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Advantages:
1.
Easy to manufacture.
2. Simple design.
3. Low cost.
4. Easy to sale
5. High demand in motor vehicle workshop.
6. Can be use in any type of work.
Market potential and competitive advantage:
1.
It is commercial.
2. Easy to manufacture.
3. The machinery required for the manufacturing of project is available in the institute.
SCOPE OF A PROJECT
1.
CONTENTS
1.
INTRODUCTION
2.
LITERATURE SURVEY
3.
COMPONENT DETAILS
4.
DESIGN CALCULATION
5.
PROCESS PLANNING
6.
7.
8.
DRAWING
9.
APPLICATION
10.
CONCLUTION
11.
REFRENCES
INTRODUCTION
CHAPTER 1:
INTRODUCTION
In a compound tool both the piercing and blanking operations are performed
simultaneously.
The piercing punches are positioned in-side the blanking die opening.
Because of the positions the mating parts assume, the blanking and piercing
operations take place in the opposite directions, but simultaneously.
Because of this the piercing' and blanking burrs are formed on the same side of the
piece part.
Compound
Compound tools pierce and blank simultaneously at the same station. They are more
expensive to build and they are used where considerable accuracy is required in the part.
In a compound tool both the piercing and blanking operations are performed
simultaneously.
The piercing punches are positioned in-side the blanking die opening.
Because of the positions the mating parts assume, the blanking and piercing
operations take place in the opposite directions, but simultaneously.
Because of this the piercing' and blanking burrs are formed on the same side the
piece part.
A fixed stripper cannot be clamped to the die because the die is mounted on the top
plate.
The stripper is actuated by self-contained purr or by the die cushion of the press.
This is achieved by a shedder which is closely fitted in the blanking die and around
the piercing punches.
The slug produced from the piercing operation falls down through the opening
provided in the bottom plate.
The piece parts are knocked out of the die as soon as the blanking is over.
8
LITERATURE
SURVEY
LITERATURE SURVEY
2.1 PRESS:-
Fig:- 2.1(A)
Presses are powered machines having stationary bed and slides (ram) which have
controlled reciprocating motions towards and away from the bed guided by their pillar.
2.2 Classification of press:
Presses are classified by following characteristics:
Source of power.
Number of slides.
Frame types.
Intended use.
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Manual press.
Mechanical press.
Hydraulic press.
Pneumatic press.
Single action.
Double action.
Triple action.
2.4.1 Single action:One ram is operated by a mechanism located in the crown or under the bed of the
press.
2.4.2 Double action:One inner ram and one outer ram operated by mechanism located in the crown or
under the bed of the press. The ram moves from the crown towards the bed on the down
stroke.
2.4.3 Triple action:Same as double action with the addition of a third ram located in the bed soon after
the two rams lower.
11
a curl or roll.
12
Piercing:
It is the operation of making hole in the stamping. Here also the entire periphery is cut
and cut piece is waste
Cut-off:
Cut off operation separates the work material along a straight line or angular or irregular
in a single cut. No scrap is produced in cutting off operation.
13
Parting off:
Parting off is an operation which involves cutoff operation to produce blank from the
strip as shown in the figure. During parting, some scrape is produced. There fore,
parting is the next best method for cutting blanks.
Perforating:
If more number of holes are pierced, it is called perforating.
14
Dinking:
To cut paper, leather, cloth, rubber and other soft materials a dinking tool is used. The
cutting edges penetrate the material and cuts. The die will be usually a plane material like
wood or hard rubber.
Trimming:
It is the operation of cutting the edges of the drawn components which are wavy and
irregular. The term trimming is also used when the material of a strip or the portion of a
blanked component or a portion of a pierced hole is partially removed
Broaching:
It is similar to shaving operation. In this a tool having a series of teeth profile
removes metal from the edges of the blanked component in a progressive way.
15
Drawing:
In drawing a flat blank is transformed into a cup or shell.
Shell or cup produced may be cylindrical or rectangular with straight or tapered
sides.
Planishing:
Planishing tool is used to straighten, blanked components. Very fine serration points
penetrate all around the surface of the component.
.
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SHEARING THEORY.
Stage 2: Penetration.
17
This imparts a bright polished finish (cut band) on both the strip
Stage 3: Fracture
In this stage, fracture starts from both upper and lower cutting
edges.
As the punch travels further, these fractures will extend towards
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19
Bottom plate:
Stripper:
Stock strip is guided and fed in line with the profile, thus maintaining scrap
equally.
It aligns punch with the plate which does not allow the strip to go along with the
punch.
the die in case the stripper also functions as a guide plate.
Made out of Mild steel , Medium carbon steel & OHNS
Hardened up to 45-50HRC
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Thrust plate:
Punch holder:
Shank:
Dowels:
This is a cylindrical pin hardened and ground on center less grinder. This dowel is
made to m6 tolerance. Dowel pins keep the alignment between the plates and prevent it
from lateral movement.
Screws:
This is fastening element. Screws are used to hold the plates together. The sizes of
the screws are selected on the basis of tool size
Stopper:
The stopper shown is a plain cylindrical pin. The pin is mounted in the die block. The
function of the stopper is to arrest the movement of the strip when it is fed forward to one
pitch length. Various types of stoppers are available.
PUNCH
Punch is the cutting element of the tool. Punch gives the hole size and shape of the
component. This is made out of high carbon high chromium steel,(D, M grade in AISI) and
hardened and tempered to 58-60 HRc
21
PUNCH
Cutting punches:
These punches are mainly preferred for the
shearing actions and these can perform operations like
blanking, piercing, notching, trimming etc.
Hybrid Punch:
22
23
COMPONENT
DETAIL
24
Chapter3:
Component name
Type of tool
COMPONENT DETAIL
: Shock Absorber Washer.
: Compound Tool.
: Mild steel
: 2 mm
Press tonnage
: 14.24 tones
Type of feed
: 42.4 mm
Scrap bridge
: 2.4mm/side.
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DESIGN
CALCULATION
26
DESIGN CALCULATION
= 1.2 sheet thickness
= 1.2 2
= 2.4 mm/side
Pitch
Strip width
Cutting force
Cutting clearance
Economic factor
1256 1 100
42.4 44.8
66.12%
27
PROCESS
PLANNING
28
PROCESS PLANNING
29
ESTIMATION
AND
COSTING
30
ESTIMATION
33
Volume = lbh
=25013525
=843750mm3
Weight = Volume density
106
=8437507.87
106
= 6.64kg
34
= 6.64kg
= 1.26kg
= 1.85kg
= 1.85kg
Shank holder
= 2.11kg
Stripper plate
= 2.26kg
Die plate
= 2.52kg
= 1.26kg
r 2 h
=3.14252568
=133450 mm3
Weight = Volume density
106
1 33450 8
106
= 1.06kg
Piercing punch
= 0.23kg
Shank
= 2.11kg
Shedder
= 0.21kg
Pillar
= 0.312 = 0.63kg
Bush
= 0.212 = 0.42kg
Dowel
= 0.13kg
Guide pin
= 0.013kg
35
= 0.06kg
= 1.05kg
= 5.2kg
= 1.0542 = Rs.44.1
= 5.260 = Rs.312
= 3.81120 = Rs.457.2
= Rs.1809.7
36
Material cost
= Rs.45/kg
Weight of component
= 10gm
= 100nos
Component cost
= Rs.0.45/component
Cycle time
= 5sec(approx.)
= 3600/5
= 720cycles
= 720 component
No. of blank
=1
= 7201
= 720
= Rs350/hr
= 350/720
= 0.48 paise
= 0.56+0.45+0.48
= 1.49/component
37
= 6.64kg
= 1.26kg
= 2.11kg
Stripper plate
= 2.26kg
Die plate
= 2.52kg
= 1.26kg
=3.14252568
=133450 mm3
Weight= Volume density
106
=
1 33450 8
106
= 1.06kg
Piercing punch
= 0.23kg
Shank
= 2.11kg
Shedder
= 0.21kg
38
= 0.312 = 0.63kg
Bush
= 0.212 = 0.42kg
Dowel
= 0.13kg
Guide pin
= 0.013kg
Stopper
= 0.06kg
=1.05kg
=5.2kg
= 3.81kg
= 21.247 = Rs.996.4
= 1.0542 = Rs.44.1
= 5.260 = Rs.312
=3.81120 = Rs.457.2
= Rs.1809.7/-
39
Machine hr
15
35
20
10
25
4
5
8
Machining cost hr
60
70
125
80
120
300
30
70
0
0
1hr press machining cost
40
Total cost
900/2450/2500/800/3000/1200/150/560/11560/1810/0
0
350/500/14220/-
DEFECTS AND
CORRECTION
41
Chapter 8:
8.1 INTRODUCTION:
8.1.1 Defects:
The word defect is derived from the word techniques which mean mistakes on
the system.
8.1.2 Remedies:
The word remedies means to recover a right, or to obtain redress from wrong.
8.2 Some of the following major causes which we have come across are described:
8.2.1 Material cutting:
Cause
Solution
Solution
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INSPECTION
REPORT
43
DRAWING
44
APPLICATIONS
45
Washer Applications
There was dozens of uses for different kinds of washer. Generally shock absorber
washers are used:
To prevent leakage
To decrease friction
Used in hollow eroded shaft to support clamping so that it can prevent rapture of the
parts.
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A process involving the heating and cooling of a metal, commonly used to induce
softening.
2.19.3 HARDENING:
While manufacturing the dies, the heat treatment cycle plays an important role.
The heat treatment cycle for hardening of dies can be divided into following steps:
Pre- heating.
Final heating.
Soaking.
Quenching.
Tempering
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CONCLUSION
CONCLUSION
HAPTER 11:
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