Beruflich Dokumente
Kultur Dokumente
1
Pg Scholar, Department of MECH, MLR INSTITUTE OF TECHNOLOGY, Ranga Reddy, Telangana, India.
2
Assistant Professor, Department of MECH, MLR INSTITUTE OF TECHNOLOGY, Ranga Reddy, Telangana, India.
Abstract A form tool is precision-ground into a pattern formed by forming operation is generally takes the shape
that resembles the part to be formed. The form tool can of the dir or punch. In the forming operation, the metal
be used as a single operation and therefore eliminate flow is not uniform and localized to some extent,
many other operations from the slides (front, rear and/or depending upon the shape of the work piece. Bending
vertical) and the turret, such as box tools. A form tool along a large radius in a straight line may also be referred
turns one or more diameters while feeding into the work. to as a forming operation. It is difficult to distinguish
Before the use of form tools, diameters were turned by between a bending and forming tools. Forming operation
multiple slide and turret operations, and thus took more may be simple and extremely complicated.
work to make the part.
A form tool is precision-ground into a pattern that
In this Project we model a form tool using CATIA V5. resembles the part to be formed. The form tool can be used
The advantages of form tools are (a) cycle time, (b) it as a single operation and therefore eliminate many other
works as POKA YOKA (mistake proofing) (c) operations from the slides (front, rear and/or vertical) and
maintains relation between operation (d) cost the turret, such as box tools. A form tool turns one or more
optimization. This tool is designed based upon the diameters while feeding into the work. Before the use of
component drawing supplied by the customer, spindle form tools, diameters were turned by multiple slide and
power and rpm of CNC machine on which this tool is turret operations, and thus took more work to make the
proposed. This tool is modeled by using a 3D modeling part. For example, a form tool can turn many diameters
software. and in addition can also cut off the part in a single
operation and eliminate the need to index the turret. For
In this the design of form tool is carried out using CATIA single-spindle machines, bypassing the need to index the
modeling software, analyzed using FEA software ansys turret can dramatically increase hourly part production
workbench. rates. On long-running jobs it is common to use a roughing
tool on a different slide or turret station to remove the bulk
Keywords tool, single point cutting tool, designing ,
of the material to reduce wear on the form tool.
modeling , simulation, structural simulation, stress ,
strain, deformation
There are different types of form tools. Insert form tools
I INTRODUCTION are the most common for short- to medium-range jobs (50
to 20,000 pcs). Circular form tools are usually for longer
Designing a forming tool is one of vital factor of tool jobs, since the tool wear can be ground off the tool tip
engineering, which must be known by every design many times as the tool is rotated in its holder. There is also
engineer. Forming a tool means giving a particular and a skiving tool that can be used for light finishing cuts.
useful shape with required dimensions to the part. The part
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Form tools can be made of cobalt steel, carbide, or high- Flat or blocked tools are further classified according to the
speed steel. Carbide requires additional care because it is setting of tool with respect to the work piece, viz. radial-
very brittle and will chip if chatter occurs. fed tools and tangential-fed tools. Further, form tools are
also classified with respect to orientation of tools with
A drawback when using form tools is that the feed into the respect to the work piece axis
work is usually slow, 0.0005" to 0.0012" per revolution
depending on the width of the tool. Wide form tools create VARIOUS TYPES OF FORMING TOOLS:
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order that the depth BC is correct profile. This distance x is The circular form tool is circular in shape. It has depth x or
to be planned by a fly cutter or planning tool and is projection of distance x produced all around the diameter
measured normal to the clearance face. The amount of x is in the form of annular grooves. The outside diameter of
less than actual depth of form AB produced on the work circular form tool is determined in accordance with the
piece because of the clearance angle . From the geometry height of profile to be turned. The graphical method is
of the figure x = AB cos() recommended for this purpose. Circular form tool is shown
in Figure.
Figure shows a flat form tool with rake angle. The wedge
angle is given by (90 ). Using geometry of the
figure, the depth x to be ground or machined can be
determined in the following manner:
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efficient should therefore be as high as possible at the types of stress previously described. These may render the
rounding of the upper die but low at the rounding of the tool unfit for use and include:
drawing ring.
- Wear
In forward extrusion operations, compressive and
- Mechanical crack formation
temperature stresses occur at the upper die and
compressive, tensile, friction and thermal stresses at the - Thermal crack formation
lower die. Thermal load also develops in cold extrusion
- Plastic deformation.
operations as a result of the inner friction during material
flow.
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Since wear is the most important type of damage, it makes The most important wear mechanisms and means of
sense to investigate its causes in more detail. reducing wear, are therefore discussed briefly in the
following
There is no one material characteristic which provides a
conclusive indication in itself, as to the level of wear
resistance of that material. This is because in the vast
majority of cases, a number of causes interact and combine
to cause wear in the tribo-technical systems in industrial
practice,
These include:
- Adhesion
- Abrasion
Adhesive wear: Occurs when bonding forces in the area
- Surface break-up and of the atomic lattice take effect between two metallic
materials. The prerequisite for this is that the lattices of the
- Tribo-chemical reaction
bodies concerned, are structurally similar and that they
approach one another until there is only a short distance
between them. Furthermore, the more the lattice structures
of the materials concerned differ; the lower is their
susceptibility to adhesive wear.
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CHAMFERING
CREATING SHAFT
THICKNESS
CREATING POCKET
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MODAL ANALYSYS
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work
Sixth mode shape of FORM TOOL Von mises stresses of SISIC is 68.986MPA
is 0.00017681mm/mm
Modal analysis
4. The Eigen values (natural frequencies) of HIGH
SiSiC is 1478.9mm
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6. http://www.technologystudent.com/joints/matprop1.ht
m
7. https://en.wikipedia.org/wiki/Cnc-formtool
8. https://www.google.co.in/?gfe_rd=cr&ei=xgGLVfKS
Bafv8wftlJO4Dg&gws_rd=ssl#q=cnc%20form%20to
ols%20wikipedia
9. https://www.google.co.in/?gfe_rd=cr&ei=xgGLVfKS
Bafv8wftlJO4Dg&gws_rd=ssl#q=cnc+milling+machi
ne+form+tool
10. Brown & Sharpe, Automatic Screw Machine
Handbook p.
11. Jump up^ Hartness, James (1910), Hartness Flat
Turret Lathe Manual, Springfield, Vermont, USA:
Jones and Lamson Machine Company,
12. Jump up^ Kanigel, Robert (1997), The One Best Way:
Frederick Winslow Taylor and the Enigma of
Efficiency, Viking Penguin, ISBN 0-670-86402-1
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