DESIGN, MANUFACTURING, INSPECTION AND

TESTING OF PRESS TOOL FOR CONNECTOR

Presented by, Guided by,

Mr. Nayan P. Kamod [B80690851] Prof. Y.D. Kokate
Mr. Mohit V. Pimpley [B80690880]
Mr. Rohit V. Pimpley [B80690881]

1
Department of Mechanical Engineering
Gokhale Education Societys
R. H. Sapat College Of Engineering, Management Studies And
Research,
Nashik 422005(MS)
Academic Year: 2014 - 2015
 PRESS TOOL

Press tool is a set of plates with a relief, or depth based design, in them. The metal is
placed between the plates, and the plates are pressed up against each other,
deforming the metal in the desired shape and size.
 Our Project lays emphasis on the design of press tool for the manufacturing of
connector used in smoke detector. Testing the press tool and inspecting the
connector completes the scope of our project. Our objective is to design the
connector by the following operations:-

Piercing Operation
Blanking Operation

Fig. 1 Connector Component

 Design of Press Tool

Manufacturing of Press Tool

Inspection and Testing of Press Tool

 Progressive Die

Floating Stripper

Shim

Replaceable Die Inserts

Materials D2, OHNS

Fig. 2 Progressive Press Tool

Design Parameters
1. Cutting Force
2. Press Capacity
3. Work Done
4. Energy
5. Stripping Force
6. Stripper Thickness
7. Selection of Screws
8. Selection of Dowels
STRIP LAYOUT[1]
Front Scrap (a1) = 3 mm

Back Scrap (a2) = 2.6 mm

Scrap Bridge (b) = 3 mm

Width of blank (w) = 5 mm

Feed (s) = w+b

= 8 mm
Height of strip = 30.41 mm
Thickness of strip = 0.25
Number of blanks = 12

% Utilization of strip =
+ +2

= 60 %
Fig. 3 Strip Layout
 Cutting force = Area*s

Cutting force(Fmax) = 112.957 kN

= 11.514 tons

By considering 33% overload,

Fmax = 15.31 tons

A press capacity = Fmax * c

where c= 1.1
Thus, Press Capacity = 16.841 tons

Thus, for safer side a Press capacity of 20 tons is used.

 Design of die block

i) Blank Perimeter = 80.2 mm

For blank perimeter from 75 mm to 250 mm,
Die Thickness = 25 mm

ii) Angular Clearance = 3o (Standard)

iii) Clearance = 0.01* t * s

= 0.136 mm
Fig. 4 Die Block
 Design of Stripper plate

i) Stripper thickness = 0.33 * Punch length

= 28 mm

ii) Length of stripper plate = 105 mm

iii) Width of stripper plate = 125 mm Fig. 5 Stripper Plate

[For simplicity of manufacturing, length and width of stripper is assumed to be same as that of die block]
Selection of Screws[2]

Stripping Force = 24.31 kN

Stripping Force M6 M8 M10 M12

TONS kN

1.25 12.455 8 4 3 2

1.6 15.942 - 5 3 2

2.5 24.910 - 8 5 4

4 39.856 - - 8 6

Size Nominal Diameter in mm Pitch in mm

M 4.00 0.7
M 5.00 0.8
M 6.00 1.00
M 8.00 1.25
M 10.00 1.50
M 12.00 1.75

Load Capacity = 31.92 kN

 Manufacturing begins with ordering of raw material

Premachining the raw materials

Precision machining is done

Heat treatment is carried out as and when required

Wire EDM along with grinding follows Heat Treatment

Plates are assembled with the help of bench fitting

 Plates Manufactured[4]

1. Top Plate
Operation Description Machine Measuring Time(hr
no. tool instruments s)
1 Pre-Machining Milling Vernier 3
and chamfering Caliper
Height Gauge
2 Surface Surface Micrometer 1
Grinding Grinder

3 Milling-Drilling Milling Vernier 4

Caliper
4 Jig Boring Jig Boring Vertical 5
TRIMOS, bore
gauge
5 Final Grinding Surface Micrometer 1
Grinder
6 Bench Fitting Hand All the 1
Grinder, measuring
Files instruments
Total 15
 2. Die Plate
Operation Description Machine Measuring Time(hrs)
no. tool instruments
1 Pre-Machining and Milling Vernier Caliper 2
chamfering Height Gauge

2 Surface Grinding Surface Micrometer 1

Grinder
3 Milling Drilling Milling Vernier Caliper 1

4 Milling-Counter Milling Vernier Caliper 1

Boring

5 Jig Boring Jig Boring Vertical-TRIMOS, bore 2

gauge
6 Heat Treatment Furnace R.C Hardness M/C
7 Final Grinding Surface Micrometer 1
Grinder
8 Wire EDM EDM Vertical-TRIMOS, bore 6
gauge
9 Bench Fitting Hand All the measuring 1
Grinder, instruments
Files
 3. Stripper Plate

Operation Description Machine Measuring Time(hrs)

no. tool instruments
1 Pre-Machining and Milling Vernier Caliper 3
chamfering Height Gauge

2 Surface Grinding Surface Micrometer 1

Grinder
3 Milling Drilling Milling Vernier Caliper 4

4 Jig Boring Jig Boring Vertical-TRIMOS, 4

bore gauge
5 Heat Treatment Furnace R.C Hardness M/C
6 Final Grinding Surface Micrometer 2
Grinder
7 Wire EDM EDM Vertical-TRIMOS, 6
bore gauge
8 Bench Fitting Hand All the measuring 1
Grinder, instruments
Files
Total 21
 4. Bottom Plate

Operatio Description Machine Measuring Time(hrs)

n no. tool instruments
1 Pre-Machining Milling Vernier Caliper 3
and chamfering Height Gauge

2 Surface Surface Micrometer 1

Grinding Grinder

3 Milling-Drilling Milling Vernier Caliper 4

4 Jig Boring Jig Boring Vertical 5

TRIMOS, bore
gauge
5 Final Grinding Surface Micrometer 1
Grinder
6 Bench Fitting Hand All the 1
Grinder, measuring
Files instruments
Total 15
 Parts to be hardened

1. Die plate 2. Stripper plate

3. Punch plate 4. Punch back plate
5. Blanking punch 6. Piercing punch
7. Guide bush and guide pillar

Sr No. Material Hardening Tempering Hardness

temp (oC) temp (oC) (HRC)

1. D2 900-950 oC 400-450 oC 60-62

2. OHNS OIL (50-60oC) 400-450 oC 50-52

3. EN-31 OIL (50-60oC) 400-450 oC 45-50

 TESTING OF TOOL
Tool is tested for the following:
Wear and Tear
Cutting Clearance
Heating of the Tool

Types of tool testing trials:

1. Tool Trial Run
2. Production Trial Run
The dimensions of the inspected
component are checked with the
dimensions of the given component
layout.
Batch no. No. of Actual Dimensions Required Dimensions
Components

Diameter of Pierced Perimeter of Diameter of Perimeter

Hole blank Pierced Hole of blank

1
3000 3.3 80.18 3.3 80.2

2
3000 3.29 80.21 3.3 80.2

3
3000 3.3 80.19 3.3 80.2

Three different batches of 3000 components are taken

Allowable deviation which is 0.01 mm.

 Special attention to design, material selection and inspection of component.

Using progressive tool, the time required for performing operation was reduced by
1 second per component.
[1] Dr. P. C. Sharmas A textbook on Production Engineering published by S. Chand
publication.

[2] Tool Design Data Book, DTE Government of Tamil Nadu

[3] Vishwanath M.C. published paper on Design of Progressive Draw tool in International
Journal of Scientific and Research Publications, Volume 3, Issue 8, August 2013

[4] D. Eugene Ostergaards Basic Die-Making published by McGraw-Hill Book Company.

[5] S.K Hajra Chaudharys Elements of Workshop Technology published by MPP Pvt. Ltd.