyril
y Donaldson,
Donaldson Mn.
y Fundamentals
u a e ta s of
o tool
too design
es g by David
av
Spitler,John G.Nee,David Alkire
,
y of Manufacturingg Engineers.
g
Smith,Society
y Fundamentals of press working by David
Alkire Smith.
Smith
y