2 PRESS TOOL DESIGN (GENERAL, Press working may be defined as a chipless manufacturing process by which various components are made from sheet metal. This process is also termed as cold stamping. The ‘machine used for press working is called a press. The main features of a press are : A frame which supports a ram or a slide and a bed, a source of mechanism for operating the ram in line with nd normal to the bed. The ram is equipped with suitable panch/punches and a dic block is attached to the bed. A stamping is produced by the downward stroke of the ram when the punch ‘moves towards and into the dic block. The punch and die block assembly is gencrally termed as adie set” or simply as the “die”. Press working operations are usually done at room temperature 2.2. PRESS OPERATIONS ‘The shect metal operations done on a press may be grouped into two categories, cuttin operations and forming operations, In cutting operations, the workpiece is stressed beyond ultimate strength, The stresses caused in the metal by the applied forces will be shearing stresses. In forming operations, the stresses are below the ultimate strength of the metal. In this operatio there is no cutting of the metal but only the contour of the workpiece is changed to get the desired product. The cutting operations include : blanking, punching, notching, perforating, trimming, shaving, slitting and lancing etc. ‘The forming operations include : bending, drawing, redrawin and squeczing. The stresses induced in the metal during bending and drawing operations are tensile and compressive and during the squee7ing operation these are compressive Below we give the definitions of the various press operations (a) Blanking. Blanking is the operation of cutting a Mat shape from sheet metal, The article punched out is called the “blank” and is the requited product of the operation. The hole and metal Jef beliind is discarded as waste. I is usually the first step of series of operations, Fig. 2.1 (a), Leen (@) Blanking (b) Punching Fig, 2.4. Blanking and Punching Plain blanking is explained in Fig. 2.2. (8) Punching (Piercing). Its 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 Fig. 2.1 (b) 6970 A Textbook of Production Engineoring (6) Notching. This is cutting operation by which metal pieces are cut from the edge of a sheet, strip or blank cap serom Dowel pin Stock: re Stock guide Stop pin Blanked: part Fig, 22. Plain Blanking (@ Perforating. This is a process by which multiple holes which together are cut in flat work material (e) Trimming. This operation consists of cutting unwanted excess material from the periphery of a previously formed component. (Shaving. The edges of a blanked part are generally rough, uneven and wnsquare. Accurate dimensions of the part are obtained by temoving a thin strip of metal along the edges. The operation is termed as shaving (@) Shining. It refers to the operation of making incomplete holes in a workpicce. () Lancing. This is a cutting in which a hole is partially cut and then one side is bent dow: fo form a sort of tab or louver. Since no metal is actually removed, there will be no scrap. (i Nibbling. The nibbling operation which is used for only small quantities of components, is designed for cutting out flat pars from sheet metal, The flat pars range from simple to complex contours. This operation is generally substituted for blanking. The part is usually moved and guided by hand as the continuously operating punch cuts away at the edge of the desired contour. () Bending. tn this operation, the material in the form of fat sheet or strip, is uniformly strained around a linear axis which lies in the neutral plane and perpendicular to the lengthwise direction of the sheet or metal (&) Drawing. This is a process of forming a flat workpiece into a hollow shape by means of punch which causes the blank to flow into a die cavity () Squeezing. Under this operation, the metal is caused to flow to all portions of a die cavity under the action of compressive forces Some of these operations are explained in Fig, 2.3 As written above, the workpiece obtained alter one or more press operations is called a ‘metal stamping. A metal stamping can be defined as one which is usually made of, but not limited to, sheet or strip metal that has been cut, coined, pierced, bent, formed or drawn in one or more Die Hock very sinall and closePros Too! Design n operations between matching dies under pressure, The size of a metal stamping, the thickness, the typo of material and shape vary widely. Meta stampings range in size from tiny instrument part 10 freight car ends. The materials amenable (o cold 1g are low-carbon and plastic al- | | loyed steels, non-ferrous metals including copper and its alloys (brass, bronze), aluminium, zine, titanium and other mate- WZ rials, The starting material for press work ing is sheet metal in the form of bands or (cutott (6) Lancing strips from tenth of a mm to about 6 or § ‘mm thick, During the stamping. process, metal. The material must be free from a | removed by pickling and other methods. The use of metal stampings is not (©) Shaving (@) Perforating, siting and confined to any single indusizy. On the potching contrary. a large percentage of manufac- Fig, 23, Some Press Operations tured products of all types employ at least one ot more n Advantages of metal stamping. Sheet stamping is working. It has got the following advantages 1. Small weight of fabricated parts. 2, High productivity of labour (upto 30,000 10 40,000 parts per 8 hour shift) 3, High efficiency of technique as regards the fabrication of items of diversified shapes, both simple and complex, such as washers, bushings, rclainers (cages) of ball bearing, tanks and car bodies ete. 4. The parts made by cold sheet metal stamping are distinguished for their size accuracy (narrow tolerances and high surface finish). In meany cases, they require no subsequent machining and are delivered 10 the assembly. shop. 5. High-volume, low-cost production. 6, Predictable strength characteristics. 7. Uniformity of parts, 8. Low cost material 9. Less labour-consuming, All the above advantages have made sheet stamping very attractive 10 a host of industries, particularly fo automotive, aiteraf, electrical engineering and others. The variety of products is immense, from aircraft skins and automobile bodies to appliance shells. Other products include construction girders, trick frames, furniture legs, supertankers, bath tubes, beer cans, wheel rims, fan blades, watch gears and so on (list is very long). Elastic Recovery or Springhack We know that in metal working proceses, the total deformation impatted to a workpiece will bbe the sum of elastic deformation and plastic deformation. We also know that clastic deformati is ecoverable whereas plastic deformation is permanent. So, al the end of a metal wor operation, when the pressure on the metal is released. there is an clastic recovery by the material and the total deformation will get reduced a litte, This phenomenon is called as “Springback”. ZB ctal stamping n advanced technique of mechanical72 A Textbook of Production Engineoring This phenomenon is more importance in cold working operations, especially in forming operations such as bending etc. Springback depends upon the yicld point strength of a metal. The higher the yield point strength of a metal, the greater the springback. The amount of springback for a Forming operation is difficult to predict and cut and try methods are most satisfactory to account {or it. To compensate for springback, the cold deformation must always be carried beyond the dosired limit by an amount equall © the springback. 23, PRESS-WORKING EQUIPMENT Pross-working equipment inchides different types of presses and tools, known as dies or jpress-tools’. Presses used for metal stamping are classified in various ways. They may be classified according to © Sources of power (4) method of actuation of ranvrams (Slide/Slides) (ii) number of slides Gv) type of frame (0) the type of work for which the press has been designed. The two main sources of power for applying force to the ram or slide of a press ate ‘mechanical and hydraulic, In mechanical presses, the linear movement ofthe ram is obtained with the help of a Flywheel driven system. The heavy flywheel absorbs energy continuously from an electric motor and detivers it 10 the ram and hence to the workpiece intermittently, Hydraulic presses are a large piston and cylinder arrangement coupled fo a hydraulic pump. The pist the press ram are one unit, The ram is actuated by oil pressure on the piston in the cylinder, Water and water-oil emulsion can also act as working mediums. Mechanical presses have the following advantages over hydraulic presses (1) mun faster (2) lower maintenance cost (3) lower capital cost Advantages of hydraulic presses are |. Most versatile and easier to operate ‘Tonnage capacity adjustable fom zero (0 maximum, Constant pressure can be maintained throughout the stroke Force and speed can be adjusted throughout the stroke, if need be 5. More powerful than mechanical presses 6, Safe as it will stop to a pressure setting 7, Stroke can be varied to any Tength within the limits of hydraulic cylinder travel, 8, The press can exert its full onnage at any position of the ram stroke, ‘The main disadvantage of the hydraulic press is that itis slower than a mechanical press ‘The flywheel of the mechanical press drives the main shaft, The rotary motion of the main shaft is converted into the linear motion of the ram or slide. The most common drive is crankshaft which is used for longer strokes, The eccentric drive can be used for smaller strokes, The other drives include : Cam, toggles, ruck and pinion, screws and knuckles which can be used to actuate the ram, Cam drive is similar to eccentric drive except that at the bottom of the stroke, dwell is obtained, Rack and pinion drive is used where a very long stroke is required, In this drive, the movement of the slide is uniform and much slower as compared to crank drive, Most press working makes use of mechanically driven and less frequently, hydraulic presses. According to the number of slides, there are three types of presses : single-. double. - or triple action press. A single action press has only one ram which acts against a fixed bed. A double action press has two slides (one inner and the other outer) moving in the same directionPros Too! Design 73 jnst the fixed bed of the press, Such presses are used in deep drawing operations. A triple action press has (wo slides moving in the same direction against the fixed bed as in double action press and the third or lower slide moves upward through the fixed bed. Such presses are used for mrge work such as motor car body panels, According to the type of frame, there are two types of presses : open frame presses ar closed frame presses. Due to their constriction, the open frame presses are less rigid and stron and so are useful mainly for operations on smatler work. These presses are available upto 200- fone capacity with strokes of 90 to 120 per minute, Closed frame presses are stronger, more rigid and balanced than open frame presses, These presses are available upto at least 3000 tonnes capacity ‘The “Throat Depth’ of a press is the distance from the slide centre line fo the frame. It dotermines the maximum distance between the shank axis and the rearmost point of a die that can be mounted on the press, ‘Small presses often have inelinable press frames which facilitate removal of the stamped pant by gravity Depending upon the type of work. the presses can be designed for doing the following types of work : Punching, Blanking, Drawing, Bending, Forming, Coining, Embossing etc According to the method of strip feeding the presses can be designed cither for manual or automatic feed. According to the method of removing finished pans, there are three types of presses 1, Presses with dies with a hole through which the part drops. 2. The ones in which the component is ejected upwards and then removed by a positive Knockout 3, Those in which the finished parts are removed by compressed air or manually 2.3.1. Rating of a press. A press is rated in Tonnes of force that can be applied to the slide ‘without undue strain and without affecting the structural strength of the press. ‘The tonnage of a mechanical press is determined by the size ofthe bearing for the crankshaft or the eccentric. It is given approximately by the relation ‘Tonnage capacity = Shear strength of the crankshaft material ‘the area of the crankshaft bearings ‘The tonnage capacity of a mechanical press is always given when the slide is near the bottom of its stroke. beeanse it will be maximum at that point, or with the crank turned through n angle of not more than 30° from the bottom zero position, The ionnage capacity of a hydraulic press is given as Rated capacity = Piston area » oil pressure in the cylinder As noted earlier, the capacity of a hydraulic press can be varied by changing oil pressure In double-action crank presses. the tonnage of the inner stide determines the maximum drawing pressure, while the maximum blank holding pressure depends upon the tonnage of the outer side, To keep the strains and the deflections ofthe press structure small it i a usual practice to choose a press rated 50 to 100% higher than the force required for an operation, In the case of single,- double.- and triple- action hydraulic presses, the rams may all be driven from a central hydraulic accumulator fed by pump, or have individual drives from one or ‘more pumps ‘The construction and working of the various types of presses mentioned above have becn discussed in dotail in the book “A Textbook of Production Technology” by the author. 2.3.2. Requirements of press tool design, The press tool design should suit the iype of production it will be used for, that is, small batch, lage batch, or mass production. The press tools should meet the following requirements74 A Textbook of Production Engineoring 1. The dimensional accuracy and surface finish of stampings should conform to the drawings and specification. 2. The working parts of the press tool (die and punch) must be adequately strong, durable in operation and easily replaceable when wor out 3. The die should ensure the required hourly out put, easy maintenance, safe operation and reliable fastenings in the press. 4. The die should be designed in such a way that as far as possible standard components are used for its manufacture. As few special parts as possible should be used i is design. 5. The scrap im the stamping operation must be kept at a minimum by suitably designing the strip layout, The percent utilization of the material is given as Total area of blank cut Toa re of Hank eH 199 Percentage material ulization = en Normally, the value of this factor is 70 10 80% 2.3.3. Press tool components. The press tool components may be divided into the following pes, sce Fig. 2.4 (@) Working components, which participate in the shaping of parts: dies. punches and their sections, (6) Structural components, which serve for joining the working components to one smother nd (o the pross : Upper shoe (Punch holder), lower shoe (die holder) and shanks. (©) Guiding components, which ensure accurate alignment of the upper shoe with the die shoe in operation : guide posts and bushings. Guide posts also facilitate tryout of the press tool in a press (d) Feeding components, which feed, the sess bono te sumpng SUS shank PhinPros Too! Design 75 (dic shoc), The available space for mounting punch and die components is called the “dic-area’ ‘The dic area on the lower shoe should be at least 6.35 mm larger all around the dic block. are provided on the Mange of the dic shoe to asten it fo the bolster plate or the bed of the Gude Punch. Shank press, with the help of 7-bolts. ia Insinaller die sets the upper shoes are made with a shank, On longer die sts (for cutting press tools) the standard shouldered shanks are press. fRusing fitted into a specially bored hole of the upper shoe, Fig. 2.6 (a). In drawing and bending press tools. threaded shanks are used Fig. 2.6 (6). Ranges There are other arrangements also for fitting the shanks into the upper shoes of larger dic sets. If the tool shank does not fit inthe press slide hol. adapter shanks or split adapter bushings may be Fig, 28, A Commenial Die employed. Arrangement of guide posts. The various arrangements of guide posis are given below (a) Back-post design. In this design, the dic-sct has two guide posts positioned in the rea Fig. 27 (also sce Fig. 2.5) SN pee foe) [6 Mh AMA ©) 26. Press ‘Too! Shanks. TPhis is the most frequently used design. This design gives clear view of the moving parts and there is no obstruction from guide posts. This helps the operator when feeding from Jefi to right. This design also leaves a clear space for hand feeding blanks for second operations. (}) Centre-post or Axiat-post design. In this design, the wo guide posts are positioned along the transverse centre line of the die-set, Fig. 2.8. This design is suitable when the load is too heavy and the strip feeding is from the front. This design provents end feeding. i val OTD Fig, 2.9. Diagonal Post Design Fig. 2.10, Fouruide Post Design Lower shoe ig, 27. Back Post Design Fig, 28. Avisl-post Design Lower shoe76 A Textbook of Production Engineoring (©) Diagonal-post design. This design, Fig. 2.9 is used when the load is very heavy and end feeding is required, The guide posts are along a diagonal line. Generally, the left guide post is in front, but if feed is 10 be from left to right, the right guide post is in front (A) Four-guide post design : In this design, Fig, 2,10, a guide post is positioned at each corner of the dic-set. This design provides maximum rigidity and accuracy of alignment. This design is used for large, very complicated, or highly accurate stampings and for multi-station progressive dics 244, PRESS SELECTION The factors which should be considered while selecting a press for a given job, are : the overall work size, the stock thickness and material, kind of operation to be performed, power required and specd of operation, For punching, blanking and trimming operations. usually the crank or eccentric type ‘mechanical press is used. This is due to their small working strokes and high production ra In these operations, there is sudden release of load at the end of the cutting stroke, This sud release of load is not advisable in hydraulic presses. So, hydraulic presses are not preferred for these operations. If however these are inevitable, then some damping devices are incorporated in the press design. For coining and other squeezing operations, which require very large forces Knuckle joint mechanical press is idcally suited. Hydraulic presses, which are slower and more powerful, can also be used for these operations. Hydraulic presses are also better adapted to pressing, forming and drawing operations, which are basically slower processes, 2.5, PRESS WORKING TERMINOLOGY A simple cutting die used for punching and blanking operations is shown in Fig, 2.11 Below, the definitions of the main components of the die and press are given ca an (ste) i shank ~ j— Back up plate +— Punch ah patna SEES (cope oho) Pench pi 8) iy A ote Punch >| ‘Stripper uo pot BE acting Dis holder ‘Die block Cower oe TL snr Be orpess Fig, 2.11. 4 Simple Cutting Die Bed. The bed is the lower part of a press frame that serves as a table to which a bolster plate is mounted, Bolster plate. This is a thick plate secured to the press bed, which is used for locating and supporting the dic assembly, It is usually $ to 12.5 cm thick Dic set. It is unit assembly which incorporates a lower and upper shoe, two or more guideposts and guidepost bushings. Die. The die may be defined as the female part of a complete tool for producing work in press, It is also referred to a complete tool consisting of a pair of mating members for producing work in a pressPros Too! Design 7 ie block. It is a block or a plate which contains a dic cavity Lower Shoe. The lower shoe of a dic set is generally mounted on the bolster platc of a press. The die block is mounted on the lower shoe, Also, the guide posts are mounted in it 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. Upper Shoe. This is the upper part of the die set which contains guidepost bushings. Punch plate, The punch plate or punch retainer fits closely over the body of the punch holds it in proper relative position. Back up plate. Back up plate or pressure plate is placed so that the intensity of pressure does not became excessive on punch holder. The plate distributes the pressure over a wide arca and the intensity of pressure on the punch holder is reduced to avoid cru Stripper. It is a plate which is used to strip the metal strip from a cutting oF non-cultin punch or die. It may also guide the sheet Knockout, Tt isa mechanism, usually connected to and operated by the press ram, for freeing a workpicce from a dic. Pitman, I is a connecting rod which is used to transmit motion from the main drive shaft fo the press slide. Shut Height. [tis the distance from top of the bed to the bottom of the slide, with its stoke down and adjustment up. Stroke. The siroke 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 hydraulic press, 2.5.1 Working of a cutting die (Fig. 2.11). As is elear inthe figure, the punch holder (upper shoe) is fastened directly 10 the ram of the punch press, and the die shoe (lower shoe) is fastened to the bolster plate of the press. Guide posts may be used to better align the punch holder with the die shoe. These main components (punch holder. die shoe and guide posts) constitute whi is known as the die set. A dic set can be hud with two guide posts located at the rear of the die sel (known as back posts), diagonally, one at the back and the other in the front of the die se, or with four guide posts, one in each corner of the die set. The lower ends of the guide posts are press fitted into the dic shoe. At the upper end. the guide posts have a slip fit with the guide bushings 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 black is fastened to the die-shoo, The punch is aligned with the opening in the dic-block. Since, both the punch and die block act as cutting tools, they ate hardened, am nen | roar PA \ Ae on deter —] Tes es Fig, 2.12. A Cuting Die78 A Textbook of Production Engineoring ‘The cutting action takes place during the downward movement of the punch into the dic block. After the cutting action, the elastic tecovery in the strip material takes place, Due to this, the size of the blank (cut portion from the strip) increases and that of the bole in the strip decreases. So, at the end of the cutting action, when the punch stars to move upwards the scrap strip clings to the punch and the blank gets clogged in the die-opening, To remove the scrap strip from the punch surface, a stripper is used. In Fig. 2.11., a simplest type of stripper is used. Tt sirips off the scrap strip from the punch surface when the scrap strip strikes the bottom surface of the stripper during the upward movement of the punch. To avoid clinging ofthe blank in the die opening, the walls of the die-opening are tapered, In addition to the two above mentioned troubles, the blank may also adhere to the face of the punch. This usually happens with thin blanks which have been treated with a lubricant. To holp the blank free itself from the punch face, push-off pins are provided which are fitted into the punch body: Fig, 2.12 The various basic designs of push-off pins are shown in Fig, 2.13. The most popular des {s a straight, round plunger with a sliding fit in the punch body. Fig. 2.13 (a). Its held in place by a light compression spring and a set screw. If al the end of the punch bods, a pilot is to be provided, then the push-off pin is located off-centre, Fig. 2.13 (b), When the space available for 8 compressing spring is insufficient, a at spring, may be used, Fig. 2.13 (@) Punch holder @ 0) o In the case of very stnall punches. no space is left to provide the push-off pin, In such cases, the sticking of the blank to the punk . Y ng the shape of the punch bottom, Fig, 2.14, With this, the oil seal or vacuum created by the oil film is broken and tendeney of the blank to stick to the punch face is greatly decreased, The drawback of this method is that blank gets distorted. Duc to this, this method is suitable for punching operation only ST Lt & Y ( OT” x WON YY Fig, 2.14, Punch Pace Contours to Prevent Blanks from Sticking to very small Punghes 2.6, TYPES OF DIES This dies may be classified according to the type of press operation and according to the ‘method of operation, 2.6.1 Type of press operation, According to this criterion, the dies may be classified as cutting dies and forming diesPros Too! Design 79 Cutting dies. These dies are used to cut the metal. They utilize the cutting or shearing action. The common cutting dies arc blanking dics, piowing dies, perforating dies, notching, ‘vimming, shaving and nibbling dies ete Forming dies. These dies change the appear- c of the blank without removing any stock. These es include bending dies, drawing dies, squeczing dies ete Z 2.6.2. Method of operation. According to this criterion, the dies may be classified as : Single- operation dies or simple dies, compound. dies combination dies, progressive dies, transfer dis, and smultiple dies Simple dies. Simple dies or single action dies perform single operation for each stroke of the press slide. The operation may be any’ of the operations listed under cutting or forming dies. Compound dies. In these dics, two or more operations maybe performed at one station, Such dies are considered as cutting tools. since, only cutting operations are cartied out. Fig. 2.15 shows a simple compound die in which a washer is made by a punch Locating pin Stripper Metal sip one stroke of the press. The washer is produced by —_— — simultancous blanking and piercing operations. Com Pound dies are more accurate and economical in —_— = mass production as compared 10 single operation dies | Combination dies. In this die also, more than Fig, 2.15, Compound De fone operations may be performed at one station, It differs from compound die in that in this die, a cutting operation is combined with a bending or drawing operation. Fig. 2.16 explains the working of a combination blank and draw die. The die ring which is mounted on. the die-shoe, is counterbored at the bottom to allow the flange of a pad 0 travel up and down. This ad is held flush with the fice of the dic by a spring. A drawing punch of required shape is ied to the dic shoe. The blanking punch is secured to the punch holder. A spring stripper sirips the skeleton from the blanking punch, A knockout extending through the centre opening my ot j tarking “pn 2 , g g g E Z EL sopper Contes io | ee c oem Hea Fig. 2.16. Combination Die.80 A Textbook of Production Engineoring and through the punch stem ejects the part on the upstroke as it comes in contact with the Knockout bar on the press. In operation, the blank holding ring descends asthe partis blanked, thon the drawing puch contacts and forces the blank into the drawing die which is made in the blanking punch, Progressive dies. A progressive or follow on die has a series of stations. At each station, an operation is performed on a workpiece during a siroke ofthe press. Betwcen stroke, the piece in the metal sirp is transferred (o the next station, A Tinished workpiece is made at each stroke of the press. A progressive die is shown in Fig 2.17. While the piereing punch euts a hole inthe Stock, the blanking punch blanks out portion of the metal in which a bole hal been pierced at a Barking, previous station, ‘Thus after the firs siroke, when only a hole will be punched, each stroke of the press produces a finished washer Guide pin —s Transfer dies. Unlike the progressive dies were the sock is fed progressively frm one 1 fe station to another, in transfer dies the already cut i ' blanks are fed mechanically from station t0 LA ow station. oer i ‘Multiple dies. Multiple or gang dies pro i i Pe duce two of more workpieces at each stroke of the press, A gang or number of simple dios and i t punches are ganged together to produce Wo oF i i ‘more parts al cach stroke of the press. 2.7, PRINCIPLE OF METAL CUTTING Bolster. The cutting of sheet metal in press work is prune a shearing process. The cutting action is exe cc & plained with the help of Fig. 2.18, The punch is of the sime shape as of the die opening except that it is smaller on each side by an amount known as ‘elearance’. As the punch touches the material and travels downwards, it pushes the material into the die opening, the material is subjected to both tensile and compressive stresses as shown in Fig. 2.18 (a) Stresses will be highest at the edges of punch and dio and the material will start cracking there. The vari- fous steps in the rupture or facture ofthe material ca ‘written as: stressing the mate- rial beyond its elastic limit, plastic deformation, reduction in arca, fracturing sian in the reduced a complete. I the clearance be- tween punch and die is comect, the cracks starting from the punch and die edges will meet and the rupture is complete as (a) Stossin de cting @)Conoct Charanco shown in Fig, 2.18 (6), Ifthe Fig. 2.18, Proviple of Metal Cotting Punch holder i i] Piercing i i he pun 27. Progressive DiePros Too! Design a clearance is too large oF 190 small, the cracks do not mect and a ragged edge results die to the ‘material being dragged and torn through the dic. This is explained in Fig, 2.19. 2.8, CLEARANCE, Too title ~, s, [Toa much (27) (clearance won woe fe arin he pens tr Cero FU Punch anicle, the die opening must be ot sufficiently larger than the punch 4 ! to permit a clean fracture of the fyyzq 7 \pol nay syn) rtal. This difference in dimen: sions between the mating mem i bers of die sot is called ‘clear- ance’. This clearance is applied ° ° in the following manner Fig, 2.19. Improper Clearance (0, When the hole has to be held to size, ‘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, Fig. 2.20 (a). oe o we {eS4] ae see 20 N SS Ma (a) Shugis scrap (©) Slug is desir pat Fig. 2.20. Applicaton of Clearanos i) In blanking operation, where the slug or blank is the desised 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, Fig, 2.20 (6), In Fig. 2.20, C is the amount of clearance per side of the dic opening. The clearance is a function of the kind, thickness and temper of the work material, harder materials requiring larger clearance than soft materials, the exception being Aluminium. ‘The usual clearance per side of the die, for various metals, are given below in terms of the stock thickness, 1 For brass and soft steel, c= S% of For medium steel, c= 6% oft For hard steel c= M% of For aluminium, © = 10% of f The total clearance between pur are for blanking and piercing opera The clearance may also be determined withthe help ofthe flowing relation = 0.0032 #-,-mm wheres, isthe shear strength ofthe matt in Nema and die size will be twive these figures, These clearances82 A Textbook of Production Engineoring The reason behind the application of clearance in the manner as given above, is explained below ‘The diameter of the blank or punched hole is determined by the burnished area, On the blank, the burnished area is produced by the walls of the dic. Therefore, the blank size will be equal to the size oF die-opening (neglecting a slight expansion oF the blank duc to elastic recovery after the cutting operation is completed). Similarly, in punching operation, the burnished area the hole is produced by the punch, therefore, the size of the hole will be the same as the punch. ‘Therefore, the application of clearance on punch or die will depend on whether the punched hole or the cut blank is the desired product. Hence. in punching operation (where hole in the strip is the desired product), the punch is made to the correct hole size and the die opening is mad oversize an amount equal to die clearance. Similarly, if the blank is the desired product, the di opening size is made to the correct blank size and the punch is made smaller an amount equal to die clearance. In other words, punch controls the hole size and die opening controls the bl A section through blanking die is given in Fig. 2.21, showing clearance, land, straight and angular clearance — =| mH x vee ty ont 1 Kr Qn The factor & is 0.2 00 0.6 if shear J = « (0.2 to 0.4 if shear J = 2¢ ‘The work done or the shearing energy may also be approximately determined with the help of the following empirical relation E = Area under the force displacement curve, Fig. 2.22 = CtPros Too! Design 87 where the constant C, is, = 0.5 for son materials = 0.38 for hard materials As already noted, when the cutting edges (of punch and die) are parallel, the length to be cot is the entire length of the contour cut, that is. the perimeter of the blank. This ean lead to ve high cutting forces. These can be reduced by placing the two cutting edges at an angle to cach other (called shear or rake) as discussed above. Here, only the instantancous sheared length needs to be considered, which will be given as in the case of sheet cutting machine, where angle of shear. 2, Slaggering of punches. As an effect similar to shear can be obtained by staggerin, ‘or more punches that all operate in one stroke of press. For staggering, the punches are art so that one does not enter the material until the one before it has penetrated through, In this manner, the cutting load may be reduced approximately 50 per com, Fig, 2.24 2.11, MINIMUM DIAMETER OF PIERCING To punch a hole without the failure of the punch, the compressive strength of the punch should be Teast equal to the foree necessary to fracture the ‘material. The hole which will be punched under thi condition will be the smallest, It, is the shear strength of the work material o, is the compressive strength of the punch material, dis the smallest hole diameter to be pierced and / is the thickness, then, Piercing pressure = ¢,d.t a f Strength of punch sats = Foto ‘ 4 d= sey IP it is assumed that, 2, then, d=2 .e,, the minimum diameter of hole that can be punched is twice the stock thickness. In actual practice. smaller holes than this are pierced successfully, showing to what extent the punch may be loaded without Failure Minimum size of punched holes depending upon their shape (round, square, rectangular. oval) are given below = 0.7 to 1.2 4 for soft steel 0,9 to 1.5 1 for steel 1.75 10 2 £ for Ti alloys 0.6 t0 0.9 ¢ for brass and copper = 0,5 (0 08 1 for Zine38 A Textbook of Production Engineoring 0.4 10 0.7 ¢ for bakelite and textolite = 03 to 0.6 1 for cardboard and paper Punching force for holes which are smaller than the stock thickness, may be estimated as follows ridley Vain” where d and ¢ are in mm and o, is the tensile strength in Nim? or MPa 2.12, BLANKING DIE DESIGN 2.12.1 Types of blanking dies. There are two genetal types of blanking dies : the drop through and the inverted. Drop-through die. In this dic, the die block assembly is mounted on the bolster plate or the press bed and the punch assembly on the press slide, Fig. 2.11. The blank drops of its own weight trough the die opening and the clearance hole provided in the bolster plate and press bed. This design is economical to build and maintain and is fast in working. However, this design is not suitable under the following condition 1. When the blank is too thin and fragile to be dropped very far. 2. When the blank is (00 heavy to be dropped for any appreciable distance. 3. When the blank is (00 awkward (0 be removed from below the press. 4. When the blank is larger than the press bed opening, Inverted type die, In this design, the punch becomes the lower stationary part and the die is mounted on the ram, This type is somewhat more complicated, more costly and slower in operation. The scrap disposal is much easier but removal of blank from the dic opening is troublesome and a device is needed 10 knock the blank out of the die opening. This type is widely used where the blank is large or heavy Fig. 2.25 shows an inverted type Blanking die. During the downward stroke of the ram. the bank is cut from the sitip, The blank and the shedder (spring loaded knockout) are forced into the die opening, which compress a spring in the die opening. AC the same time, a compression spring attached to the stripper is compressed. On the upstroke of the ram, the stripper strips the scrap aff the punch and the shedder forces the blank out of the opening. The blank falls dow or is blown out the rear of the press, Usually, the press is inclined to aid the discharge operation. aes Gee ae I = Je Pach olor De: Shedler Blank Guide ‘Stipper— = a at Fig. 2.28. Inverted Blanking Die 2.12.2. Strip layout. In the design ofa blanking die set, the firs step is to prepare blankin layout, that is, 10 layout the position of the workpieces in the strip and their orientation with respect fo one another. This is called “Strip layout’. The factors which will influance the stock layout arePros Too! Design 39 Economy of material. Dirvetion of material grain or Fibre Strip or Coiled stock. required. Direction of bur Pm ned Pros Die eos 1 Beanomy of material In Fig, 2.26, the difent wap of aang t lank te given workpiece re shown Tic arageneitin Fig 2260 canbe worked at single tw ile pce witha ie pinch For sean of Fir 2.200 teaip would er fave to be fed twice, once for each row, or [P r {P Soe nking Sel ave have be aplye The ge wat ira 1 te Sy be ingens sma the r ii} Lr ir ip sangeet ot Fig 330 Gta, by iovins two or vom: thee) wove oe ® blanks. Fig. 2.26 (c) shows a single row, Ba pas he call Saoek seit Hoe he srl hae tobe , pest ivi hee ones raed ee had ped tro des a econ time. Nesting considerably reduces the ( Ba ay gout se thea somntston may become more complex which would offi the Scns io tr econo ans ge moro ase 1 Be pode ‘not inpontnt conden in sry aot the dance beeen he ns! pois of bias an tween blake athe edge te ap To pete sat from hos nd vgn btwonn te anche eth dataset cee pate kk Sonnac ed we att 1 hes the ma sre show in Fin 277 ‘Sora fe rapa) w Sage peso fo 1G 12 Fig. 227. ‘The distance between the blank and edge of strip. known as back serap (Front scrap) may bbe determined by the equ tip Layout a= 10015 h 2.8) TPhe distance between successive blanks and also the scrap bridge, b. is given in Table 2.3 In general, softer metals require larger spacing and thinner metals require larger spacing.90 A Textbook of Production Engineoring The feed or advance or the length of one piece of stock needed 10 produce one blank is, sewtb 29) ‘The number of blanks which can be produced from one length of stock can be found out as, L-b . (2.10) Table 2.3, Material Thickness > as os 08 to covet 32 32 The scrap remaining at the end of one length of strip may be calculated from, y= L-(Ns+b) can) Measure of material utilization : ILis defined as, -8 . 4 % scrap = x 100 Now area of matetial available per blank = Feed or advance » Stock width Feed is also called “Progression”. wah ForFig 227, Yo ullzaion.n, = ——T For a round blank of diameter d, rp ee (aso) 20) ny should not be Jess than 70% for economical working. However, for complicated shapes of blanks, n,, can be less than 70% 2, Direction of material grain, This fictor is to be considered if the cut blanks hae to ‘undergo any subsequent operation, such as, bending or deep drawving. When the sheet metal strip {is rolled in the mill, a fibre is produced in the direction of stip length, During subsequent bending operation on the blank, to obtain maximum strength from bent parts, the bends should be made across the strip, of at an angle of 90° to the fibre. Therefore, some part prints specify that the fibre is to run in the direction of an arrow shown on the print. In such cases, the blanks can not be tipped or rotated to just any position desired, 3. Strip or Coiled stock. Another important consideration in the strip layout is whether the stock used will be in the form ofa strip or cail. Whereas, the stock strip may be passed through the die more than once, the coiled stock is usually passed through the die only once ‘When coiled stock is used. decoiling and recoiling of the stock is expensive (a decoilin reel, a stock straightner and feed rolls are necessary). Thus coiled stock is used when (@) Production is high, (®) Thinner metal sheets are employed (©) The stock needs to be passed through the die only once, (2.12)Pros Too! Design a Strip stock is used when = () Production is low, Gi) Thicker sheet metals are used. Git) The stock needs to be passed through the die more than once, Here, the stock feed is mannal 4, Direction of burr. When sheet metal is of the scrap sirip and on the punch side of the bla then the expensive operation of removing the burr need not be done. For this, a note is often placed on the part drawing which reads “burr down”. To control the position of the burr may limit -layout arrangement. Scrap may not be reduced (0 a minimum, 5. Press used. During production planning. a press has been assigned (0 the operation an the die. Therefore, the siock layout has to be suci tat it allows the die to be designed within the press capacity. Shear may have to be provided on punch or dic, to limit the maxinnum cutting force ‘within the press capacity. Another factor is the bed area of the press. The relation of the press bed area to the blank area is a definite factor controlling the stock layout The third factor is to have the cutting forces of the dic evenly balanced around the centre line of the press ram. 6, Production required. The following guide lines may be followed when production is the ‘main consideration (a) Low production-thin material (Strip stock and a single-pass layout (9 Cutting of one of mote blanks at a time () Low production-thick material ( Sutip stock and a single or double-pass layout 9 Cutting one blank at a time. (© High production-thin material ( Coiled stock and a single-pass layout Gi) Cutting of one oF mote blanks at a time. (d) High production-thick material ( Suip stock, and a single- or double-pass layout (4 Cutting of more than one blank at a time. 7. Die-cost. Die-cost will be higher for () Higher productions. Gi) Cutting more than one at a time, particularly when cutting extremely complicated blank shapes, or when cutting extremely accurate blank sizes, However, for simple round ot square-edged blanks. multiple cutting at one time is often practical. Also, double-pass dies are less expensive than cutting 10 at a time, So, the designer has to decide while making the 1 stock layout, as 10 which is Dowel pint /— Set screw preferred: more operator time per blank or more ma- chine time per blank. 2.12.3. Die-block. The die block is the female halt of the two mated tools which carry the cutting edges. It is subjected t0 extreme pres- Sot sow S| 8 sures and wear conditions. ' Hence the dic block is made ! of a superior quality of tool sicel. A simple layout of the Rig 2.28, Die Block Layout in a die, a burr is produced on the die side IP the burr has (0 be on the hidden side, Die-caviy | [Donel pn92 A Textbook of Production Engineoring die block is shown in Fig, 2.28. The die block may be of solid or sectional construction, depending on the size and contour of the die opening, If the die opening is small and its contour is simple, a solid die block is the choice, Sectional dies are made up of accurately ground matchin components which may be assembled together easily. Sectional dies have the following advantages 1. Dies with tong. and complicated contours can be broken up imo sections of simple ‘geometrical forms which can cusily and economically machined, 2. Building the die block in sections eliminate heal, treating, distortion and cracking as the separate pieces handled are more uniform in cross-section. 3, Grinding of the sections is more easily done, 4. Maintenance of the dic is simple and less costly, because if one section happens to crack or chip, only that particular section will have to be replaced. Sectional dies have the following disadvantages : 1. This design is not suitable when the stock thickness is quite large and there is great side pressure in blanking 2, Ifthe bed and press slide are not absolutely parallel, proper alignment between the punch and the sectional die will be extremely difficult to maintain, For the high production of accurately shaved die products of complicated shapes, secti dies have definitely an edge over solid dies. However, the availability of modern toolin equipment by which punch and die can be made in one cut, for example by contour sawing method, has extended the range of solid die construction, Generally, high carbon, high chromiun steels ate used for die sections which are hardened and ground. The die block is either mounted on or hield in a die shoe, as shown in Fig, 2.29, Sait ‘Seatanal ‘Mounted On Shoe ‘Sunk Into Shoe Fig, 229, Fixing of Die Block 1 Die St Die block thickness. The minimum thickness of die block depends upon the streng! required to resist the cutting forces, and it will depend upon the type and thickness of the material being cut. The determination of die block thickness is usually based on experience and thumb rales. According f@ one “Rule of Thumb”, the die thickness may be obtained ( Die thickness = 19 mm, for blank perimeter > 75 1m Gi) Die thickness = 25 mm, for blank perimeter = 75 mm to 250. mm. (iit) Die thickness = 31 mm, for blank perimeter > 250 mm, followsPros Too! Design 93 This rule of thumb is for die blocks made of tool steel The dic thickness may’ also be obtained from table 2.4, in which it is given as a function of siock thickness and quantity of production. Allowances for polishing must be added 10 the values ‘When the parts are made of lamination stock or other extremely hard or towgh materials, the thickness given in table 2.4 can be increased by 3 mm. However, for bakelite, brass or similar soft materials, it can be reduced by 3 mm. Care must be taken not to make the die block unnecessary thick as it adds to the cost of manufacture and results in an excessive shut height ‘Table 2.4, Die-Block Thickness. Stook Thickness Production Quantity million) 5 25 0 100 500 | Cilintted 037s | 937s 19 25 8 ams | 2s | isas | 19 2s 28 28 | Die Block avs |ises | 25 2 aI 34 | Thickness, 3.25 9 25 2% 2 aL en om 4675 25 28 By n M ys 625 3 31 31 ™ 375 a5 or, dic-block thickness can be taken as 1 = YF om; Fis in tonnes 7.5 mm and 10.5 mm. for die-surface area above 3200 mm Die opening. A section of the die block is shown in Fig. 2.21. The side walls of the die block opening should be provided with sufficient relief, Fig, 2.18a or taper s0 that the blank drops clear through. This taper can either star from the top surfice itself or after a straight kan from the surface of the dic, Fig. 2.2. Where the filing and grinding of the dic is dane by machine the fully tapered cavity is quicker to produce and is therefore eheaper. But if the die has to be finished on bench, the straight land is easier 10 file and sandstone Soft metals such as copper. brass and aluminium tend to swell more rapidly after being cut This may be due to a slight spring back or retum of the material along the lines in whic it which it has been stressed in compression. So, for such metals, the dic cavity’ should be fully tapered. But for stecl, the taper or relief should start after the straight land from the dic surface. The chief advantage of the straight land is that the original dimensions of the die are retained after ropoated regrinding, With fully tapered die cavity design, the die opening size increases after cach regrinding, This increase, however. is very negligible to cause any appreciable effect on blank dimensions As already mentioned, the staight land should be at least equal to stock thickness and not S Jess than 3 mm, The relief angle or taper may be taken as: —~ 10 1° for small dies, 1° to 2° for average dies and 2° to 3° on large dies. For softer materials, these values can be slightly increased. Also, the claser the blank tolerances, the less the relief. ‘The nominal size and outline of the die cavity is identical with the blank dimensions. At least distance equal to stock thickness should be provided between blanks and the edge of the stip. The die wall thickness from the edge of the die opening to the die block border, that is, the distance [Fig, 2.29 (a)), should be at least equal to as given below94 A Textbook of Production Engineoring A= 1,5 to 2 times the die thickness (7) for small dies = 2 t03 times the dic thickness for lar Ll; | . t me | o feel oo. Ret Fig 229 (a) After that, the dic thickness J must be checked, According to an empirical rule, the cross- sectional area d > 7; [Fig. 2.292 (4)] must bear a certain minimum relationship to the maximum cutting foree (2), fora die put on a flat baso. This is given in Table 2.4 (a). Ifthe die thicknoss, as calculated above, does not give sullicient area for te critical distance 1, the dic thickness must be increased accordingly According to “Rule of Thumb” there should be a minimum of 32 mm margin around the opening of the die block (distance 4). In general, on very thin materials, 12.7 mm die block tke wl be aufient bu. except for tora ons, fished thickness Getaing ing allowance of 2.5 to 5 mm) is seldom less than 22 mm, which allows for blind setew Holes. Sharp comers in the contour may lead vo cracking in hat treatment, and so require preter wall thickness at such points. 1 dics. Table 2.4 (a) Maximum Cong fore, “Area beaween dle opening kv border (ent) 200 335 500 630 750 975 1000 15.00 Fastening of die block. The dic block is secured either to the die shoe er bolster plate, The size of screws and bolts employed is usually not calculated, They are usually chosen by personal judgement and practical experience, According to one empirical rule Screw diameter = 0.5 4, for Ts 19 mm, = 044 for 7 19 mm. Along with screws, dowel pins are also used for alignment purposes, They are usually ly opposite comers of the die block, for maximum locating effect, The cter of the dowel pins is taken to be equal to the ontside diameter of the fastening, screws, Two, and only (wo, dowel pins should be provided in the die block for permanent Dowel Pins. Any misalignment of die details may cause severe damage. Therefore, any details that must be located accurately are held in such a position by dowels. Two dowels are necessary for one detail to achieve complete location. Most dowels used in dic construction we hardened and ground stee! pins. They are pres ited in the detail and the mounting plate or shoe Keeping the dowel diameters same as that of the screws facilitates the drilling and reaming of dowel holes. The position of the dowel pins isso sclecied as to make through holes for them. Fig. 2.30, otherwise the removal of the pins during disassembly will be too difficult. IF through holes at not available taper pins are driven, the holes for them being machined by a taper reamer.Pros Too! Design 95 Whenever possible. treading hardened components shoul be avoided. For example «Ojon the threads should be cal 1h6 oy dis shoe (which is made orcs CEES i SHeel and is not hardened) and ! rT ! owe! the block should be clearance ' | : dled ‘and counter bored to i 1 ficeept the cap serens. The ef. i) Wy) } i; Y Wi} feotive thread depth of the //// i eM) serons should be 1 to 2 tines ' Ue Soe the scrow diameter 1. On die blacks up to 18 tem square, use (v0 10 mim screws and (so 10 mm dowel pins. 2. On sections upto 25 cm square, use three serews and two dowel pins, 3. Forbblanking heavy stock, use serew and dowels of 12.7 mm diameters. Counterbore the cap screws about 3 mn deeper than usual, to compensate for die sharpening, Screws and dowels are preferably located about 1.5 to 2 times their diameter from the outer edges or the blanking contour, Min, permissible centre distance between the tapped hole and dowel pin > 2 » serew diameter. ‘The diameter of fastening serews can also be found by calculations. The basis for the computation is the stripping force, which depends upon many'factors, but may be taken as 10 per cent of cutting force. With this force, the screws which fasten the stripper (o the die plate or secure the punch holder fo the punch plate can be easily calculated, Practically, the same values are then taken for screws which secure the die block to the press table ~ Stripping force, Fe= 01% Pxtxt= ab doxnxs, where de is the core diameter of screw, o, is the safe tensile stress of serew material and ‘n” is the number of screws usually an even number; 2 for small dies, 4 for medium dics and 6, 8 or ‘more for large dies. Note. A minimum of 16 mm should be provided between punch and die blocks and guide pins and bushings to allow clearance for the grinding wheel when resharpening. When this is not possible, removable guide posis may be used for easy access to dies for maintenance purposes ‘The die holder or the lower shoe should be at least 6.5 mm larger all around than the die block. 2.12.4. Punel, The punch must be a perfect mate to the die block opening the sizeof the working surface of punch is ebtained by subtracting the total clearance from the desired size of the blank. As already mentioned, shear is provided on the die surface for blanking operation. The punch is usually provided with a wide flange or shoulder o facilitate mounting and prevent its deflection under load, The minimum length of punch should be such that it extends far enough into the die block opening to ensure complete shearing of the blank. The punch length must also provide for the anticipated number of regrinds. The maximum length of the punch can be calculated from the formula, from the consideration of an axially loaded street, mae d\z or. the maximum permissible free length of circular punches to be safe against buckling can also bbe determined as, Fig, 230. Dowel Pin where F is the modulus of clastic96 A Textbook of Production Engineoring units are min Total length of punch guided in stripper plate > thickness of guides + thickness of stripper plate + thickness of punch holder plat + sharpening allowance + Min. distance between the stripper and punch holder f= 20 to 25 mm) General 1. 600 85 mm Punches are made of good gride tool steel, hardened and ground, The hardness recommended is Rockwell C 60 10 62. Punches with unguided length of more than 100 mm are avoided. A sharpening allowance of 6 to 125 mm is Punch Holdr provided in punch length 4 The strength ofthe punch is checked for the weakest 3 cross-sectional ara, by the formula, 32 Ey slolpemisste NN J ‘where A = erosssetional area of punch, at is weakest section 2.126. Back up plate. For small punches, back up en plates of pressure plates ae oflen provided belween the Pate punch plate and punch holder (Fig. 2.31). The ‘punch plate” for ‘punich retainer’ fits closely over the body of the ‘punclr'and holds it in proper relative position. Ik is attached to the punch holder, The back up plate is provided to take the cutling force of the punch head. provide a base and insurance against punch deflection when punch does eet not have a flange or shoulder and provent the hardened ig 2.31, Hack up Plate. punch from being pushed into the softer punch holder. thus, becoming loose. ‘The main criteria whether a back up plate should be provided or nol is the unit of compressive stress on the punch, given as, p= PA where | is the cross-sectional area of the punch, ede fee fk al — Ti / H ak le ol ® o @ @ Fig, 2.32, Punch Construction.Pros Too! Design o7 Depending upon the punch construction, Fig. 2.32, the above equation will be FAR ae, For straight punches (Fig. 2.52 (yh p= = Soy 4 For punches with a shoulder (Fig. 2.52 (b)) P= Ate, 1d For punches with turned heads (Fig. 2.32 (©) and (c] Ate ody 1 ‘Abback up plate is provided if p exceeds 245 N/mm’, As a rule, a back up plate is to be used whenever the punch diameter is less than four times the stock thickness, A back plate is usually ‘made from plain carbon steel, hardened and ground parallel, The thickness of the back up plate ‘depends upon the stock thickness. For stock thickness upto 2 mm, the thickness of back up plate should be about 3mm and for thicker stock, it should be about 6 mm. 2.12.6, Methods of holding punches. The mounting or securing of a blanking punch in the punch holder does not present any problems, Being relatively bigger, they are made with flanges tat are doweled into position and directly fastened to the punch holder by screws without the use ‘of punch plato and sometimes withou plate (Fig, 2,33). When used, the thickness ‘of punch plate should be 1.5 times the punch diameter. For press fed punches, a fit H,/p, or H/p, is 10 be macht rae ae eo i fy ft : | | earch te ntained, la Punch Punch range « © ° Fig, 2.33. Methods of Holding Punches. 2.12.7. Centre of pressure. When the shape of blank fo be cutis irregular, the summation of shear forces abou the centre line of press ram may not be syrameiical. Due to this, bending le ‘moments will be introduced in the press ram, producing misalignment and undesit deflections, To avoid this the ‘centre of pressure” ofthe shearing action of the die must be foun and while laying out the punch position on the punch holder, it should be ensured that the centre line of press ram passes exactly through the centre of prossure of the blank. This ‘centre of pressure’ is the centroid of the line perimeter of the blank, It should be noted that itis not the centroid of the area of the blank, ‘The centre of pressure can be found out by the following procedure 1, An outline of the piece part is drawn, Fig, 2.34 2. The Y and F axes are placed on it in a convenient position. 3. The outline ofthe piece part is divided into convenient line elements. These are numbered as 1, 2, 3 and 99 on, 4. The length f,. 1, /, ete. of these line elements are determined. 5, The centroids of these line elements are determined.98 A Textbook of Production Engineoring 6. The distance of the centroids ftom the and Yaxes is determined, Let x,, x, x, ete, and Dy dy My C., be the distance of comtroids of line clements J, /, /, ete. from the ¥ and axes respectively 7. The distance of the centre of pressure from cach axis is determined by the method of centroids, ie, xy hy, + eu hth+h+ hy thys thes heheh ¥ = v distance to centre of pressure F = y distance to contre of pressure ee - ox 6 alias, 2 3 \—25 | 325 4 ce iz ry 5 ies Fig. 2.34, Conve of Pressure ‘The centre of pressure of the component shown in Fig, 2.34 can be found out in the {ollowing manner Element 1 x » & » l 10 5 0 50 ° 2 1.25 10 0.425 2s 0.78125 3 625 6875 1.28 4296875 7.8125 4 3.75 5 28.125 375 5 125 3.12) 875 3.90625 10.9375 6 78 28 5 18,75 375 7 2s 125 L2s 3.125 3.105 8 125 o 042s 0 0.78125 Eyes Ely = 159.375 Ely = 984375Press Too! Design 90 1503 775 onus 315 Note, Life of dc is usually 2 to 3 times the life of « punch, 2.4228, Stripers. AMtera blak has Bon cut by the punch on is downwards stoke the serap stip has the tendon to expand. On the return sroke of the punch, the sap stip lis the teens to adere othe pe and ied bt. This atin ineferes with he Reding 0 he Stock though the de and sive device must be sed to sirp the scrap material from the. puch as it : Gasp the de block, Such a vice led [1] stnpper- of ‘pper pat” Stppers are of two types Fixed or sutionary and. spring Woaed or movable. (Fig. 235). As i clear His ue Pune parallel with and above the de surface, An opening {5 on through the stripper plate for fee passage of the punch. By rule of thumb, this opening, can be \ Stripper about 6 min lager han th lank size onal sides YA, oor gue (a) Fixed Stripper [Fig. 2.35 (a)]. Th stripper is attached a fixed heigt over ihe die block The Height should be sufcien oper the T sheet metal to be fed feels batween the upper die Surlice and te under srfae ofthe stripper plac, De St ‘The stripper plate is sly of the same width and ayes eippr Tenth thei block. In sip dis, is Fasc Wig 238 Sipps with the same screws and dowels wich ar sed for die block: In complex dies, the siippe fastening wil be independent of ditatening. The thickness ofthe stapper plate shouldbe slice fo withstand the free needed to stip the scrap Skip fom the purch The ual values 9 min to 16 mim The following pial Forma may also be used or determining stripper pat thickness 425em 625em ers) a1 ‘wand # are the width and thickness of stock strip. or f= 05 * Tif guided 0.75 « 7,if um-guided ‘The thickness of the stripper pkatc may also be determined by the size of the socket-hea cap screws used to hold it in place. The stripper plate must be thick enough to allow for the screw-head counter bores, which in most cases provides adequate stripper strength, In addition to screws, dowels are used to ensure accurate alignment of the die block. Stripper may’ be made of cold rolled M.S. The fixed stripper is also knows as ‘channel stripper For the stripping action, on the upward movement of the punch, the scrap strip will strike the underside of the stripper plate and gcl stripped off from the punch. The underside of the stripper plate which comes in contact with the strip should be machined and preferably ground, ‘The height of the stock strip channel should be at least equal to 1.5 times the stock thickness. If the scrap trip is to be lifted over a fixed pin slop, this height should be increased. The width of the channel should be equal to the width of the stock plus adequate clearance. The disadvantages of fixed stripper are that it hides the work from the operator and it would interfere with removal of the sorap strip in large blanking operations. (®) Spring Loaded Stripper. Fig. 2.35 (6)]. This type is used on large blanking operations and also on very thin and highly ductile materials where itis desirable to uilize the pad pressurethe punch holder, with the lower surface of the stripper RRL vary from 2.5 10 20% of cutting force. However, the , more common values for most of the applications are $ | fo 10%, The stripping force may also be determined Yj | with the help of the following relation F.,, = SPi,KN (©) Spring Operated Stipper ‘where P and sare in mm and Sis the stripping constant, Fig. 2.38, Stippers given below S'= 0.0105 for Jow C-stecls with sheet metal under 1.6 mm thick where the cut is close to the edge of the strip or preceding cut. 0.0145 for the same materials but for other cuts. 0.021 for the same materials with ¢ > 1.6 mm, 0.024 for harder materials, or F,, = (0.05 (0 0.08) F, for normal clearance (0.10 10 0.20) » F. for narrow clearance and complicated contours, Comparison of fixed and spring loaded strippers 1. Solid stripper is simple in construction and is cheap. 2. Fixed oF solid stripper does not apply any hold-down pressure like a spring stripper. Due {o this thinner sheets may buckle and jam in the stripper. So, it is mainly used for thick sheets, 3. Clearances in the fixed stripper channel allow the sheet to shift slightly. Additional edge stock is necessary to insure complete blanks being cut 4, Fixed stripper is used mainly for strip sheet metal where feeding of the sheet metal is accomplished by hand. Coiled shect metal uses a feed roll and spring stripper in most cases, 5. For very large stripping force, fixed stripper is preferred because it may not be possible to provide enough stripping force with springs in the space available 6, The travel of spring strippers is limited by the compression allowance of the springs, 7. In spring strippers, the full stripping force is not available throughout the stripping action. It is build up as the springs are compressed. 8. Additional dic space is required for placing the springs around the punch. Design of Springs: The maximum force the spring can exert, no, of springs Now, movement of stripper spring deflection,» Considering sharpening allowance. 3 (0 4) (+ 2) +s; here s is the sharpening allowance. 1+ 2,mm G tod) y,, at FPros Too! Design 101 Helical Springs: Wire diameter, 3 Hi = 4 t0 6 for shearing dies = 12 10 15 for drawing dies +, = Permissible shear stress, 600 to 700 N/mm? Deflection of one free coil, No. of free coils, 2 = y,,, 0 Compressed length of spring where max. force acts, = Li nd+ Taw + Vows Free length of spring, Pro-compressed length of sprin ty, ts fe more tough, ie, less deflection for higher loads, so, are good te: Bellville springs for shearing dies for stripping 2.129, Stock stop. The strip of shel metal is fed and guided through a ] slot in the stock guide, Fig, 2.35 (a), or through a slot in the stripper plat, Punch ‘After each blanking. the strip has to be Combined guido se advanced a correct distance. The de- & Vice used 10 achieve this is called S7PPe" Pile ‘tock stop’. The simplest arrangement may be a dowel pin or a small block, against which an edge of the previously blanked hole is pushed after each stroke of the press. On its upward stroke, the punch carries the stock strip as far as the underside of the stripper plate. Duc fo this, the slock strip wots released from the stop, With constant pressure exerted pushing the stock strip to the Je, the stock will move as itis lifted clear, then drop with the next hole over the stop as the scrap strip is stripped from the punch, Fig. 2.36, This type of stock stop is suitable {or only Tow and medium production dies and not for high production dies, Fig, 2.36, Sloek Stop since the operator has to force the stock over the shoulder to sccure a desired feed length, Also,102 A Textbook of Production Engineoring this needs considerable skill on the part of the operator. This stop is also, not suitable where frail die sections would be damaged by a misfeed, Other types of stock stops are discussed below 1. Lateh stop or Trip stop or Pawl stop. Fig. 2.37. In this type of stop, a latch or pawl is pivoted on a pin fitted into a block on stripper and is held down by a tension spring, The latch is lifted by the scrap bridge on the ratchet principle and drops into the blanked area, asthe stock is fed forward manually into the die, The operator then pulls the stock back until the vertical surface of latch bears exactly against the scrap bridge. The design is also suitable for low production only Punch botler N N Svipor juste SS tier UY — \ Guide post Die shoe! Fig 237, Latch § Fig, 2.38, Automatic Stop 2. Automatic stop. In this design also, a hinged latch or lever (finger) is used. The workin of an automatic stop is shown in Fig, 2.38. An adjustable strip serew is fastened to the punch older. During the downward stroke of the slide, as the punch cuts the blank, this strip screw strikes the end of the latch, thereby ling its pin end. On the return stroke, the pin end drops The finger is pivoted loosely, so that it can have endwise movement. Due 0 this endwise ‘movement of the finger, its pin end does not drop into its former position, but drops on t0 the {op surface of the stock. As the stock is fed forward, the pin drops into the next blank space. This cenables the operator 10 locate the stock strip exactly. Another design of automatic stop is shown in Fig, 2.39, Hingo pin Plunger spring Plunger Gauge pin Stnpper. Direction ofteed UK ZA a Fe Fig, 239. Automatic Stop In this design, as the gauge pin is raised from the blank space due to lever action, it rocks, So, as the stock is fed forward. the gauge pin rests on the top surface of the stock until it drops into the next blanked hole. 3. Solid stops or Shoulder stops. Solid slops ate extensively used on progressive dies, ‘when the last operation is a cut off or trimming one, to position the end of the stock or the workpiece, Two designs are used in Fig, 240. In Fig, (2), the stop is fastened to the die, whereas in Fig. () it is fastened to the stripperPros Too! Design 103 ~ ‘Stock Cutott- Cutoff ol cut ES ‘Stock- 5 ook, 4 = Oat By S piece piece: per 4, Starting stops. A starting stop ora primary stop is used to position stock as i is initially {ed into the die. I is mounted on the stripper plate, Fig. 2.61. It consists of a latch, which is pushed inward by the operator by one end until it contacts the stripper plate. The stock strip which is Seow being fed by the operator with his other hand is Coil sping made to locate against the latch. The latch is held Lk nut in position until the first die operation is completed supper ind then the latch is released. 4 Note. Stock stops are needed when the stock {is fed manually. In the case of automatic feeding. stops are usually not needed as the strip can be advanced quite accurately 2.12.10 Stock Guide, Stock guide is the space provided in the die-block, through which the stock strip is guided as it is fed into the dic. The design of the stock guide will depend upon the {ype of stripper. For fixed strippers (channel strippers) the channel for guiding the stock is show in Figs, [2.35 (a) and 2.36] and its design is given under “fixed stripper”, For spring operated sirippers, the various designs for guiding the stock are shown in Fig. 2.42 (a, b,c). Inthe figure, guide rails are mounted on the die block for puiding the stock. In Fig. 2.42 (a), the stripper acts as pressure pad and presses directly against the stock strip. The stripper does not contact the ‘guide rails. In Fig. 2.42 (c), hooks are provided on the guide rails in order to improve the guidin effect, When there is space limitations, button stock-strip guides may be used, Fig, 2.42 (d). AL Teast three button guides should be used on each side of the stock strip. The guiding is not as efficient as with guide rails, be ——+| look Fig. 2.41, Starting Stops Ba ZA (a) (b) ra © (9) Fig, 242, Stock Guides with Spring Operated Steppers104 A Textbook of Production Engineoring 2.12.11. Strip feeding. Stock strip may be fed imto the die either manually or mechanically (automatic feeding), Manual feeding is suitable only for low production or with presses operatin at Tow values of strokes per min, Modern presses operate at 200 to 300 strokes per min. (may be up to 500 strokes per min.), For such cases, manual feeding is not feasible and automatic feeding isthe only answer, For this, the strip is prepared in large coils. The first step inthe feeding of stip is the unwinding of the coil. Two methods are in use for this purpose : (2) Reel, (4) Coil cradle The reel is considered to be better as it does not damage the strip in any way: The reel may be or may not be power driven, In the case of power driven reels, a roller at the end of a lon Joop arm, rides on the uncoiling strip. When suificient coil has been unwound, the Toop arm actuates a switch which stops the power drive, Now, as the strip is used up and the loop arm gets raised, the power supply is switched on, In the case of unpowered reels, the coil is unwound by ‘an external power source, which may be feeding mechanistn or straightening rolls. When enough coil has been unwound the reel is stopped from uncoiling by a manual or automatic brake. In the case of eradle, the strip is supported on the outside diameter of the coil, The coil locates against rollers and due (© this scratches may from on the coil. ‘The second step in stock feeding is straightening of the uncoiled strip. This is done to remove wrinkles and curvature from the strip. For straightening the coil, itis passed through between a series of rollers, Altcr uncoiling and straightening, the final step isto feed the stip into the die. The two main {typos of feeding system are 1. Roll feed 2, Slide or hiteh feed The roll feed moves the stock between a pair of rollers, which is driven through an overrunning clutch or ratchet mechanism timed from the press main shaft or ram. Roll feeds ‘may be : single or double, In the case of single roll feed, rollers are provided only on one side of tho press and they push or pull the strip through the dio. In the case of double roll feed. feeding ‘mechanism is mounted on cach side of press bed with a drive connection between them. On feed pushes the stock and the other pulls stock through the dic. This will kcep strip tight and prevent its buckling Inthe case of slide or latch feed, grippers are used which grasp the strip mechanically and feed it into the die by a reciprocating mechanism which may be driven from the press cranksha, cam mounted on the punch holder, hydraulically or pneumatically 2.12.12. Knockouts. As already stated, the function of a knockout is to shed or eject a workpicce from within the die cavity as the workpiece may get jammed in the die eavity due t0 friction, A knockout 2.25) of by a positive acting knockout pin Fig. 2.43. KnockoutPros Too! Design and bar arrangement, The knockout pin usually leads through the shank. It may be a single pin ora double pin fastened to a pad or collar above the shank. The working of a positive knockout pin arrangement is shown in Fig, 2.43, for an inverted OBY press. On the rotumn stroke of the press, the knockout pin strikes the Knockout bar, This makes the knockout pin to actuate the knockout plate which forces the blank out of the die-opening, The function of the knockout plate is 10 support and guide fragile punches. 2.12.13. Die-set. The dic shoe, the punch holder together with two or more guide posts constitute a di 5 ,O [8-8 ©) Other possible designs sel, Fig. 2.44. The die shoe and the punch holder are made of C. [, C. Sand rolled steel. For smaller dis, CL is used, whereas for larger and special die sets CS. shoe (die shoe), The bushings and posts are sized 10 ql provide a slip fil, For average range of die sets, the diameter of guide posts varies from 2.5 cm to 7.5 em. Larger pins m: required. When dic is fully closed, the upper ends of the guide posts should not project beyond the top surface of the upper shoe Cavity for de Fig, 248. Bottom Bols nd rolled tool steel are used, Bushings are | Beene assembled to the upper shoe (punch holder) by press. Bbuch fitting and guide posts are press fitted into the lower % 2 J Prose tt Fig. 2.44. Dic Set Tole [erie ‘able A typical bottom bolster (die shoe) plan is shown in Fig. 2.45, ‘The dimensions of round diagonal-post die sets are given in Table 2.5. All dimensions are given108 A Textbook of Production Engineoring ‘Table 2.5. Dimensions of Die Sets Die Area Thickness Die holder Min guide demteer past Rectangular | Diam Die Punch | diameter Irolder holder 4a5 «89 7 127 445 318 127 S72 x Lad 89 1525 443 318 160 7x4 102 1780 soo 380 190 sox 178 1335 90 soo 380 255 tas 2290 | 1780 2195 soo 380 2xs The minimum die holder or die shoe thickness in terms of culling force is given below in Table 2.6. Table 2.6. Die Shoe Thickness Cutting force AN Die shoe thickness ma Upto 100 Ea 100 10 300 50 300 t0 600 as 600 19 900 6 900 10 1200 % 1200 © 1500 wos 1500 t0 2000 27 over 2000 525 Thickness of the punch holder plate, can be taken as, f= 05 *T, for guided punches = 0.75 © 7, for un-guided punches. In tables 2.5 and 2.6 the materials of die shoe and punch holder are not mentioned, However, C.1. shoes must be made thicker than C.S, and rolled steel shoes to provide the same ‘mechanical strength and resistance to deflection. Punch holder thickness may be 12.5 to 25 mm thinner than the die shoe thickness because the punch holder is firmly backed up by the ram. ‘whereas the die holder is often over a hole in the press bed. When a large hole is present in the bed of the press and no bolster plate is used, increase the dic shoe thickness by approximately 50 per cent. The thickness of the shoe will be limited by the shut height of the press as discussed later, Note : Ifa die set is not used, the working die details would have to be mounted on the press ram and bed, Normally, a die is used for a period of one or tivo years, amd then replaced by a new die for the new part. On the other hand, the press must be used for several years If the die details are mounted directly on the ram and bed surfaces. the later will get damaged by the numerous screw and dowel pin holes used for attaching die details, The mounting of the new die details will become difficult, It will be very expensive 10 rework the press bed and the ram, these being the pants of the press frame. Due to this, the dic details are mounted in a dic set, which is relatively cheap. The same press can be used for different dic sci,Pros Too! Design 107 Shut height of press. As already defined, the shut height of a press is the height of the opening between the ram and the bed, with the ram down and the adjustment up, Ram adjustment is provided by a special screw between the ram and connecting rod, One end of the screw is usually a ball that rides in a socket in the ram. The end of the screw is threaded and engages the connecting rod, By turning the screw clockwise, the overall length of the connecting rod and ram assembly is shortened. The tolal amount of adjustment is called the press “adjustment” Adjustment is used to change the closed opening of a press. Adjustment may decrease this ‘opening from the shut height (maximum closed opening) down, but it does not increase upon the shut height Shut height of Die, Die shut height is found as follows: It is the distance from the top of the punch holder to the bottom of the dic holder. Thus, Dio Shut Height = Punch Shoe thickness + Die Shoe thickness + Die Height + Punch Height ~ Bypass of Dic and punch (3.2. 10 6.4 mm), or, The die-shut height or the tool shut height, #, is given as, H+ W DON va] | pnt ~ E ‘Qual si — per Bush” ‘Quill. A @ » Fig 2.47. Quiled Punches 3. Square headed punches. Square headed punches, Fig. 2.48 (a), are usually used in high quality tools. They are machined from round bar stock of larger diameter than the punch bod leaving an integral head of sufficient size. The head prevents the punch from pulling out of the punch plate. The head thickness is usually 6 mm, The chicf disadvantage of this design is an increase in labour and material costs, Heat far NY Ii N rune 2\ ras shank YY a + LI rs o Fig. 248. Square Headed Ponches. (A) Headless punches. In the above mentioned designs of the punches, the punch plate has to be dismounted in order to change the punch. There is no such problem in the case of headless of straight-shanked punches. They can be frequently changed by loosening the set screw. Fig, 2.49 (a) and (6), of by the ball-spring mechanism, Fig, 2.49 (c) Punch plate Seron Punch, plato 4 @ o ° Fig 2.49. Headless Punches110 A Textbook of Production Engineoring The punch is fitmly secured in the punch plate by the spring-loaded ball pressing into a recess in the shank of the punch, To remove the punch, the ball is pushed up against the spring by means of a pioce of dull rod inserted through the hole, and the punch is pulled out by hand, To replace the punch, it is inserted into the retainer and pushed into place. The ball, automatically. presses into its seat and locks the punch securely 5. Ring-necked punch, For larger stripping forces, an adequate circular groove is provided towards the top of the punch instead of leaving a machined shoulder. A stp ring is, filled in this groove and the punch is inserted through a Punch holier counter bored TT pin Tack ti uy ig. 20, 1 a small + pexoratr punch wosmm? fe ta he mounted close to a Manking punch, the vin 281 Maung crring _atangonentisshonin Fig 2 S1-sethe fang of hs phe, 281, Mouning of essing Tanking punch is aso generally dardencd: the sal perfor pune should na be pressed dicey Io the flange stad aso met plug shouldbe sre hs ll prevent ching of ts anes ‘ots slondcr pein pan sould made shorter thn the les punch shot proven detection cased Oy the action the ier punch Note To minimise the baking of slomlor punches, taper he working em ef he 0.25 9.030 mm. This faites sipping, since most punch breakage occurs dating stppi 2M. PILOTS Pilots are wsed in progressive dies, Inthe design of proressve dis, the fist stp sto esabish the segues of operons. ls Sequence te plteis operons ae placed fst ‘Ms holes Hacon pores thee hols ae ed or pang ah oan pce oh the olan fomed is aly Cnccnne to te aleay punched hole This plot achcyed by means of pols secued wider te blanking punch which engage the lead pire ols, T9 De etecine he pila must be sonata align the sock eon Bening las ae made OF god are of to! sel heal Wosed lo maui lousy and wa hadess of 36 (000 Rost Pilot dimensions. The ilo stl the alieady pened Hoe wih close hing ts sire mW 0.076 min sar than the punch se for anal ork and om OL mn rpesson rk Th pa shud cas 3 tnt he prs ed ers It wi pric efore cling bei. The two mow coronly wed omout of 9 fons ate gnen'n Mig, 2.52 The dimersons of thy plot hoarse ge blow 2.5mm x 45" Chamier— 2.5 mmx 4S" Chamfer «ip = oi rene. —| (©) Fatened ype 2.52, Pilot noses Fig, 2.50, Ring Necked Punch (@) Spherical typePros Too! Design or Spherical type Flattened type BoA BRA © = 0284 C= 0625.4 L = Aw2d L = 0754 E = 0625.4 E = 054 T= 1.6 mm or stock thickness whi then polished. ‘Types of Pilots. There are two types of pilots L. Direct pilots, and 2. Indireet pilots 1. Direct pilots. Pilots which are mounted on the face of 1 punch are called direct pilots The pilot holder is generally a block of steel which ean be fastened to the punch holder. The simplest arrangement is a press fil pilot, Fig, 2.53 (a). This is often used for low speed dies. Ik is not recommended for high specd dies us it may drop out of the punch holder. Threaded sh design, Fig, 2.53 (h), is recommended for high speed dies. In Fig, 2.53 (c), the pilot is held by a sockel screw. If the diameter of pilot is less than 6 mm, it may be Readed and secured by a socket set serew 2,53 (a), The pilot can also be held by ball lock mechanism, 2.53 (e), cr is greater, The nose of the pilot is hardened and @) “ oy ms ~~. Punch holder La | a @ Fig, 2.53. Mounting of Piles 2. Indirect pilots. I is not always necessary 10 fix a pilot to the bottom of a blanking | The pilots may be independent of the blanking punch and directly retained in the punch holder. They are designed to enter previously punched holes in the strip some distance away from the blanking punch. In this way, they help to position the stock strip accurately and bring it into proper register for subsequent blanking and picrcing operations. During manual fecding of stock sirip, there is usually a slight overfeeding beyond the register position, The pilot then helps to bring the strip back into registry position in a direction away from the stock stop. This prevents buckling of the stock strip against the stock stop. Such pilots are well guided through the hardened bushes in the stripper plate. 2.15, DRAWING DIES Drawing operation is the process of forming a flat piece of material (blank) into a hollow shape by means of a punch which causes the blank to flow into the die-cavity, Fig. 2.54,112 A Textbook of Production Engineoring De. @ © Fig, 2.54, Drawing Operation ‘The depth of draw may be shallow, moderate or deep. If the depth of the formed cup is upto half ts diameter, the process is called “Shallow drawing”. Ifthe depth of the formed cup exceeds the diameter, it is ermed as “Deep Drawing”, Parts of various geometries and sizes are made by drawing operation, two extreme examples being bottle caps and automobile panels. As the drawing progresses, ‘c.. as the punch forces the blank into the die cavity, the blank diameter decreases and causes the blank to become thicker at its outer portions. This is duc to the circumferential compressive stresses 10 which the material element in the outer portion is subjected. If this stress becomes excessive, the outer portions of the blank (flange) will have the tendency to buckle or wrinkle. To avoid this, a pressure pad or blank holder is provided. The holding down pressure is obtained by means of springs, rubber pad, compressed air cylinder or the auxiliary ram on a double action press ‘The portion of the blank between the dic wall and the punch surface is subjected to nearly pure tension and tends to stretch and become thinner. The portion of the formed cup, which weaps yround the punch radius is under tension in the presence of bending, This part becomes the thinnest portion of the cup. This action is termed as ‘necking’ and in the presence of unsatisfactory drasving operation, is usually the fist place to fracture, As noted above. the outer portions of the blank under the blank holder becomes thicker during the operation, When these portions are drawn into the die cavity, “ironing® ofthis section will occur if the clearance between the punch die is not enough to accommodate this increased sm Blank holder Blank or work pico Spring sippor ring Fig. 2.85. A Simple Push through Drawing Die,Pros Too! Design 113 thickness ofthe workpsce. This toning is useful if uniform thickness ofthe prodct is desi aftr the drawing operation, Deep Drawabiity. Deep dravabiliy or drawing rato, ofthe metals defined asthe ratio. of the maximum blank diameter tothe diameter ofthe eup drawn fom the Dank Casually taken to be equal 6 the punch diameter, e. Del Fora given material there is lining drawing ratio (LDR) after which the punch wil piene a ole inthe blank instead of drawing the blank This ratio depends upon many factors, sich as typeof material, amount of friction presen ete: The sual range ofthe maximum draing ratio 1.6 to 2.3 b-d_, dt p '~p lp Reduction ratio, R= or BR A simple push through drawing die is shown in Fig. 2.55. The drawing punch must be properly vented with drilled passages. Venting serves double purpose. It climinates suction which would hold the cup on the punch and damage the cup when it is stripped from the punch, Secondly, venting provides passages for lubricants, of Draw Die. The edge radius ofthe first draw dic ithe blank is drawn, is vers important. IF the rads is too small, the resistance tothe al increases reslling in cating or tearing of the metal. On the other hand, too large alc radius may indice the formation of wrinkles in the metal as itis drawn into the die eavity from bencath the blank holder This radius, rin Fig 2.54, usually ranges from to 10 times the blank thickness or = 008550 +(D al Punch Radius. Like the radius of draw dic, the punch radius is also critical. The edges of the punch must be rounded t0 avoid cutting oF tearing the metal, An excessive punch radivs increases tendency of material to buckle. Where more than one draw is needed to give the final shape to the pari, the minimum panch radius, r, in Fig. 2.54, should be 4 times the stock thickness. On subsequent dra, dhe punch radius'can be reduced proportionately, That i r= BwO*6 Draw Clearance, The side clearance between the punch and the die should be more than the stock thickness to take info aecount the thickening of metal over the die radius when the Mat blank is drawn into the di cavity: otherwise the blank may get jammed in the die cavity. The side clearance between the punch and the dic is usually taken as 125 times the stock thickness, ic Punch diameter = Die opening diameter ~2.5 « The average draw clearance is given in Table 2 Table 2.7. Draw Clearance Blank Thicsess_ mm Hirst draw Redraws Up @ 038 LO? #10 1.094 108 416 11 0.40 10 127 Los sto 11 109 st0 112 ¢ 130 318 List Lize Liz sto Ld 3.20 and op Lid eto Lie Lise 12e For sizing draws, the clearance is Iess Drawing Speed. The punch travels downward to force the blank into the die cavity, by the action of press ram, The ram speed is critical since 10 initiate plastic deformation, the internal inertia of the work material must be overcome. Sufficient time must be given for this to happen114 A Textbook of Production Engineoring otherwise the metal can rupture instead of being drawn. The ideal drawing speeds are given in Table 2.8. Proper die design, proper lubrication etc, help to increase the permissible speed of ra travel Table 2.8, Ideal Drawing Speed Tork material Speed, mpra ‘Alumina as Brass 525-60) Copper 374-45, Ste 5515 Stainless Stel 9.12 Zine s75.45 Cateulating Blank Sizes. The frst step in the drawing process is 10 calculate the approximate size of the blank required for a particular drawn part. There are several methods to do’ so, but below we give the equations based on Arcii-methods’ fo determine the bkank size for drawing plain cylindrical shells, In this method itis assumed that the surface area of the blank is equal 10 the surface arca of the finished shell. (@ Where thin gauge stock is used and the shell has sharp inside comers, Fig, 2.56, the formula may be Fie 256 used, D= Ja? adh (2.16) where, D is the diameter of flat blank, ‘dis the diameter of finished shell and ‘fis the height of finished shell, This formula is valid for dr 20 and more, where, r is the radius of bottr comer, ii) For a round comer cup, when the ratio 0,6 ~ 0.7, will be D= 1.13, —0.847,2 +407 0.437, ) 0h 0.437) where 1, = corner radius in plan andr, = corner radius in front view Normally, ener 80. D= 113 WW? 0847 $400 ~048 Uh - 0.43), () Rectangular Shell: Dimensions : L » Wh (length, width, depth) and comer radius = The blank will be approximately in the form of an ellipse, Fig, 2.59. Fig. 2.89 Approximate form of blank for a rectangular ahol —_— Minor axis of the blank Be fi27F—0se Major axis of the blank, 4= JB +c? where C= \(-W E+" 0767) and F = Total atea of the shell (box) = LIF ~ 0.86 r+ 2 (+ W086 r) (h~ 0.43 7)118 A Textbook of Production Engineoring To construct the ellipse, the radii , and 2, are given as, OB and ) Drawing of non- 6 C, = 0.2 10 03, for easy to severe draw conditions e Flanging: See Fig. 2.60, 90° hote flanging (for tapping): beat? «efore 1.2 = 0.28 ¢forf< 12 mm Fig, 2.60, Hanging = fr 12 mmPros Too! Design 119 Pre-pieoed ole diameter, d= or (>) Direet hole piercing and flanging (with stepped punch): Force = (2 10 25) «nd x 1% 4, (©) Hole flanging after pre-piercing the hole: Force = (1.5 2) * md x r= 4, (11) Embossing/Beadin Fore =1-L-0, where 1. = Height of embossing ot bead Bottoming force = 6, «A where 1 = Plan area of bottoming zone (04 Coining: Fore = Ap, where 41 = Total area of deformed surface Po = Surface pressure tis given as, 1200 ~ 1500, Nimm®, for Gold coins 1500 — 1800, N/mm, for Silver coins 1600-2000, N/amm?, for Ni coins 1200 — 3200, N/mm, for Steel coins Depending upon C-content and hardness = 1000 ~ 1700, Némm’, for Al and Alloys coins (vii) Flattening: dep Surface arca of the flattening portion p= Surfice pressure or specific pressure where It is given as Material pyNimmt AL ~ soft 20-150 AL — hard 300-400 CRS ~ soft loo ~ 150 CRS~ Mediu 250-400 CRS — Hard 500 — 600 2.16, BENDING DIES Bending is the metal working process by which a straight length is transformed into a curved Jength, It isa very common forming process for changing sheet and plate into channels, drums, tanks etc. During the bending operation, the outer surface of the material is in tension and the inside surface is im compression. The strain in the bent matcrial increases with deereasing radius cof curvature, The stretching of the bending causes the neutral axis of the section fo move towards the inner surface, In most cases, the distance of the neutral axis from the inside of the bend is (0.3 #0 0.5 1, where ‘r”is the thickness of the part, Bending terminology is illustrated in Fig, 2.61120 A Textbook of Production Engineoring Neutral axis — yi Teen i Fig. 2.61. Bending Terminology 2.16.1. Bending methods, The two methods commonly used are : Fbending and Edge bending, V-bending. In I-bending, a wedge-shaped punch forces the metal sheet or strip into a wedge shaped die cavity, Fig, 2.62, The bend angle may be acute, 99°, or obtuse. As the punch descends, Bevel anglePros Too! Design 121 the contract forces at the die comer produce a sufficiently large bending moment at the punch comer to cause the necessary deformation. To maintain the deformation to be plane-strain, the side creep of the part during its bending is prevented or reduced by incorporating a spring loaded knurled pin in the die. The friction between the pin and the part will help (0 achieve this, Fig 2.63. Plane strain conditions will also be established in the centre of the sheet if its width is more than 10 times its thickness, Edge bending. In edge bending, or cantilever bending, Fig. 2.64, a flat punch forces the slock against the vertical face of the die. The bend axis is parallel (0 the cage of the die and the stock is subjected to cantilever loading. To prevent the move- ‘ent of the stock during bending. itis held down by a pressure pad before the punch contacts it. The die is called “Wiping die’ 2.16.2. Design Principles. Bend radius. It is defined as the radius of curvature on the inside or concave surface of the bend, To prevent the cracking of the material on the outer tensile surface, the bend radius cannot be made smaller than a certain value. ‘ery ductile materials can have zero bend radius, that is, they can be folded upon themselves. However, to prevent any damage to the punch and dic, the bend radius should not be less than 0.8 mm, In general Fig 2.64. Bdge Bending soft metals can be bent 180° with a radius equal to or Jess thant the stock thickness. The bend radius must be larger and angle less for metals of high {cmper. For such materials, the bend radius is kept cqual to or grcater than five times the stock thickness, For magnesium the bend radius may be up to 20 times the stock thickness, ‘When bending to an angle of 90°, the minimum bend radius = 21051 for Cstecl 1. for stainless steel = 2103.5 1 for Ti alloys = 0.3 10 0.5 ¢ for brass = 0.35 1 for AL Bend Allowance. To calculate the blank length for bending, the length of material in the curved section oF bend area has t0 be calculated. This length in the bend area which will be more than the corresponding length of blank before bending, is called “Bend Allowance’. ‘The ben allowance added to the lengths of the straight legs of the pant will give the length of blank. The bend allowance varies with the distance of the neutral axis from the inside surface of the bend. Bend allowance can be calculated from the following formula Bm poe) where B= Bend allowance along neutral axis, em. ‘= Bend angle in degrees. r= Inside radius of bend, em. = Distance of neutral axis from the inside surface of the bend em. The values of ‘4° are given in table 2.11 Blank length for bending = Length of the wo arms upto the bend +B122 A Textbook of Production Engineoring Table 2.11. Value for ‘#’. Stock Material where r= 20 where r = 2 1 Mild Steel (4) Bilge Bending om 0331 (a)? ending, U-hending 0.500 2. Soft copper, Soft brass, soft 0508 to ball hard aluminium 3. MalEhard copper, Half hant oar os brass, Halla steel, Hard 4. Hard copper, Hird bras, 051 or Hand steel, Spring steel (On sharp comered parts, the bend allows blank length can be calculated as @ Lah +h+osr ) Leh +Q- sr A bend should not be closer to an edge than 1 Sr plus bend radius Spanking, During bending, the area of the sheet under the punch has a tendency to flow and form a bulge on the outer surface, Fig. 2.66 (a). This is prevented by having tool surfaces of sufficient area to restrain metal flow: Thus the nose radius of the punch is gradually blending into the punch faces, Fig. 2.66 (b). The lower die should be provided with mating surfaces, so that when the punch and die are completely closed on the blank, any bulging developed earfir will be completely pressed or “spanked” out ‘Small nosed @ ance may be kept as 0.51. Referring to Fig. 2.65. the | | —— tle ( } { ) tC? » Fig. 2.66. Spanking Width of die opening. The width of dic of press exertion a ‘opening controls the “spanking” area, the amount the length of effective press stroke. The width of die opening is generally taken as 8r, For material of high tensile strength such as magnesium and on stock thickness greater than 25 mm, itis taken as 126Pros Too! Design 123 Spring back. At the end of the bending operation, when the pressure on the metal is released, there is an elastic recovery by the material. This causes a decrease in the bend angle and this phenomenon is termed as spring back, For low carbon stecl, it can be 1° to 2° and for medium carbon steel, it can be 3° to 4°, for phosphor bronze and spring steel the spring back ca be from 10 to 15°. To compensate for spring back, the wedge-shaped punches and the mating dies are made with included angles somewhat less than required in the formed component. Due to this, the component will be bent (9 a greater angle than desired, but it will spring back to the desired angle. For other types of bending, the part is overbent by an angle equal to spring-back angle by having the face of the punch undercut or relieved. The values of spring back given above are for 90° bends and are usually greater for greater angles, Bending pressure. Bending pressure depends upon the thickness of the stock, the length of | the bend, the width of die opening and the type of bend. For “I” bendi formula is, 1G, E N (2.23) where length of bend (Fig. 2.61), mm, i.e., width of the stock ultimate tensile strength of material, MPa or Nimm width of dic-opening, mat blank thickness, mm K = dic-opening factor varies from 1.20 fora die opening o! for a die opening of < 161, Tor, © 1.33) or K is given as, De w (2) V-bonding (0) Udending Fig, 2.67. Determining w. For (or channel bending, the pressure will be twice as for Jbending and for edge bendin it will be about one-half of that for /-bending, of, the values of K can be Laken as Vv U Edge Condition Bending Bending Bending w< lo 133 267 0.67 we lo 1.20 240 0.60124 A Textbook of Production Engineoring (Or we can use equation (2.23) with the values of as given below = 0.67 for Usbending or channel bending = 0.333 for edge bending or single wiping be 8 Here w will be the width between contact points on die and punch ( span) and is determined as shown in Fig, 2.67 (6), and is given as w= R, be +R, where R, Punch edee radius Die edge radius ‘e= Clearance = ¢ Shank ~ /— drome Stipper pin ne = ower plato I Fig. 2.68, Bending Die For channel and U-bends, where bottoming is necessary. a blank holding pad is goncrally employed. To calculate the press capacity, the resistance of the pressure pad should be added t© the required bending force. Thus, P= P+ @xp) (2.24, ‘minimum press capacity Area of pad face p, © Average blank holding pressure, ranging from 1.05 Nimm* for the less ductile and thick materials to 2.8 N/mm? for more ductile an thin materials, (Or, the pad force may be takens as Pad force = 0.67 6.1 A F-bending die and a U-bending die are shown in Fig, 2.68 and Fig, 2.69 respectively Stripper pins are provided fo shed the part from the punch, wherePros Too! Design 125 shark | | Upper pate | (al Die back —_ Fig, 2.69, U-Bending Die Bottoming force. To overcome springback, the bend area is often placed under high compressive sitess 10 set the metal, This is called “Botioming”. It is achieved by having a projection or bead on the punch, Fig. 2.70. Bottoming force is calculated as, Botioming force = 0.46 where bb = plan project width of bend or beads, 6, = compressive or setting pressure. Punch va a \ De tee Pea (a) Vebonding (a) Ubending Fig. 2.70, Punch Beads 2.16.3. Forming dies. Forming dies are much like bending dies, with the difference that, ‘whereas, in bending dies, the blank is formed or bent along a straight axis, in forming dies, itis formed or bent along a curved axis. There is not enough metal flow in forming operation, So, no excessive thinning or tearing, of the metal takes place,128 A Textbook of Production Engineoring Fig. 2.71 Solid type forming die ‘The examples of forming operations are: embossing, curling, coining, bulging, beading, ‘visting, hole flanging and assembly operations. ‘Types of forming dies: Dies used in forn dies and pressure pad type dies. Forming dics are normally provided with guide posts. Solid type forming dies: These dies are usually of simple construction and design. A solid type forming die consists of male punch and female die shaped to the contour of the workpiece Fig. 2.71. The shape of the punch and die is reproduced on the blank. Allowance for clearance equal to the thickness of the workpiece is provided between the punch and the dic. These dies are used for forming blanks of soft grade metals, mostly strip stock. Pressure pad ype dies: A pressure pad may be necessary when the workpiece contains sharp radii or intricate details or when the workpiece may shift during the forming operations. Pressure pads are applied above (see Figs. 2.54 and 2.55) or below the workpiece (Fig. 2.72) depending upon the design of the dic and type of bend. Pressure for the pad may be applied by springs (Fig 2.72), Air, or hydraulics. In most of the designs, a knockout arrangement is incorporated {© release the formed component from the punch, ng operations are mainly of wo types: Solid type Shank 1p | I t Punail Shoo t iso i I I Suki Post Blank 4 I I I NY oe Pressure 4 | Bi iG | ‘Springs | Fig. 2.72. Pressure pad type forming diePros Too! Design 127 2.11. DESIGN PROCEDURE FOR PROGRESSIVE DIES A progressive die, also known as cut-and-carry die, is a multi station die that performs several operations in succession in a single stroke of the press tam, The various operations may be all cutting operations or a combination of cutting and forming operations. The first step in the design of the dic is the development of the blank. For this. the ditection of metal grain is kept in mind, Normally, the grain of coiled strip is parallel to its length. To eliminate any tendency to fracture, the forming operating are usually performed perpendicular 10 the grain, Thus, while ‘making a scale layout ofthe developed blank, the bend line is kept perpendicular to the strip, The next step is t0 plot the probable design of the scrap strip. In a progressive die, the individual operations (which are normally relatively simple) are combined in several stations. Due to this, it is usually difficult to evolve the most practical and economical strip design for optim ‘operations of the dic. However, when establishing the sequence of operations for progressive dies, the following guide lines should be considered 1, While evolving the strip design, the positioning and proper location of the stock in each station is of prime importance. For this, pilots are incorporated in the die, Advantage should be token of any required holes in the workpiece for piloting, This method is known as “Direct piloting”. Thus piering operations must be placed first in the sequence, However, sometimes (when direct piloting is not ideal or satisfactory) special piloting holes can be placed in the scrap part of the strip. This is called “Indirect piloting”. Advantages of indirect piloting are : greater freedom of size or location and not affected by workpiece change. However, the material width and lead may increase, Care must be taken to avoid having pierced holes tool close to a bend. 2, Distribute pierced arcas over several stations if they are close together or are close to the edge of die opening. 3. Check, if the blanked areas can be divided into simple shapes, so that commercially available punches of simple contours may be used. A blanked area will be partially cnt at one station and the remaining area will be cut in later stations. 4, Use idle stations, They help the designer to distribute the total load uniformly over the complete length of the die, They also strengthen die blocks, stripper plates and punch retainer etc and facilitate strip movement, Also, they permit later changes in workpiece design by providing for additional operations 5, Bending and forming operations ist be at the last stations. 6. Cutting and forming areas should be located to provide uniform loading of the press slide. 7. While designing strip layout, ty for minimum scrap. Use a multiple layout if possible, 8. Design the strip so that scrap and workpiece can be ejected without interference The next step is to design the die, The design of the various die elements (die block, punches, strippers etc.) is done on the same lines as has been discussed for blanking die and piercing die. A progressive die is usually a heavy construction, Note, Some hints on Press work 1. The counterbores in the die-block, the tapped holes in the die shoe and the reamed dowel holes in the die shoe must all be made from 6,35 mm {9 9.5 mm deeper than needed to allow {or grinding of the die block 2, If the punch diameter is twice the material thickness, it need not be guided. 3, I'the punch produces a hole 40% deeper than its own diameter, the shank diameter mu be af least twice the punch size, 4. Punches should be a tap fit in punch plates. For purposes of stability, the flange of the punch should never be smaller in diameter than the length of the punch. Punches should be secured with pins, flats, Keys ete, against rotating inthe punch holders.128 A Textbook of Production Engineoring 2.18. Table 2.12. Dimensions of Back-post Die Sets (cm) Die Area Thickness Win guide Recangular | Diam (| _Die Holder Fnch Holder pest From To From To ia, Teas 35 32 oo 13 Wo 10 35 as 32 25 «15 38 10 32 57 2 123 x19 35 445 25 125 «125 2s 38 50. 32 45 25 125 x20 a8 as 32 57 25 15475 38. so. 32 44s 25 15 «10 las 38 10 32 57 25 15 «15 16.25 38. 625 32 57 25 15 «225 38. 25 32 57 2 175 « 125 Mas 38 16 32 57 25 ls «175 18.75 38 625 32 57 25 175 x25 aa 82 35 57 32 20% 10 38. 625 32 57 25 2x15 Is 38 158 32 57 25 20x 20 2128 a8 62s 32 87 25 225 «30 - 445 890 38 57 38 25 «12 38 625 32 445 32 2517. 35 10 a5 57 32 28 «28 2s 4 82 aS 87 32 25 35 475 95 4 82 a8 275 «225 25 443 a9 38 57 32 «10 4.45 37 38 50 32 30 «15 38 625 38 50 32 3 «30 3125 445 89 445 37 38 30 «40 so. 95 4s 82 38 35 20 45 25 4a 82 38 386 28 45 25 4 82 38 356 35 4s 25 4a 57 38 315 «125 38. 38. 50 38 48 «20 38 38 50 38 45 «25 38. a8 50 a8 45638 a5 50 18 4as 38. Rs 50 8 445 38 445 625 38 8 445 625 38 38 50 15 38 so. 38 45 73 38. 57 38 445 15 a8 57. a8Pros Too! Design 129 ‘The shut-height is established by the length of the guide-posts, which must be at least 12.5 ‘mm shorter than the shutheight in order 10 allow for the reduced short-height due to resharpening, 2.19. MATERIALS AND MANUFACTURE OF SHEET METAL WORKING DIES 2.19.1, Materials, Tool materials are chosen mostly on the basis of the expected life of the production nm. The efficiency, sirength and dimensional stability of the working parts of the tool pend on the material for each component and its beat ueatment. The tool steel used for punches and dies should possess the following properties High strength, High hardness, Adequate wear resistance, High toughness, Good hardenabiliy, show litle sensitivity to over heating, Good machineability and Good grindabiliy Blanking tools are subjected to severe wear and are made from the various cold-working die steels, Bending and Drawing dies are made of similar materials, although C.1 and even hard zine alloys or plastics are suitable for short production suns or softer workpicce materials, Below. we discuss the various materials used for making tools for press working, 1, Blanking (@) For Al, Mg and Cu altoys @ Znalloy (W) Water hardening steel : 0.6-1.4C, Hardness = 62-66HRC (u) Oil hardening steel ; 0.9 C, 1 Mn, 0.5Cr, Hardness = 57-62 HRC (iv) Air hardening, steel : 1C, SCr, IMo, Hardness = 57-62 HRC (©) Cold working die steel : 1.5C, 12Cr, IMo, Hardness = 58-64 HRC () For Sieets and Ni altoys () Mo HSS. : 0.85C. 4Cr, SMo, 6.25 W. 2V. Hardness ~ 60466 @ we 2, Deep Drawing : (@) For Al, Mg, and Cu alloys ( Water hardening steel, Hardness (o) Oil hardening steel, Hardness (i) Air hardening steel, Hardness () Cold working die steel, Hardness = 58-64 HRC () For Sieets and Nr alloys ( Water hardening steel, Hardness = 60-62. HRC (ii) Mo H.SS., Hardness = 60-65 HRC (wn we 3. Press Forming : (@) For Al, Mg and Cu alloys () Eposy/metal powder (ii) Zn alloy (ai Mild steel (mc (©) Oil hardening steel (11) Aitshardening steel (v1!) Cold working die steel () For Steels and Ni alloys» Eposy/metal Powder Note. Dic materials mentioned first are for lighter duties, shorter runs. Other basic die materials are 1. Al bronzes. These have often been used for draw rings and other forming tools, especially those intended for working stainless steel. They possess : fait machineability. high dimensional 60-62 HRC130 A Textbook of Production Engineoring stability, high antigalling properties. high compression strength, good retention of high polish and no need for heat treating. Used for medium sized draw dies and irregular contours 2. Semi-steel. Ts a term often applied to C.I. alloyed with about 10% Si, 1% Ni, 2% Cr. 3% Mn. I is most commonly used for strippers, blank holders and secondary structural members of the die Flexible, Short Run and Alternative Materials L Cerromairix. Iis a special low melting point alloy of Bismith, Lead, tin and antimony with hard setting and expandable properties, designed specifically for die applications. It is widely used for the repair of dies and for the scating and holding of punches and dic sections, especially long, slender members in intricate dies where precision machining would normally be ‘time consuming and costly. The material is also used as the form block or die block member is short run forming, 2. Kirksite, A cast Zn base alloy with Al, Cu, and Mg is extensively used in the aircraft industry and to some extent in the automotive industry for large forming and drawing and stretch Jorming. It is most applicable on experimental and short production run, Kitksite dies are quickly ade, being cast closely to shape and size required, are used without heat treating and are easily finished, 3. Plastics. Cast phenolics, cast or laminated epoxy and glass inforced polyester. They are proving of exceptional benefit to the aircraft, automotive, appliances and other industries for certain types of work. They are used principally for large forming and drawing dies, where their fast fabricating time, low cost and light weight are definite advantages. They are casily repaired and modified. Plastics are not necessarily limited to short run or experimental dies. 4. Rubber: Mostly used for forming dies, 2.19.2, Sintered carbide dies. A longer life of tools for different press working operations can be achieved by using inserts made from tungsten and cobalt carbides, Carbide tools Have found widest application in large Tot and mass production, where conventional stecl dies and punches do not prove stable cnough, which calls for frequent duplication of dies, The life of carbide blanking dies rises by 8 or more times, This effect grows ‘manifold when operating om high strength sheets of stainless, electrical and similar stecls; carbide dies in such cases are $0 times as durable as conventional dies. Carbide dies differ somewhat in design from steel dies, which is due 0 the physical and ‘mechanical propertis of carbides. The design and manufacture of such dies must ensure 1. High stifthess of the die structure. 2. High wear resistance of guide posts, bushings, stock guides, stops and other die ‘components, 3. Secure fastening of carbide inserts and their accurate fitting to the bearing surfaces. 4. Minimum penetration of the punch into the dies, ensured by application of limiting rests 5. Elemination of the effects of in-accurate travel of press slide by using float type shanks nd symmetrical arrangement of guide posts with respect the contour of the cut. 6. Increased 2.19.3. Die Manufacture. The dies for the sheet metal working are manufactured by the same processes as used for the manufacture of forging dies, that is, mechanical mac methods (copying milling. NC milling), EDM, ECM and casting. Dies can be manufactured by these methods individually or these processes can be combined to manufacture a die at lower cost. (@ Manufacture of blanking and piercing dies. Among the mechanical machi processes, in addition (0 the more common methods of milling, turning and grinding, processes such as sawing, shaping and planing are also employed. With EDM besides die sinking, cuttinPros Too! Design 131 so be performed using a NC wire electrode. The size of the work piece. the desired contour, the die material and the required accuracy all influence the choice of the machining process edges are usually machined conventionally to required tolerances in the case of simple contours, such as those with cylindrical openings. More complicated contours are usually ‘machined by conventional EDM or WEDM. This results in significant cost and time savings. For example, with dies made of WC, savings of 30-50% may be achieved, EDM die sinking and culting, using a wire electrode, has lead to improvements in quality. (precision dies) because of climination of distortion and of improved strength. This is because hardened tools can be ‘machined by EDM, CAD/CAM techniques minimize the production costs involved in the desige ‘manufacture, maintenance and modification of dies, especially for the design of progressive dies and dies of complex configuration. Additional heat treatment of the dic surlace, such as nitriding, surface coating of tools with a layer of WC, or ion implantation, leads to significant reduction in the wear of culling edge. (b) Manufacture of dies for sheet-metal working (deep drawing ete.). The single or double comvex or concave working surfaces of sheet m.v, dies are largely machined by copy milling or EDM. In the case of medium and large-sized dies. the die block is generally cast with a 10-28 mm machining allowance. The choice of one or two process combinations is based primarily on the complexity of master models and electrodes and on the amount of hand finishin roquired in the form of spot grinding. lapping, polishing, and so on (about 60-80% of total ‘machining time). Inconventional manufacture, using copy milling, individual dies are first rough and finish silled following a master patiora. Afr initial grinding to smooth down the milling edges, the surface is spot ground using a blueing model, smoothed and then polished. With complex die shapes, the finished male die may be used as a blucing aid in finish grinding the lower die. The desired gap width required for the sheet metal is checked with the aid of lead or Al wit. EDM is best suited for finishing premachined (copy milled) dies to a high standard of accuracy and surface finish. The machining allowance may vary between 0.2 and 0.3 mm. The overall machining time may be reduced by 20-50%, and, depending on the die geometry, the time roquited for manual finishing by 40-90%. The die blocks made by casting are first contour milled and then the remaining working surfaces are rough machined using copy milling. About 0.2-3 mm is Teft on the die surface and machined by EDM to tolerances of 0,-0.3 mm and a surface finish of 1-3 mm Ra, The final ‘manual finishing consists of grinding the projections left opposite the electrolyte supply channels as well as the edges formed between the case of multiple electrodes. This is best done by using a blueing model. In addition. minor shape corrections may be made ‘where the electrodes are wom out and the drawing radii may be smoothed out and polished. Dies of lange working surface areas and gradually changing curvatures, such as dies for automobile body parts (doors, roof pannels etc.) are mainly machined by copy or NC milling and requite little subsequent hand finishing. With large body panels, perfect stream fining is essential This requires special precision machining. Heavily ribbed and ridged deep drawing dies may be machined advantageously using EDM. Note, In general, working surfaces > | m? are considered large dies, while small dies have working arcas 10° ~ 10' mu 2.19.4. Machining of punches. Normally, the following steps are involved 1. Cutting of a blank 2. Rough machining 3. Rough grinding 4. Hardening 5. Finish grinding the profile 6. Finishing the profile 7. Sharpening the cutting face,132 A Textbook of Production Engineoring Straight punches for blanking round contours or piercing round oles are casy to ‘manufacture, They are 1. Turmed on Lathe 2, Hardened, 3. Ground on circular of uni ersal grinders, 4. Then their working surface is finished by polishing and the cutting face is sharpened (ground), ‘The shaped punches are far more difficult make. The following steps are involved in their ‘manufacture 1. The contour ofa punch is first machined on metal cutting machines keeping an allowance {or further machining 2. Then an impression of the contour is made by the hardened and finished die. 3, Next, the punch is filed off aecording to the contour of the impression with due account for the requited die-punch clearance. 4. Lastly, the punch is hardened and its working part is finished, 2.19.5, Increasing press tool service life. The life of a press fool may mean any of the following : The number of stampings made, 1. between sharpening and repair 2, between two sharpenings 3. between two repairs or 4, the total number of stampings made before the tool is completely worn out The life of press tool can be increased by 1. Case hardening (nitriding) 2, Chrome plating. It is used for increasing the wear resistance of new parts an reconditioning wor parts made from carbon steels. The thickness of chromium layer can be fro1 3 jum upwards. It may be 50-60 yum in case of reconditioning. Chrome plated ports are subjected to heat treatment in an oil bath (2h at 170-180°C), 3. Comented carbide inserts inerease the life of press tools dozens of times (as discussed above under Art. 2.19.2) 4, Hard facing of tools aims at increasing the wear resistance of new, mostly large size, press tools and at reconditioning worm tools. Hard facing is done by means of oxy-acetyline flame. Ik is done with special electrodes or hard alloys. Electrodes 6 to 7 mm in diameter and 400 to 500 ‘mm long are used, The material of the electrodes (cast alloy) is satellite for blanking and cut off digs and chromite (based on chromium and iron) for bending and draw dies. “The hard faced press tool is placed in warm sand to allow it to cool slowly. The hard faced paris are annealed at a temperature of 800-900°C for 2-4 hours and subsequently tempered in ofl aa temperature of 450-600°C for one hour. 2.19.6, 1LS. Code. LS. Code for Tool and Die stecls for cold work is : IS : 3749-1966. It specifies requirements for plain carbon and alloy tool and die steels in the form of bars, blanks, rings and other shapes for cold work, capable of being hardened and tempered. Chemical composition and hardness are among the requirements. See Appendis-I (C) The L$. code for High Speed (ool steels is: LS + 7291-1974 2.20, SOLVED EXAMPLES. Example. 2.1. Find the total pressure, dimensions of tools to produce @ washer 5 em. outside diameter with a 2.4m diameter hole, from material 4 mm thick, having a shear strength of 360 NinnPros Too! Design 133 Solution. The production of washer consists of two operations » Blanking the outside diameter and piercing the inner hole Blanking Pressure, P= abte, = rx 504 x 360 226 KN Piercing Pressure, F, = ndee, Sax Mx 4 x 360 108.768 kN Total Pressure required, PoP +P, = 226.6 + 108.768 = 335,368 kN 3354 kN Clearance is taken as 10% of stock thickness. Therefore, Piercing punch diameter = 2.4 cm Piercing die diameter = 2.4 + 0,04 = 2.44 cm Blanking die diameter = 5 em Blanking punch diameter = 5 ~ 0.04 = 4.96 cm ‘The above calculations give the press capacity for tools without shear. When suitable shear is applied. the loads calculated can be reduced by 20%. ross capacity = 0.8 335.4 = 268.32 kN ‘The blanking punch will be flat and shear applied to the blanking die and for piercing. the punch will have shear and the dle will be Mat Example. 2.2. | cup without flanges and of height 10 cm. and diameter 5 em isto be made from sheet metal 2.5 mnt thick. Find the suitable number of draws Solution, Fits fal Hank danse sold obtained 15 gven as b= a eta vee d= Sem and f= 10cm D=18em ‘The height diameter ratio of cup is 2. Therefore, from table 2.9. the tentative number of draws is 3, Let the reduction be : 45%, 25% and 20% respectively Ist reduetion = 45% = 15 = 04S = 6.75 Diameter d, a first draw = 15 ~ 6.75 = 8.25 em 2nd reduction = 25% = 8.25 x 0.25 = 2.06 em Diameter d, at second draw = 8,25 ~ 2.06 = 6.19 em, 3rd reduction = 20% = 6.19 x 0.2 = 1,238 em, Diameter eat final draw = 6.19 ~ 1.238 = 4.952 em To get exactly the value of 5 em, the third reduction can be slightly lower than 20% (19.25 per cent exactly) Example 2.3. 4 37.5 cm long, 19 mm wide and 2.5 mm thick sirip is to be bent in a J shaped die. Calculate the bending force necessary if the steet has 630 Nim? tensile strength Solution, Let the width of die opening be 161, te. w= 16 x2 = 40 mm134 A Textbook of Production Engineoring Now Bending force is given as, Kilo Now K= 1.20,/=37.5 em, ¢= 2.5 mm 630mm? 5s" 19" 6307 (25) = 44.3 kN Example 24, Estimate the blanking force to cut a blank 25 mm wide and 30 mm long from 415 mm thick metal strip, if the altimate shear stress of the material #6 480 Nm’. Also determine the work dove if he percentage penetration is 28 percent of material thickness Solution, (a) Perimeter of blank = 2 (25 + 30) = 110 mm Blanking force Area under shear » ultimate shear stress Povimoter 1, = 10» 15 450 = 74.25 KN o Punch travel = Percentage penetration 1 , = pete 7 20375 mm Work done = Force » punch travel 74.25 «10? x 0375 x 27.84 Nm Example 2.5, 4 washer with a 12.7 mm internal hole and an ouside dlameter of 25.4 mm Js (© be made from 1.5 mm thick strip of 0.2 per cent carbon steel. Considering the elastic recovery ofthe material, find : (a) the clearance (b) Blanking dte-opening size (c) the blanking punch size (d) the piercing punch size (e) the piercing die-opening size Solution, (2) The clearance (one side) for sot steel 5% oft 0.05 «15 = 0.075 mm. (Iris clear from Fig, 2.20 (6), the blanking die opening size is equal to the blank size But o allow for the expansion of the blank, the die opening should be made smaller. Thus, Blanking dic opening = 25.40 ~ 0.08 2 (©) Blanking punch size= Blanking dic opening ~ 2C 25.38 — 0.15 25.20 mm. («) The punch size determines the size of the hole produced. To allow for the contraction othe hole due to elastic recovery, the punch size should be made larger by an amount 0.05 mm. (ee article 2.8.1). So, the piereing punch size will be,Pros Too! Design 1935 Piercing punch size = 12.70 + 0.05 12.75 mm die size = Piercing punch size + 2C, [Fig, 2.22 (a 12.75 + 0.15 12.90 mm, Example 2.6, The ultimate shearing strength of the material of the washer in example 2.3 is 280 Nm’. (a) Find the total culting force if both punches act at the same time and no shear is applied 10 either punch or the die. (b) What will he the cuting force tf the punches are staggered, so that only one punch acts at a time. (e) Taking 60% penetration and shear on purtch of I mm, what will be the cutting force if both punches act together Solution. (a) Fan (D+ dt, D= 254 mm, d= 12.7mm, ¢ +=,= 280 Nimm? P= m Q54 + 12.7) x 15 «280 50.27 kN (®) When the punches are staggered, the punch taking te largest eut will requi force. ©) Piercin 3mm P= nbee, x 254 « LS « 280 335 KN OK Ke (Rerva) K= poreontage of penetration 1 shear on punch = 1 mam en = 50.27 KN 15x 06% 5027 (0941) = 238 KN Example 2.7.1 hole of 60 mm diameter isto he produced in steel plate 2.5 nm thick: The alimate shear sirength ofthe plate material is 450 N mn’. Ifthe punching force isto be reduced to halfof the force using a punch without shear, estimate the amount of shear on the punch. Take percentage penetration as 40% Solution. The punching force with non-sheared punch, aDe, mx 60 2.5 x 450 212 kN Work done f,,. * penetration (punt travel) = Od at © (Eqn.2.6) 0.60 = 212 x 10 « 04 «2.5 = 212 Nm Now work done remains the same with a sheared and a non-sheared punch,A Textbook of Production Engineoring Wig, 2.77. A Bell Crank lever, 51. A steel eup of height 30 mm and intemal diameter 40-am with a flange width of 10 mm is to be deep dawn from a sheet Imm thick, Determine the diameter of the blank and the drawing foroe. What is the draw ratio? Can the cup be drawn ina single operation? (GATE 1996) (Ans: 94.28 mm, 32:54 KN, 2.38, No, in 2 draws) 52, In deep dravving of sheets, the value of fimiting draw ratio depends upon (A) Percentage elongation of sheet metal (B) Yield strength of sheet metal (C) Type of press used (D) thickness of sheet (Ans. : D) (GATE 1994) 3. (a) Determine the diameter of the hole that can be punched in a steel sheet of thicknest 16 mmm, for which the ulimate shear stress is 310 Nimm?, Press Capacity is 250 KN. (#) What will be the ponch size if punching is the needed operation 7 (©) If the Blank isto be drawn into eup, determine the diameter of the cup after the Sst daw. sot @) FonDixs, : 230 - 1000 = xD» 16» 310 From ber, D = 160mm (by Punch wre Sie of hole ~ 160- mm 16 © Now thsiness mio, @) = + 0q 1 © ) 18100 for this at safe Du = 2 Drameter of cup aller the fist dea, 160 £4. Solon of Problem 49 (a) Avsime Clarice, C 10% of 4 (by Paneh dimer Hale size ~ 100 mm Die diameter Punch diameter +20 100 + 42 = 10140 mm (6) Using equation (2, Me ra 1 Fo DAS. 2» WO $6 ~ $50 ~ 968 kN Toa, f= 3004y 968 12 vow 56 um tung 7 1 723 bo rom here, 0 4.26