Two Days Workshop on

Sheet Metal Tool Design (Press Tool Design) & Forming Simulation

19th & 20th Nov 2010 Hotel Basil Bangalore

Organized by

Govt. Tool Room & Training Center (GT & TC), Tumkur

DHIO Research & Engineering Pvt. Ltd.,

Copyright @ Mr. N B Suresh, PANNAGA INTERNATIONAL ACADEMY

Training program for Two Days Sheet Metal Tool Design (Press Tool Design) & Forming Simulation Day 1
1st hour

Presentation and objective Physical exhibition of sheet metal components (simple complicated from flat to formed Introduction to press tools.

2nd hour Sheet metal industries activities Press machines -- press brakes, shearing machine, fly press, bull press, lever press, four post press, etc Shearing Cutting clearance 3rd hour Cutting-operations Identification of operations: blanking, piercing, notching, cut off, part off, shaving, trimming Non-cutting operations Identification of operations: bending, forming, drawing, extrusion, flanging, curling, embossing, stamping, bulging

Lunch break
4th hour Materials and process Tool materials: heat treatment process for die and other tool elements

Component materials: finishing operations, tumbling, rolling & vibrators

5th hour Basic construction of the tool Material Function Die sets and types of die sets 6th hour Non- cutting operation Introduction Bending Varieties of bending

End of the day one

Day 2
1st hour

Review of the previous day Continuing non - cutting operations: forming, curling, bulging, stamping, coining, flat length calculation

2nd hour Draw operations: shallow drawing: deep drawing, lubricants, flat blank calculation 3rd hour

Defects and remedies Exhibit physical components Slide show of defective components Discussion regarding the defective components

Lunch Break
4th hour Strip lay out Types of strip lay out Importance of strip lay out Ecocomic factor of the strip lay out Optimization of strip lay out Single pass and double pass strip lay out 5th hour Work shop on design of strip lay out in groups 6th hour Conduct objective type test Collect feed back Issuing certificate

End of the day two Conclusion of the Training Program

TRAINING PROGRAMME ONPRESS TOOLS

DAY ONE: 1ST HOUR 1. PRESENTATION DEAR PARTICIPANTS, HEARTY WELCOME TO THE TWO DAYS SHORT TERM COURSE WITH WORKSHOP ON PRESS TOOLS. WE AT DHIO TECHNOLOGIES, CATER HIGHLY VALUED SIMULATIONS AND MECHANICAL DESIGNS FOR MANY INDUSTRIES THROUGHOUT THE WORLD. AS WE HAVE FOUND INSUFFICIENT KNOWELDGE IN SHEET METAL FABRICATION AND ITS FORMATIONS IN MANY PERSONS THOUGH, THEY ARE ALREADY IN THE FIELD. THIS SHORT TERM COURSE ON PRESS TOOLS WILL CERTAINLY BOOST YOUR KNOWELDGE AND MISCONCEPTIONS, IF ANY WILL BE RECTIFIED. WE KNOW THAT, IT IS DIFFICULT TO GIVE ALL THE INFORMATION RELATED TO THE SUBJECT. BUT EVERYTHING IS POSSIBLE, IF WE PUT OUR MIND IN THE RIGHT DIRECTION. WE APPRECIATE YOUR SINCERE PARTICIPATION IN THESE SESSIONS. TRULY YOURS DHIO Research & Engineering Pvt Ltd.,

DAY ONE: 1ST HOUR 2. OBJECTIVES TO KNOW ABOUT PRESS TOOLS AND ITS WORKING TO KNOW VARIOUS SHEET METAL PRODUCTS TO PRACTICE THE BASIC DESIGN CONCEPTS OF PRESS TOOLS AND STRIP LAYOUTS TO UNDERSTAND THE SUBJECT IN A SYSTEMATIC METHOD TO ELIMINATE WRONG CONCEPTIONS TO LEARN AND PRACTICE CERTAIN CALCULATIONS PERTAINING TO THE SUBJECT TO IDENTIFY DEFECTS AND FIND THE SOLUTIONS

DAY ONE: 1ST HOUR SHEET METAL COMPONENTS

(SIMPLE COMPLICATED FROM FLAT TO FORM) BLANKING OPERATION: PIECE PART (BLANK OR COMPONENT)

PIERCING OPERATION: HOLE OF ANY PROFILE

 NOTCHING OPERATION: SIDE CUTTING OF ANY PROFILE

SHAVING OPERATION: MAKING OUTER COUNTOUR UNIFORM, SMOOTH AND PRECISE

 TRIMMING OPERATION: MAKING OUTER COUNTOUR UNIFORM AND SMOOTH

SIDE CAM PIERCING: SPECIAL HOLE MAIKKNG OPERATION IN DRAWN CUPS

 DINKING OPERATION: FOR FIBRE MATERIAL

LOVERING OPERATION: PASSAGE FOR AIR TO ENTER

LANCING OPERATION: PARTIAL TEARING OPERATION

 BENDING OPERATION: FOR SHAPING OF PRE-CUT BLANKS OR SHEETS IN STRAIGHT AXIS

FORMING OPERATION: FOR SHAPING IN CURVED AXIS

 CURLING OPERATION: FOR HINGING, PIN GUIDEING PURPOSE

FLANGING OR EXTRUDING: FOR ORIGINATING THREADS IN SHEET METAL

DRAW OPERATION: TO SHAPE FLAT BLANK SHEET METAL INTO CUP

COINING OPERATION: SOLID BLANK IS SQUEEZED TO REQUIRED PROFILE

 STAMPING OPERATION: DEPRESSED LETTERS, SYMBOLS, LOGOS ARE POSSIBLE ON SHEET METALS

EMBOSSING OPERATION: REQUIRED FOR PLACING SCREWS, FOR RIVETTING ETC ON SHEET METALS

BULGING: SWELLENING OF THE IRREGULAR PROFILE ON THE TUBE SURFACE

DAY ONE: 1ST HOUR INTRODUCTION TO PRESS TOOLS

Sheet metal components are produced by a device called Press tool. Generally, these tools are Cold working and manufactured to improve the productivity of the components qualitatively and quantitatively. APPLICATION OF PRESS TOOLS Press tools are extensively used for the production of sheet metal components in mass. Examples Almost all products like television, tape recorder, radio, refrigerator, car, watch, computer etc, which consist number of components made of either plastic or sheet metal. DEFINITION FOR PRESS TOOLS Press tool is defined as a device used for producing sheet metal components in large volume by applying an external force with the help of a machine tool called PRESS.

Press tools are mainly manufactured for high rate of sheet metal component production. If the requirement of components is less (less than 1000 numbers), these devices are not economical. Hence, press tools are categorized according to the requirement, CATEGORIES OF PRESS TOOLS Simple press tool Medium production press tool Large scale production press tool High speed press tool Precision press tool Horological press tool (watch component)

SPECIAL PURPOSE PRESS TOOLS Cantilever press tool Side cam press tool Straight cam press tool Angular cam press tool Curvature cam press tool

TYPES OF PRESS OPERATION Cutting press tool Non - cutting press tool Hybrid press tool (Cutting and Non-Cutting operation)

DAY ONE: 2ND HOUR SHEET METAL INDUSTRIES ACTIVITIES

Sheet metal industries have a significant role in the present industrial society. The production of sheet metal components have increased in many folds due to continuous research and development. In our country, major activities lies with sheet metal industries only. As per the present survey, it occupies 55% of the industrial supplies.

Sheet metal industries are classified into many categories. 1. Fabrication industries

House hold products Conventional products Commercial products Non precision industrial products General engineering products

2. Medium precision industries Engineering products of second priority 3. High precision industries Aero space products High end engineering products Products with special material

 Products for research and development

For any industry to run efficiently 3 M are very important. 1) M = Money 2) M = Machine 3) M = Men

Money and Machine are supported by many agencies and consultancies, whereas, it is difficult to find skilled man power with good knowledge of both theoretical and practical.

SIGNIFICANT POINTS
Most Tool and die makers need 4 or 5 years of classroom instruction and on-the-job training to become fully qualified. Employment is projected to decline because of strong foreign competition and advancements in automation. Despite the decline in employment, excellent job opportunities are expected.

NATURE OF THE TOOL MAKERS

1. Tool and die makers are among the most highly skilled workers in manufacturing. These workers produce and repair tools, dies, and special guiding and holding devices that enable machines to manufacture a variety of products we use daily from clothing and furniture to heavy equipment and parts for aircraft. Toolmakers produce precision tools. They are capable of handling machines that are used to cut, shape, and form metal and other materials. They also produce jigs and fixtures that hold workpiece while it is bored, stamped or drilled and handle gauges and other measuring devices. Die makers construct metal forms called DIES, that are used to cut metal in stamping. Tool & Die makers use computer-aided design (CAD) to develop products and parts. Tool & Die makers set up a test run using the tools or dies they have made to make sure that the manufactured parts meet specifications. If problems occur, they compensate by adjusting the tools or dies. They study metalworking processes, such as heat treating and plating. Classroom training usually consists of tool designing, tool processing, blue print reading.

2.

3. 4.

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9. 10.

11.

TRAINING, QUALIFICATIONS AND ADVANCEMENT

1. Even after completing a formal training program, Tool & Die makers still need years of experience to become highly skilled. Most specialize in making certain types of Press tools, Moulds, or Dies. While a State certification is not necessary to work as a Tool & Die maker, it gives workers more flexibility in employment and is required by some employers. Apprentices usually must be at least 18 years old. People entering this occupation also should be mechanically inclined, able to work and solve problems independently They should have strong mathematical skills, and be capable of doing work that requires concentration and physical effort.

2.

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4. 5.

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ADVANCEMENT a) There are several ways for skilled workers to advance. Some move into supervisory and administrative positions in their firms or they may start their own workshop. b) Others may take up computer courses and become computercontrolled machine tool programmers. With a college degree, a Tool & Die maker can go into engineering or Tool design. PRESENT GLOBAL STATUS OF TOOL AND DIE MAKERS About 75% of Tool & Die makers are in manufacturing industries, such as the Fabricated metal products, Machinery and Aerospace products and Spare parts industries. Rest is self employed in the related field.

BASIC WORKSHOP MACHINES

Drilling Machines

Lathes

Shaping Machines

Universal & Vertical Milling Machines

Slotting Machine

Planer / Planning Machine

Horizontal Boring Machines

Vertical Boring Machines

Universal Gear Hobbing Machine

Hydraulic Hacksaw

Grinding and Polishing Machines

Universal Tool & Cutter Grinder

Pedestal Grinders

Bench Grinders, Bench Polishers, Pedestal Buffers

Abrasive Belt Grinders

Surface Grinders

Roll Grinding Machines

Knife Sharpening / Blade Grinding Machine

Cylindrical & Centreless Grinders

DAY ONE: 2ND HOUR PRESS MACHINES

Metal forming press is one of the most commonly used manufacturing machines. Every day, millions of parts are produced by metal forming ranging from battery caps to automotive body panels. Therefore, even a small improvement may add to significant corporative gain. A press, or a machine press is a tool used to work metal (typically steel) by changing its shape and internal structure. Currently, the metal forming presses can be divided into two categories: a) MECHANICAL PRESSES b) HYDRAULIC PRESSES The former is fast (high speed presses may reach up to several thousand shots per minute) and energy efficient (the large flywheel eases the impulsive force), but lacks flexibility. On the other hand, the hydraulic presses are flexible (their motions can be programmed) and accurate, but are expensive to build and to operate. Recently, there are mechanical presses driven by servomotors. They could perform as flexible as hydraulic presses with high speed. Nevertheless, they are even more expensive to build and to operate.

FLY PRESS

Fly presses are simple hand devices used for light work. These are extensively used in small scale industries and need very less space and any unskilled worker can operate with minimum supervision. Fly presses are available in different range of capacity. Generally, Blanking, Piercing, Notching, V Bending and L Bending are performed using single stage press tools. Bending press is a typical machine applies direct pressure to the material and forcing it to change shape.

PRESS BRAKE
A brake press is a special type of press machine that bends sheet metal into required shape.

Example: Backplate of a computer case Brackets Frame pieces

 Electronic enclosures Some press brakes have CNC controls and can form parts with accuracy to a fraction of a millimeter. Machine presses are used extensively around the world for shaping all kinds of metals to a desired shape. SAFETY ASPECTS Injuries in a press may be permanent, because of the large forces used. Bimanual controls (controls the use of which requires both hands to be on the buttons to operate) are a very good way to prevent accidents, as are light sensors that keep the machine from working if the operator is in range of the die. TOOLS FOR POWER PRESSES Planishing press has a set of plates with a relief, or depth-based design, in them. The metal is placed between the plates and the plates are pressed up against each other deforming the metal in the desired fashion. This may be Coining or Embossing or Forming Punch press is used for forming holes Capping Presses form caps from rolls of aluminium foil at up to 660 per minute. Progressive press tool is a manufacturing method that can involve punching, coining, bending and several ways of modifying the metal, combined with an automatic feeding system. The feeding system pushes or pulls a coil of metal through all of the stations of a progressive stamping die. Each station performs one or more operations until a finished part is made per the requirements on the print. The final operation is a cut-off operation, which separates the finished part from the parent stock. The parent stock material that is punched away in previous operations is considered as scrap metal or skeleton.

Power press with a fixed barrier guard SHEET ROLLING MACHINE SHEARING MACHINE

PRESS BRAKE

CNC BENDING MACHINES

CNC PUNCHING MACHINES

Presses & Hammers (for Sheet Metal and Forging applications)

Hand Fly Press and Arbour Press

'C' Frame Power Press

Pillar Type Power Press

Deep Drawing Press

Screw Press / Forging Press

Mechanical Forging Hammers

Friction Drop Hammers

Metal Gathering Machine / Heating Upsetter

Metal & Sheet Metal Working Machines

Hand Lever Shearing Machines

Foot Operated Mechanical & Motorized Guillotine Shears

Billet Shearing Machine

Universal Sheet Nibbling

Circle Cutting Machines

Spinning Lathes

Hand Operated and Motorized Swaging Machines

Sheet Folding

Mechanical Press Brakes

Pinch Pyramid Plate Bending Machine, Hand Operated & Motorized Bending Rollers & Taper Rollers

Seaming Machines

RO / ROPP Cap Sealing Machine

Section Straightening Machine

Machine vice

Cut to Length Line

Roll Forming Machines

Profile Bending Machine

Other Machine Tools

Tapping - Threading Machines

Form & Thread Rolling Machines

Riveting Machine

Pantograph Milling & Engraving Machines

MECHANICAL BLANKING & FORMING PRESSES

General view of a blanking and forming press

ADVANTAGES More parts are produced Improved part dimensional accuracy Greater material strength With its blanking and forming presses in this series offers manufacturing systems that permit cost-effective blanking, drawing, coining, piercing, and calibrating for the production of ready-to-install precision parts in a single operating sequence. A number of field - proven modules can be assembled to form application specific, customized manufacturing systems. Press models in these series are mechanical presses with modified knuckle-joint drive. They are available in nominal press forces of 200T up to 1500T and bed dimensions of 1,500 to 4,000 mm with fixed or adjustable stroke. ADVANTAGES

High stroking rates even for complex parts Multiple forming operations in a single press pass Extreme rigidity of the entire system Reduced impact speeds to protect dies Optimized slide motion Precision, ready - to - install components requiring no subsequent machining

Die space with progressive die MECHANICAL PRESS LINES

Mechanical press line with feeder automation

ADVANTAGES 1. Automated mechanical press lines ensure efficient manufacturing of medium-size and large panels in production of high volumes. 2. Depending on the number of required forming operations, the lines consist of four, five, or six automated mechanical single presses. For high quality drawing results and high stroking rates at a constant drawing speed link drive the preferred drive method since it permits motion curves by which the drawing speed can be reduced by a third as compared to eccentric drives. 3. Advanced mechanical presses offer a long slide stroke and thus permit the manufacture of complex part shapes. Equipped with innovative, fast and reliable crossbar automation and quick die change systems these presses already meet the demands of the stamping plant of the future. 4. Fully automated systems solutions for high - volume manufacturing 5. Fast and reliable component transport with advanced technology 6. Parts of the highest quality thanks to perfected press and bed cushion technology 7. The most advanced automation technology increases production rates 8. High levels of uptime for the lines 9. Process reliability

Mechanical press line with automation

DAY ONE: 2ND HOUR SHEARING

DEFINITION The result of the force imposed on the stock material by the action of the blanking or piercing punch and die is called Shearing Action. These are also related to the effective working and durability of the tool.

The 3 stages of Shearing action are: 1. PLASTIC DEFORMATION 2. PENETRATION 3. FRACTURE

1. PLASTIC DEFORMATION As shown in the illustration, the stock material is placed on the die, the press trips off and the punch is driven towards the die. The punch contacts the stock material and exerts pressure on it. When the elastic limit of the stock material is exceeded Plastic deformation takes place. A radius is formed on the top edge of the hole and bottom edge of the slug or blank. The radius is often referred to as Roll over and its magnitude depends upon the ductility of the stock material.

Load STOCK MATERIAL EDGE RADIUS PUNCH

DIE

2. PENETRATION As shown in the illustration, the driving force of the punch continues. It is forced to penetrate the stock material and the blank or slug displaced into the die opening by a corresponding amount.

Load STOCK MATERIAL PUNCH BURNISHED PORTION ON STOCK MATERIAL

DIE BURNISHED PORTION ON SLUG OR BLANK

This is the actual cutting portion of the cutting cycle. Compression of the slug material against walls of the die opening burnishes a portion of the edge of the blank. BRIGHT BAND At the same time the plastic flow pulls the material around the punch, causing a corresponding Bright band or Burnished area in the work material. The sum of the edge radius depth and the burnished depth is referred to as Penetration.

3. FRACTURE It is clearly shown in the illustration that further continuation of punch pressure causes fracture to start at the cutting edges of punch and the die. Under proper cutting conditions, the cut edge meets exactly at the breaking lines.

STOCK MATERIAL

Load PUNCH

BURNISHED PORTION ON STOCK MATERIAL UNDER COMPRESSION

DIE
BURNISHED PORTION ON SLUG OR BLANK

UNDER TENSION

The punch enters the die opening pushing the blank or slug slightly below the die cutting edges. A slight tensile burr will be formed along the top edge of the slug and the bottom edge of the stock material. The edge radius appears more when using soft materials. Highly burnished land is the result of the material being forced against the walls of the punch and die and rubbing during the final stages of plastic deformation. The remaining cut portion is the Fractured area or Break. The angle of the fractured area is the breakout angle or slug which is towards the punch and the burr side of the work material is towards the die opening.

4. BURR

Burr is the projection which appears during fracture. When normal cutting clearance is provided, burr level will be permissible where as if the cutting clearance is insufficient, compressive burr will appear and if it is excessive, tensional burr appears at the cut edge. This burr is not preferable, since the breaking lines of both the cutting lines will not meet each other, resulting in the reduction of the tool life.

SEPERATED PIECE PART

BURR BREAK BURNISHED LAND OR CUT BAND EDGE RADIUS PENETRATION

DAY ONE: 2ND HOUR CUTTING CLEARANCE

DEFINITION Cutting clearance is the intentional gap provided between the punch and die for the purpose of separating a piece part from the stock material. It is expressed in Percentage [%] NATURE OF CUTTING CLEARANCE The cutting clearance depends on the type of 1. STOCK MATERIAL 2. SHEAR STRENGTH OF THE MATERIAL 3. SHEET THICKNESS A visual check of these characteristics tells whether the punch and die have the proper amount of clearance between them. One can also easily identify, whether the punch is properly aligned with the die opening. When a tool is running in production, the degree of burr on the piece part is an indication, whether the die is ready for re-sharpening. PLEASE NOTE: The burr side of a Blank or Slug is always towards the Punch. The burr side of the Pierced opening is always towards the Die opening

This illustration shows the uniform distribution of Cutting clearance between Punch and Die at each side

OPTIMUM OR NORMAL CUTTING CLEARANCE If the cutting clearance given is sufficient Burnished area or cut band will be approximately 1/3 (one third) of the sheet thickness Piece part separated from the stock material will have negligible or permissible burr Breaking lines will coincide exactly and the life of the punch and die will be optimum.

P IE C E P A R T
TE N S IO N A L B U R R B REAK

P U N C H O U T LI N E O P T IM U M C U T T IN G C LE A R A N C E S T O C K M A T E R IA L D I E O U T L IN E

PUNCH

B U R N IS H E D L A N D O R CU T BA ND ED G E RA DIUS P E N E T R A T IO N O P T IM U M C U T TI N G C LE A R A N C E B U R N IS H E D P O R TIO N O N S T O C K M A T E R IA L U N D E R C O M P R E S S IO N

D IE
B U R N IS H E D P O R T IO N O N S LU G O R B LA N K (1 / 3 rd O F S H E E T T H IC K N E S S ) U N D E R T E N S IO N

EXCESSIVE CUTTING CLEARANCE If the cutting clearance given is Excessive Cut band or the burnished area will be less than 1/3 (one third) of the material thickness Tensile burr (loose burr) will be more Tool life will be less Flow radius or edge radius will be more because of excess material flow into the die during the operation Breaking lines will not meet each other, as there are more gaps between punch and die.
P IE C E P A R T
TE N S IO N A L B U R R BREAK B U R N IS H E D LA N D OR CUT BAND

P U N C H O U TLIN E E X C E S S IV E C U TTIN G CLEAR AN CE S TO C K M A T E R IA L D IE O U T LIN E

PU N C H

P E N E TR A TIO N E X C E S S IV E C U T T IN G C L E A R A N C E B U R N IS H E D P O R TIO N O N S TO C K M A TE R IA L U N D E R C O M PR E S S IO N

E D G E R A D IU S

D IE
B U R N IS H E D P O R TIO N O N U N D E R T E N S IO N SLU G O R B LANK (LE S S T H A N 1 /3 rd O F T H E S H E E T T H IC K N E S S )

INSUFFICIENT CUTTING CLEARANCE If the cutting clearance given is Insufficient More than one cut band Breaking lines will not meet each other Tool life is very less because of frequent re-sharpening of the punch and die Force required to shear the material will be more Serious accidents like breaking or chipping of punch and die cutting edge is common
T E N S IO N A L B U R R

P IE C E P A R T
BREAK BU R N IS H E D LA N D O R C U T B AN D

P U N C H O U T LIN E IN S U F F IS C IE N T C U T T IN G C LE AR AN C E S T O C K M A T E R IA L D IE O U T LIN E

PU NCH

P E N E T R A T IO N IN S U FF IS C IE N T C U T T IN G C LE A R A N C E B U R N ISH E D P O R T IO N O N S T O C K M AT E R IA L U N D ER C O M P R E S S IO N

E D G E R A D IU S

B R E AK

D IE
BU R N IS H E D P O R T IO N O N S LU G O R B LAN K U N D E R T E N S IO N

(M O R E T H A N 1 /3 rd O F T H E S H E ET T H IC K N E S S )

MISALIGNMENT OF PUNCH AND DIE This is the actual shift between the punch and die which affects the proper cutting of the stock material. This shift results in insufficient cutting clearance at one side and excessive cutting clearance on the other side. Due to this there will be an irregular cut band appearing on the periphery of the component. Thereby tool wear and tear will be frequent. Sometimes it leads to very serious accident like chipping of the punch and die cutting edges.

Cutting characteristics indicate whether, the Punch and Die are in perfect alignment. This will give a clear indication to the Tool and Die maker, who is handling the die. It also enables him to detect and correct misalignment conditions, when they occur during assembling or working of the die.
PIECE PART
TENSIONAL BURR BREAK PUNCH OUTLINE INSUFFISCIENT CUTTING CLEARANCE STOCK MATERIAL DIE OUT LINE

PUNCH

BURNISHED LAND OR CUT BAND EXCESSIVE CUTTING CLEARANCE BURNISHED PORTION ON STOCK MATERIAL EDGE RADIUS UNDER COMPRESSION

DIE

IRREGULAR BURNISHED PORTION ON SLUG OR BLANK

UNDER TENSION

Hence, proper alignment should be made between punch and die for maximum tool life. There are 3 methods commonly used by the tool makers to achieve this. 1. BY USING PRUSSIAN BLUE When the cutting clearance punch and die is very less i.e., ranging from 0.01 to 0.03 mm per side this method is most appropriate. Prussian blue is available in paste form, which may be spread uniformly on the metal surface. It is very useful in the assembly work like matching the parts.

Procedure of using Prussian blue: A thin film is applied on the punch and inserted in the die profile in the assembled condition. The thickness of the blue should be uniform when punch is taken out from the die. If it is not so, then the punch or the die has to be slightly shifted till uniform thickness of blue remain on the punch.

P r u s s ia n B lu e

2. BY USING SHIM Shims are thin foils of soft metal like copper, brass etc, which are inserted in between punch and die to maintain the cutting clearance. Proper thickness of the shims must be selected equal to the cutting clearance per side. Procedure for aligning Punch and die with Shim: While aligning the punch and die with the die set assembly, these shims must be inserted before tightening all the screws of punch and die.

This method automatically maintains the cutting clearance. Once the screws are tightened both the units can be separated and shims can be taken out and transferring of the dowel holes may be done for both the units.

3. FEELER GAUGE These are checking gauges of thin foils made with good tool steel material, hardened and tempered. Different thickness and length of checking gauges are available depending on the application. These are used for checking the gap between Punch and Die, after setting them in the die set.
0.5

0. 4

0 .3
0. 2

3. BY USING SOURCE OF LIGHT This is one more method of aligning the punch and die, where cutting clearance is ranging from 0.03 to 0.08 mm per side. Procedure: The punch and die should be assembled in the die set and the punch is inserted in the die for about 0.5 mm and a source of light is provided between the punch and die. From the bottom surface of the base plate we can see clearly the cutting clearance around the punch and die by the light beam. If this beam is not uniform between punch and die slightly loosen either punch unit or die unit and adjust the uniformity. NOTE: Clearance is expressed in terms of PERCENTAGE (%) per side or Clearance is expressed in terms of MILLIMETER (mm) per side

0.1

DETERMINING CUTTING CLEARANCE There are 3 important methods in practice 1. By referring the standard Cutting clearance chart 2. By using the Formula 3. By using the Thumb rule 1. By referring the STANDARD CUTTING CLEARANCE CHART C/2 = Clearance per side in mm Sheet thickness Hard rolled Stainless Brass Soft steel Aluminum steel steel 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.80 3.00 3.30 3.50 3.80 4.00 4.30 4.50 4.80 5.00 0.010 0.025 0.040 0.050 0.060 0.075 0.090 0.100 0.110 0.130 0.140 0.150 0.170 0.180 0.190 0.200 0.220 0.230 0.240 0.250 0.015 0.030 0.045 0.060 0.075 0.090 0.100 0.120 0.140 0.150 0.170 0.180 0.200 0.210 0.230 0.240 0.260 0.270 0.290 0.300 0.020 0.035 0.050 0.070 0.090 0.100 0.120 0.140 0.160 0.180 0.200 0.210 0.230 0.250 0.270 0.280 0.300 0.320 0.340 0.360 0.010 0.020 0.040 0.050 0.060 0.070 0.090 0.100 0.110 0.120 0.140 0.150 0.160 0.170 0.180 0.190 0.210 0.220 0.230 0.240 0.020 0.050 0.070 0.100 0.120 0.150 0.170 0.200 0.220 0.250 0.280 0.300 0.330 0.350 0.380 0.400 0.430 0.450 0.480 0.500

2. By using the FORMULA ___ C/2 = 0.01 X t X fs Where, C/2 t fs = Cutting clearance per side = Sheet thickness in mm = Shear strength of the stock material in kg /mm2 SHEAR STRENGTH CHART Shear strength (fs) in kg/mm2 Soft 24 30 36 45 55 70 80 50 45 30-35 7-9 22 32-40 22-30 18-22 3 12 Hard 32 40 48 56 72 90 105 56 55 13-16 38 40-60 35-40 25-30 4 20

Material Steel with 0.1 % C 0.2 % C 0.3 % C 0.4 % C 0.6 % C 0.8 % C 1.0 % C

Stainless steel Silicon steel Steel deep drawing quality Aluminum A 1 99 & 99.5 Aluminum alloy A1 Cu Mg Bronze rolled Brass 63 & 72 Copper Tin Zinc

3. By using the THUMB RULE Clearance can also be calculated in Percentage [%] of Sheet thickness: C/2 (CLEARANCE PER SIDE) Percentage of Clearance 5% 6% 7% 5% 8 10%

Sl. No. 1 2 3 4 5

Material Brass Soft steel Hard steel Stainless steel Aluminum

NOTE: 1. Pierced hole is getting the dimension of the PIERCING PUNCH. Hence the clearance should be added to the die opening. 2. Blanked component is getting the dimension of the BLANKING OPENING or DIE. Hence the clearance should be subtracted on the Blanking punch. Example: Material: Steel with 0.3% Carbon Shear strength (fs) = 45 kg/mm2 Sheet thickness (t) = 1.75 mm

Component:

Dimension of the Piercing punch = 15.00 mm

Dimension of the Die opening =15+ (2 X C/2) (From the table C/2 = 0.10 mm) = 15 + (2 X 0.1) = 15 + 0.2 = 15.20 mm Dimension of the Die opening = 15.20 mm Dimension of the Blanking punch = 35 (C/2 X 2) (From the table C/2 = 0.10 mm) = 35 (0.1 X 2) = 35 0.2 = 34.80 mm Dimension of the Blanking punch = 34.80 mm x 34.80 mm Dimension of the Blanking die = 35.00 mm x 35.00 mm

The following chart shows the EFFECTS AND RESULTS of different types of cutting clearances provided between punch and die. Name Effects (During the operation) Results (After the operation)

Permissible burr appears Requires normal shearing Flow radius is minimum Sufficient force Cut band is 1/3 rd of sheet cutting thickness Breaking lines meet each clearance other exactly at the Tool life is more fracture point Component quality is assured Maximum component production Roll over radius is less Requires more shear Cut band or Burnished land will be force more than 1/3rd of the thickness of Breaking lines does not sheet Insufficient meet each other Tensional burr appears cutting Cutting edges will wear clearance Fracture is less very soon because of Less tool life friction caused during Frequent maintenance of punch the operation and die results in poor production Shearing force will be Roll over radius is more more rd Breaking lines does not Cut band will be less than 1/3 of sheet thickness meet each other Excessive Cutting action will not Fracture will be more cutting perform properly Compressive burr will be appeared clearance because the stock Tool life will be less material will rush into Tool may get damaged the die causing damages Production will be less to the cutting edges of both punch & die

DAY ONE: 3RD HOUR CUTTING OPERATIONS

IDENTIFICATION OF OPERATIONS BLANKING: Cutting the outer contour of a piece part. After completing all the remaining operation, it is called as COMPONENT.

PIERCING: Hole originated within the piece part. Any geometrical profile of hole can be pierced.

NOTCHING: Partial cutting is done at the side of the stock strip. Usually, notching operations are done to simplify the blanking profiles.

SIDE NOTCHING

CUT-OFF: Single line cutting without Scrap Bridge. Produced components are of secondary importance. Usually, used to produce commercial components with maximum economy on tool cost

PART-OFF: Double line cutting producing scrap normally equal to the value of one scrap bridge.

TRIMMING: Secondary operation carried to redefine the contour of the component. Usually Drawn cups and Die cast components are trimmed to remove the excess material appeared during the production.

SHAVING:

Secondary operation performed on pre blanked components to resize the dimensions and achieve higher accuracy. This operation produces smooth surface on the periphery of the component through its thickness

SIDE PIERCING:

Usually, this is a secondary operation performed on drawn cups. Cups of required shape and size are drawn followed by cam piercing.

DINKING:

Components from fiber material like Nylon, Plastics, Rubber, Fiber glass, Printed circuit boards (PCB) etc, are produced with this operation. Blanking punch is the only member which is employed for cutting the contour. Piercing is done as usual with punch and dies. The cutting face of the piercing punch is made as concave profile.

LOVRING:

It is a partial tearing and bending operation usually made on engine covers, cabinets, etc for the entry of air.

LANCING:

This is also a partial tearing and bending operation. Usually two or three sides are teared with one side left with the parent material. Used for spring locking in the assembly or riveting.

DAY ONE: 3RD HOUR NON - CUTTING OPERATIONS

IDENTIFICATION OF OPERATIONS BENDING: Bending is performed on pre-cut sheets or blanks to the required angle. It is done in straight axis. General bending profiles are L Bending, U Bending and V Bending. Usually, Bending has to overcome both Tensile stresses as well as Compressive stresses. When Bending is done, the residual stresses make it rebend or spring back towards its original position, so we have to over bend the sheet metal keeping in mind the residual stresses.

FORMING: Any profile with curves can be formed with proper study of material behavior. Materials must posses good ductility and deep draw quality. Forming takes place in a curved axis.

CURLING:

More than 3/4th forming in a continuous curvature is referred as Curling. This operation is divided into a) Pre curling. b) Final curling Material must be soft enough to accept the severity of the forming. Hence, deep draw and extra deep draw quality materials are preferred. Usually, employed for the production of hinges for links, to the components which need fulcrum points etc.

FLANGING:

Sometimes it is also referred to as Extruding. Many methods are used in this operation. 1. Flanging without pre pierced hole 2. Flanging with pre pierced hole 3. Flanging with pre pierced hole located by the punch pilot The height of the flange depends on the diameter of the pre pierced hole.

DRAWING: Cylindrical or Rectangular or Square cups are produced with this operation. Material undergoes severe strain and flow into the die from all the directions. Hence, it must have maximum tensile strength and yielding capability. Materials with extra deep draw quality are best suited for this operation. In draw operation the draw tool must be proved first, well before the blanking tool is manufactured.

COINING:

The material will experience maximum strain, because of squeezing. The die halves are pressed against the material, which is sandwiched and forced to accept the inner profile of the die. Coining requires higher tonnage than any other press operation.

STAMPING: Punch profiles are directly transferred on to the work piece. Depressed profiles to a certain depth are possible with this operation.

EMBOSSING: Sheet metal surfaces can be depressed to a depth till it tears. Hence, before the material selection CUPPING TEST has to be conducted. In this operation thinning does not take place.

DAY ONE: 4TH HOUR MATERIALS AND THEIR PROCESS

Different materials are very essential to construct the tool and production of components. Materials are divided into two main groups. 1) Steel material for the construction of the tool 2) Sheet material for the production of component 1) STEEL MATERIAL FOR THE CONSTRUCTION OF THE TOOL The construction of tool involves various types of steel material. It depends on the function of the part in the tool. Usually, HCHCr, OHNS, St-42, Mild steel (MS) and 17Mn1Cr95 materials are used. a) HCHCr: High Carbon High Chromium steel IS Codification: T215 Cr12 W90 Oil Hardened Non Shrinkable steel IS Codification: T110 Cr1 W2 Steel with 0.42% Carbon Mild steel Case hardening steel

b) OHNS:

c) St42: d) MS: e) 17Mn1Cr95:

The below chart may be referred for appropriate temperature required to heat treat different materials commonly used in tool making.

Sl. No.

Type of steel

Annealing temp o C Hardening temp o C

Tempering temp o C

HRc

Quench Media

High Carbon Steel (2.15%)

750 - 780

750 - 780

120 - 350

62 40

Water

HCHCr (2.15%) T215Cr12W90

820 - 850

920 - 970

200 - 350

62 - 56

Oil or Air

HSS(W) (0.6%)

820

1250 -1300

550

62 - 60

Oil

HSS (Mo)

820

1100 - 1175

550

62 - 60

Air

HDS (0.4%)

850 - 875

950 1000

550 - 590

52 42

Air

OHNS (1.1%) T110 Cr1 W2

750

820 840

150 - 300

62 - 56

Oil

A brief description is given below about the material and the tool element. 1. Die and Punch for cutting operation -------------- HCHCr (T215 Cr12 W90) 2. Die and Punch for Non-Cutting operation -------- OHNS (T110 W2 Cr1) 3. Punch Back plate ------------------OHNS or 17MN1CR95 4. Die Back plate ---------------------- OHNS or 17MN1CR95 5. Punch plate ------------------------- Mild steel (MS) 6. Stripper plate ---------------------- Mild steel (MS) 7. Stripper insert --------------------- OHNS 8. Guide plate ------------------------ Mild steel (MS) 9. Strip support plate---------------- Mild steel (MS) 10. Top plate --------------------------- Mild steel (MS) or Cast iron 11. Bottom plate ---------------------- Mild steel (MS) or Cast iron 12. Shank ------------------------------- Mild steel (MS) 13. Guide Bush and Pillar ------------ OHNS 14. Tie bar ----------------------------- Mild steel (MS) 1. HIGH CARBON HIGH CHROMIUM STEEL (HCHCr) These are specifically used for cold working press tools and oil hardened up to 60-62 HRc. The chemical composition is 2.15% carbon, 0.9% tungsten, 12% chromium and small percentage of silicon and manganese. These materials are best suited for cutting dies and punches, as they retain the cutting edges for a longer period. Frequency of resharpenning the cutting edges is less compared to other steels. Note: After completing all the machining operations these tool elements must be stress relieved for better tool life.

2. OIL HARDENED NON-SHRINKING STEEL (OHNS) These steels consists carbon 1%-2% and chromium 4%-12% may distort slightly during heat treatment. These are useful when it is not possible to do finishing operation on a component. Oil hardened upto 60-62 HRc. But for non-cutting operations 56-58 HRc is quite sufficient. These steels are used for forming intricate profiles in Non cutting press tools. 3. MILD STEEL (MS) and St-42 These are used for most of the parts in press tool, mould box, jigs and fixtures. Mild steel contains less than 0.3% carbon and 0.1%-0.8% manganese. Example: Steel En2. This steel can also be case carburized and hardened upto 54-56 HRc. Free cutting Steel like En contains less than 0.15% carbon and cannot be hardened. Generally all parts which are supposed to be kept in soft condition made of mild steel because it is the cheapest material available compared to other steels. 4. CAST IRON (C.I) These materials are easy to cast to any shapes. Hence used for casting different shapes to save unnecessary machining but require a pattern for casting. Pattern making cost has to be compared with cost of machining. Cast iron contains 2.25 - 2.75% carbon and can absorb vibrations well and suitable for bases, machine beds and bodies of fixtures. These have self lubricating properties, hence also suitable for machine slides and guide ways.

5. 17Mn1Cr95 These are case hardening steels have good toughness and cost saving. Used where there is no movement of parts and needs good support for the other tool elements. As the percentage of carbon in the material is not sufficient for hardening process the case must be enriched with carbon by carburizing process. A case depth of 0.5 to 0.7mm is achieved by a prolonged period of 4 to 5 hours. After carburizing, the material is hardened and tempered similar to other tool steels. 2) SHEET MATERIAL FOR THE PRODUCTION OF COMPONENT Many types of sheet materials are used for the production of components. Namely, Non Conventional materials 1. Plastic coated paper 2. Thin plastics 3. Polyfibres 4. Corrugated sheets 5. Printed circuit boards (PCB) 6. Tablet strips Conventional materials 1. Steel CRCA (Cold Rolled Close annealed) D Quality (Draw quality) DD Quality (Deep Draw Quality) EDD Quality (Extra Deep Draw Quality) 2. Brass 1/4th hard, Half hard, 3/4th hard and Full hard 3. Copper 1/4th hard, Half hard, 3/4th hard and Full hard 4. Phosphor bronze -1/4th hard, Half hard, 3/4th hard and Full hard 5. Aluminum 1/4th hard, Half hard, 3/4th hard and Full hard

2A) FINISHING OPERATION OF COMPONENTS

a) VIBRATORY FINISHING GUIDE In vibratory finishing, energy in the form of vibratory forces is transformed by the machine's drive system into a mass of loose media and then into the parts. The entire load is in motion at same time so that the media act against the parts throughout the complete mass. Producing good surface finishes using barrel finishing depends on the right selection and use of tumblers, abrasives, lubricating agents, carrying agents and polishing agents. Barrel finishing, also known as Barrel tumbling, is a surface improving operation in which a mixture of parts, media and compounds are placed in a sixor eight-sided barrel and rotated at a predetermined speed for the purpose of rounding corners, deburring, grinding, descaling, deflashing, improving surface finish, burnishing, polishing and radiusing parts in bulk. It works by tumbling parts in a rotating barrel, thus creating friction by tumbling parts against each other and against other materials, such as media and compounds.

Tumbling Highlights Parts can be finished less expensively than by hand. Many parts can be processed at one time. Requires very little handling. Parts are tougher and stronger after tumbling Tumbling provides a certain amount of stress relief Forgings and castings can be blended Machine parts and stampings can be deburred and burnished to a high finish On long runs, the systems can run overnight Careful and proper machining of your parts will save tumbling time

DAY ONE: 5TH HOUR BASIC CONSTRUCTION OF THE TOOL

1. Die and Punch for cutting operation -------------- HCHCr

2. Die and Punch for Non-Cutting operation -------- OHNS

3. Punch Back plate -------------------

OHNS or 17Mn1Cr95

PUNCH BACK PLATE Material = OHNS

4. Die Back plate ----------------------

OHNS or 17Mn1Cr95

DIE BACK PLATE Material = OHNS

5. Punch plate -------------------------

Mild steel (MS)

6. Stripper plate ----------------------

Mild steel (MS)

SECTION-AA

7. Stripper insert ---------------------

OHNS
SECTION-AA

A A

8. Guide plate ------------------------

Mild steel (MS)

9. Strip support plate----------------

Mild steel (MS)

SECTION-AA

10. Top plate ---------------------------

Mild steel (MS) or Cast iron

SECTION-AA

TOP PLATE Material = St-42

11. Bottom plate ----------------------

Mild steel (MS) or Cast iron

SECTION-AA

A A
BOTTOM PLATE Material = St-42

12. Shank -------------------------------

Mild steel (MS)

13. Guide Bush and Pillar ------------

OHNS

14. Tie bar -----------------------------

Mild steel (MS)

SECTION-AA

15. Die set and its types

1. 2. 3. 4.

Diagonal pillar dies set Rear pillar or Back pillar die set Center pillar die set Four pillar die set

H7/j5 H7/h6 Top plate

Thread for fixing the Shank

Guide bush

Guide pillar

H7/p6 Bottom plate

PROGRESSIVE STAMPING DIE

Progressive die with strip and punchings A progressive stamping die is one of the types of press tools, designed and built to convert a flat strip of metal into parts that conform to component specifications.

SHUT HEIGHT OF THE TOOL

FUNCTION OF PROGESSIVE TOOL The die is mounted on a suitable press. As the ram moves up, the punch unit opens and closes when the press moves down. The stock material is fed through the die while the die is open to a precise amount with each stroke of the press. When the punch unit is brought down, the tool performs its work on the sheet metal. Due to this action one or more completed piece parts will fall down through the opening in the bottom plate. These dies can modify the stock metal into different shapes like Bending, Embossing, Drawing, Forming, Horning, Extruding, Coining, and Punching. Different hole profiles is possible to cut in the stock metal. Since additional work is done in each stage of the die, it is important that the strip be advanced very precisely, so that it aligns within accurately as it moves from station to station. ROLE OF PILOTS DEFINITION Pilots are non-cutting male members, mounted usually in the punch holder for re-registering the pre-pierced hole for consecutive stations especially in progressive tools. These are made with good tool steel material that is OHNS (T110 W2 Cr1) and hardened up to 56-58 HRc. These pilots are also available readily (material used is HSS) in the market with standard diameter and length. Function of a Pilot: The function of a pilot is to position the stock strip accurately and bring it into proper register for successive stations.

Bullet shaped or conical "pilots" enter previously pierced round holes in the strip to assure this alignment, since the feeding mechanism usually cannot provide the necessary precision in feeding. The key components of dies are made of tool steel to withstand the high shock loading involved, retain the necessary sharp cutting edge, and resist the abrasive forces involved.

VARIOUS OTHER TYPES OF PILOT NOSE PROFILES

ROLE OF STOPPERS DEFINITION Stoppers are stopping agents, fixed or engaged on the die to arrest the feeding movement of the stock strip. This is the location of the actual stopping point or stage against which the stock is halted. TYPES OF STOPPER Name of the stopper

Sl. No.

Sketch
Butting surface

Solid stopper or Solid stop block

Solid Stop block

Pin stopper a) Plain pin b) Headed pin

Side or stage stopper

Trigger stopper

Heeled punches A typical heeled punch condition is illustrated in the figure. Specially, the illustrated punch is a notching punch. However, principles relating to the heel function will be much the same for other punches as well. Here, the heel is made in a manner commonly used in progressive dies. The nature of the notching operation is such that, cutting force at the front of the punch is unopposed and thus tends to displace the punch away from the front cutting edge. Also the stock material is fed through the die, either the punch may be required to cut partial notches at the side portion of the strip or partial notches may occur un-intentionally as a result of miss-feeding.
HEEL

Partial cutting punch with Heel Secondary strip width SCRAP Primary strip width

Partial notching will tend to displace the punch in a direction parallel to the feeding. The purpose of a heel is to support the punch by resisting displacement. This type of heel is an integral boss extending beyond the working face of the punch. The heeled portion is made a sliding fit in the die opening on three sides. Therefore, the heel affords lateral thrust resistance along any displacement included within the three directions. Pitch punch Pitch punches are cutting punches used in the progressive tools for accurate feeding of the strip. These are made of good Tool steel material i.e. (T215W90Cr12) HCHCr and hardened up to 60-62 HRc and ground to the exact size equal to the pitch. These pitch punches are suitable for sheet thickness less than 2 mm and are placed in the very first stage of the operation. These are also called as Partial cutting punches for the reason that they cut only a portion of the side of the stock strip which is exactly equal to ONE PITCH. In case pilots are provided then the pitch punch width will be slightly more than the required dimension i.e. 0.1 mm to 0.2 mm, which is called as O F A (Over feed allowance). This is provided because when the strip is fed, it has to be re-registered by the pilots either moving the strip forward or backward before the operation is performed.

. 0

45

0.5xSheet thickness

M5 0r M6 x 20mm deep

a 2xscrap+2mm 5to6mm R2(TYP)

HEEL

Pitch punch with HEEL

Secondary strip width SCRAP Primary strip width

Since pitch punches cut only a portion of the side of the stock material. Due to this cutting action is imbalanced which deflects the punch resulting in punch breakage. Hence, heels are provided behind the cutting edge to support the pitch punch.

Heel enters into the die opening and gives full support to the cutting edge and the cut edge will also be perfectly straight. Heel is provided for all partial cutting punches irrespective of the size and profile. VALUES FOR SIDE SCRAP AND SCRAP BRIDGE Sheet thickness in mm 0.5 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 Component horizontal width in Millimeters Upto 10 1.5 1.0 1.5 2.0 2.0 2.0 2.5 3.0 3.5 4.0 5.0 6.0 7.0 10 50 2.0 1.75 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 8.0 50 -100 3.0 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.5 8.5 100 -150 3.5 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 8.0 9.0 150 - 250 4.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 8.0 9.0 10.0

Stripper

Inside step headed stop pin

Out side

step headed stop pin

Die plate

Outside step headed stop pin

DAY ONE: 6TH HOUR NON CUTTING OPERATION

INTRODUCTION Present day calls for lots of innovative products which essentially require good knowledge of tooling. Mechanical, Electrical, Electronic and Automobile industries need products having verities of profiles for different applications.

Examples of products for Non Cutting operations 1. Pressure cooker 2. Pressure pan 3. Utensils 4. Contacts and Relays 5. Heating elements 6. Computer hardware 7. Electrical appliances 8. Gear box cover 9. Automobile parts Doors, Bonnet, Wheel drums Clutch plates etc., 10. Aviation and Space components

DEFINITIONS Non - cutting operations are those which shape the flat blank to the required profile. In these operations material undergoes severe strain and needs very good knowledge about the material property, behavior, strength and its limitations. In many tools these operations are integrated depending on the size of the component.

THEORY OF ELASTICITY
DEFINITION It is the basic behavior of material. Whenever a sheet metal deformed and an external loading is unloaded, it will be restored to its initial state i.e., after unloading nothing in the state of structure remains of the previous condition. CHARACTERISTICS OF MATERIAL This unique character of the material is most useful in sheet metal fabrication because most products of sheet metal press work are not flat components that can be produced by die cutting operations alone. They generally have a third dimension obtained by a shaping operation, which can be performed in the same die as of the cutting operation or in a separate die. Shaping operations are generally divided into three groups.

1. BENDING Bending is shaping the material around a STRAIGHT AXIS, which extends completely across the material. One or more bends may be involved in the bending dies. These dies are important class of press tools. The sheet material flow in these tools is always uniform and its thickness remains unchanged. TYPES OF BENDING a) L Bending b) U - Bending c) V - Bending

NEUTRAL PLANE AND ITS IMPORTANCE

Inside of bend (SQUEEZED) FORCE
e lan p l tra u Ne

DIE

Outside of bend (STRETCHED)

Neutral plane is an imaginary plane exists between the area under tension and the area under compression. The neutral plane always moves towards the inner surface at a distance of one-third (1/3) to one-half (1/2) the thickness of the material. The length of the Neutral Plane does not change as a result of bending.

EFFECT OF GRAIN DIRECTION DURING BENDING DEFINITION As the sheet material is rolled, the particles are stretched in the rolling direction and a chain link is developed between them. This particle chain is called Fiber and these fibers are arranged parallel to each other and called as Grain direction. In bending operation the grain direction should be considered for effective bending of the component. CONDITION OF GRAIN DIRECTION IN BENDING

STOCK MATERIAL

GRAIN DIRECTION

The Grain direction should always be perpendicular to the bend axis. Bending will not be effective and bent portion will not be strong, when the axis of bend is parallel to the grain direction. The bend component will be weak and loses its strength after some use.

DETERMINING THE FLAT LENGTH BY BEND ALLOWANCE METHOD

Where, B. A A or IR t K K K

= Bend allowance [Arc length of neutral axis] in mm = Bend angle in degrees = Inside radius of bend in mm = Sheet metal thickness in mm = Constant for neutral axis location = 0.33 when IR is less than 2t = 0.50 when IR is more than 2t

DEFECTS IN BENDING 1. SPRING BACK After bending operation if the pressure is released, elastic stresses remaining in the bend area will cause a slight increase in the bend angle. Material movement of this type is known as SPRING BACK.
BENDING RETAINED UNDER LOAD SPRING BACK SPRING BACK

2. THINNING This defect occurs when there is misalignment and axial deflection between the punch and die. If clearance between punch and die is less the sheet thickness, results in the elongation of side wall of the component.

THINNED AREA

METHODS OF PREVENTING SPRING BACK A) B) Over Bending in V-bending and Air-bending dies Corner setting or Coining or Squeezing in Vbending and U - Bending

A) OVER BENDING It is the simplest way of overcoming spring back problems. In this method the blank is bent to a lesser angle than required and the blank is spring back to the required angle. DIFFERENT METHODS OF OVER-BENDING CASES

SKETCH
Punch 88 Component 90.0 Die 90.0

1. Over bending in a V-bending die is accomplished by under sizing the punch to 880.

Component

2. In a single L or U-bending die clearance between punch and die must be slightly less than the sheet metal thickness and punch must be under sized to 880.

Punch 88.0 Die Pressure pad

90.0

3. In this case the punch is made to 900 but the bending die is under sized to 880 and clearance provided between punch and die is less than the sheet thickness. 4. In this case both punches are under sized to 880 to allow the component to achieve 900

Pressure pad Punch Die

Movable side punch

.0 88
Punch

. 88 0
Pressure pad

88 .0

B) CORNER SETTING In this method the metal is squeezed slightly in the corner in order to relieve elastic stresses. This method is also known as Coining or Squeezing. The punch nose is modified for corner setting operation. When the punch is bottomed pressure builds up rapidly. REMEDIES 1. Squeeze the intersection points to retain the bent angle permanently. 2. Bottoming is done by squeezing the bent area to retain the bend after releasing the load.
Die

SKETCH
Punch
88
A Detail-A Punch

90.0

BENDING FORCE DEFINITION It is the amount of force required to bend and give a desired shape to the piece part. It depends on the sheet thickness, die opening factor, length of bend and the amount of bottoming or ironing used. FORMULA TO DETERMINE BENDING FORCE K X SU X W X t2 FB = ------------------------ =------- Tons L Where, K = Die opening factor (0.33) L = Length of bend (rd + rp + C) Su= Ultimate tensile strength in kgs/mm2 t = Sheet thickness W = Width of the component or stock material Where, K is 0.33, when the die opening is less than [<] 5 times the thickness, 0.667 when the die opening is 5-10 times the thickness and 1.20 when the die opening is 10-16 times the thickness.

DAY TWO: 1ST HOUR

REVIEW OF THE PREVIOUS DAY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Learnt about the present situation of the industry Understood the general activities of an industry Understood the role of a Tool and Die maker Leant the definition of Press tool and its necessity Understood the categories of press tools Understood the types of press tool operations Understood the definition of each cutting operation Understood the theory of Shearing Practiced to find the amount of cutting clearance Learnt the basic elements of a press tool and their role in the tool construction Learnt about types of die sets Learnt types of Non Cutting operations and definition of Bending

NON CUTTING OPERATION

DEFINITIONS 2. FORMING The operation of forming is similar to bending except that the line of bend is along CURVED AXIS instead of a straight one. The metal flow is not uniform. Forming dies transfers more complex forms to sheet metal components.

3. DRAWING In draw tools, flat blank is transformed into a cup or shell. The parent material is subject to severe plastic deformation. Shell formed may be cylindrical or rectangular with straight or tapered sides.

4. HORNING Horn dies are provided with an arbor or extended horn over which the parts are placed for secondary operations such as Seaming. Horn dies may also be used for piercing holes in the sides of shell.

5. CURLING It is an operation of rolling the edges of the sheet metal into a curl or roll. The purpose is to strengthen and provide a protective edge. Example: A hinge in which both members are curled to provide a hole for inserting the hinge pin.

Component with Pre-curling

Uniform curve Good quality component

Component without

Pre-curling

Deformed component

Inferior quality component

Final radius 6

1 2

5 2 3 4

1 6 4

5 3

6. BULGING Bulging is an internal forming operation used to expand portions of a drawn shell or tube. The bulging force is applied from inside the blank piece and is transmitted through a medium that will flow but not compress. This is just similar to blowing high pressured air into a balloon to bulge.

Most common medias are rubber, urethane, bulging oil or water. This presses and expands the walls of a cup, shell or tube with an internal expanding segmental punch or compressed air or liquids or semi liquids, such as waxes or tallow of rubber and other elastic materials.

After After Before Before

BULGING DIE USING LIQUID MEDIUM
Cross section of the component RUBBER SEAL PLUNGER O-ring GASCKET Before bulging SPLIT DIE PARTING SURFACE CYLINDRICAL TUBE LIQUID BULGING MEDIA SPLIT DIE After bulging

In the case of using bulging oil as bulging media gaskets must be fixed in between the two halves of the die to prevent leakage of oil. Otherwise the pressure of the oil cannot be controlled and which may result in the variation of the shape and size of the component.

BULGING MEDIUMS Urethane is commonly used because it is more resistant to abrasion, tears and cuts and is superior to oil and grease. This is clean, easy to use and either made to order or readily available. Grease, oil, water are used only when shape of work piece prevents the use of urethane. The piece part is filled with liquid medium in the die cavity. Since time consuming is more, this is used for limited production. 7. SWAGING The operation of swaging sometimes is called NECKING, and exactly opposite to bulging. When a work piece is swaged, a portion is reduced in size and this causes the work piece to become longer than it was before swaging.

Before

After

8. EXTRUDING This is a special process to manufacture collapsible tubes, shells etc. The blank is also called as Billet which is loaded in the die is forged upwards or downwards under a high pressure between punch and die. The amount of clearance between punch and die determines the wall thickness of the extruded shell.

After

Before

9. FLANGING (Flaring) The process of forming an outward protrusion (flange) in a piece part is called Flanging. It is performed particularly for creating threads, inserting guide pins for further assembly. Flanging is done in stage tool as well as progressive tools with pre piercing or direct flanging with hybrid punches.

FLANGING WITHOUT PILOT

DIRECT FLANGING PUNCH WITH PILOT

DIE RADIUS

DIE RADIUS

PRE PIERCING

FLANGING WITHOUT PRE PIERCING (WITH HYBRID PUNCH)

FLANGING PUNCH DIE RADIUS

PRE PIERCING PUNCH

10. DIMPLING A forming die which produces a conical flange (stretch flange) encircling a hole in one or more sheets of material.

Dimpled projection

11. COINING

In coining metal flows and occupies the space between two halves of the die suffering too much of strain in cold state. Hence it is also called as Cold forming.

12. IRONING An operation in which the wall thickness of the drawn shell or bent component reduced intentionally and then its surface is smoothened.

t T

Ironed surface

13. EMBOSSING It is a process which produces relatively shallow indentation or raised deformation with theoretically no change in the material thickness. Embossing is also used as locater for springs in certain electrical assembly so that the spring is not displaced during working. It also serves as a locking arrangement for locking contact carrying in the contact house.

PUNCH

PUNCH

DIE
Depression

DIE

Projection
14. PLANISHING OR PLANNING It is an operation done to flatten dished components produced by conventional press tools. There are two types of planning in practice. 1) First method: Between two hardened plain blocks dished components are placed and pressed with sufficient pressure. 2) Second method: Components are placed in between two hardened blocks having diamond projected points as shown in figure and pressed. In this operation the drawback is indentation marks which appear on the components. But this method is most effective in relieving the internal stresses that may induced due to many reasons.

PLANNING DIE

PLANNING DIE PLANNING DIE PLANNING DIE Cross section of a planished component

PLANNING DIE

15. ASSEMBLY PRESS OPERATION These press operations are done for assembling the sheet metal components together with rivets. Two or more number of components placed in position as per the requirement and rivets are inserted in the pierced holes. Then all these are placed in the tool between punch and die and pressed till rivets gets bulged and perfectly holds the parts. This unit is called as Sub-assembly. The pressure on the rivets can be easily controlled by placing setting blocks in the tool.

Rivets

Assembly press operation

HYBRID PRESS TOOLS 1. LANCING This is a combined bending and cutting operation along a line in the work material. The punch is designed to cut on two or three sides and bend along the fourth side. Lancing is a very important press operation involving 3 or 2 side shearing and one side bending or forming. Lancing is widely used when a relief is to be provided for a matching part. It is also used to locate one part into the other. In many of the sheet metal application lancing is used to lock the part to the other for proper assembly. Ex: Mosquito coil stand.

LANCING

2. LOUVRING Louver is a passage with flat sloping profiles with one side opening to allow light and air to enter in while keeping rain water out. This is a typical operation commonly done for air vents for stabilizer cases, regulator cases, electrical panels etc., where air has to circulate and keeping the equipment cool. In this operation only one side is cut and the other three sides are bent, such that, the air can enter into the equipment through the opening.

Entry for air

MATERIAL WEIGHT CALCULATION

DEFINITION 1. WEIGHT It is the sum of the volume and the specific gravity of the material. Weight is expressed in Kgs. Value of Specific gravity for each material varies depending on the density of molecules in it. CALCULATION: Weight W = Volume X Specific Gravity = V X Sp. Gr.

Where,

W V Sp. Gr.

= Weight of the material in Kg = Total volume of the material in mm3 = Specific gravity in Kg/mm2

Volume of the Flat material =L X B X t Where, L B T = Length of the material = Width of the material = Thickness of the material

X d2 Volume of the Round material = ------------- X t 4 Where, = 3.1416 D = Outer diameter of the material t = Thickness of the material

SPECIFIC GRAVITY CHART Material Steel Cast steel Grey cast iron High speed Steel Hard metal H1 Invar (36% Ni) Brass (Ms 60) Al bronze Al cast bronze Tin bronze Lead bronze (Pb Bz 25) Al cast bronze Specific gravity gm/Cm3 7.85 7.85 7.2 9.0 14.75 8.7 8.5 8.4 7.6 8.6 9.5 2.8

DAY TWO: 2ND HOUR DRAW OPERATION

BASIC FUNCTION OF A DRAW TOOL To produce a cylindrical cup a round flat blank (cut from flat strips) is placed on the draw die, the punch pushes the blank in to the die by the application of an external force. During the return stroke, cup is removed by the counter bore made in the bottom of the die. DRAW OPERATION WITHOUT BLANK HOLDER
Air vent Punch

Flat blank

Blank locator

Die

Drawn cup

DRAW OPERATION WITH BLANK HOLDER

Air vent Flat component Punch Blank holder

Die

Drawn cup

AIR VENTS During the operation the punch tries to push the blank material into the die. At this time, the air in the draw die has no way to escape. This leads to rupture of the component. Hence, a small diameter through hole is drilled in the punch & die, to allow the entrapped air to escape. CLEANING OF AIR VENT HOLE During continuous production of components, the air vent often gets blocked. This is because of continuous use of lubricants. Hence, it is advised to clean the air vent hole frequently by blowing out the foreign substances with compressed air. PUSH THROUGH DRAW DIE A simple draw operation is shown in the following illustrations. A round flat blank cut from flat strip is placed on the die face and punch pushes the blank in to the die. On the return stroke the cup is stripped by the counter bore in the die. This operation is known as Shallow drawing and die is called as Push through die. DRAW OPERATION WITHOUT BLANK HOLDER
Air vent Punch Blank locator

Flat blank

Die

Drawn cup

DRAW OPERATION WITH BLANK HOLDER

Air vent Flat component Punch Blank holder

Die

Drawn cup
DRAW OPERATION WITH RIGID BLANK HOLDER

Air vent Flat component Punch Blank holder

Die

Drawn cup Drawn cup

1. SHALLOW DRAWING The drawing of deeply recessed parts from sheet material, through plastic flow of the material when the depth of the recess is less than the minimum part width is known as Shallow drawing. Operations where the depth is less than half the cup diameter the operation is also called as Shallow drawing. Note: Shallow drawing: Where, depth of cup is less than half the cup diameter. Example: Plates, Shallow pans etc., 2. DEEP DRAWING The drawing of deeply recessed parts from sheet material through plastic flow of the material when the depth of the recessed equals or exceeds the minimum part width is known as Deep drawing. Deep drawing is drawing a cup whose depth is more than half the diameter of the cup. A rigid blank holder is usually used on heavier thickness material that has fewer tendencies to wrinkle. Spring loaded pressure pad is more common than the rigid blank holder. Note: Deep drawing: Where, depth of cup is more than half the cup diameter. Example: Cups, Washing machine tubs etc., DETERMINING THE FLAT BLANK DIAMETER Flat blanks are the previous shape of the material in any draw operation. These are produced from cutting press tools, usually blanking tools and used for the production of drawn components.

Drawn cup A h1 Flat blank

PROCEDURE: 1. Draw an arc C-D with B as centre and BC as radius 2. Draw an arc D-E with A as centre and AD as radius, which bisects the line BC produced at E 3. The length B-E gives the radius of the blank DETERMINING THE FLAT BLANK DIAMETER OF A DRAWN CUP BY ALGEBRAIC METHOD

The Drawn cup consists: d2 d

h1

d1

Drawn cup

Cylinder

Flat bottom
Where, d1 d2 d h h1 = = = = = Inside diameter Outside diameter Mean diameter Mean height Total height X d2 Formula for calculating the Area of the Bottom = ---------4 Formula for calculating the Area of the Cylinder = X d X h X D2 Formula for calculating the Area of the Bottom = ----------4 Area of Flat blank = Area of the Bottom + Area of Cylinder X D2 ----------= 4 D2 = X d2 --------------4 d2

+ X dX h

4dh

________ D = d2 + 4dh Flat blank diameter: _________ D = d2 + 4dh

Formula for calculating the cup height: h = [D2 d2] / 4d Some of the factors are listed below. 1. 2. 3. 4. 5. 6. 7. Blank diameter Percent reduction in drawing and re-drawing Draw force Blank holding force Ironing force Hydraulic press of proper capacity Whether Draw beads are required or not

1. BLANK DIAMETER It is the diameter of the flat blank produced from blanking tools. This must be determined theoretical calculations. 2. PERCENT REDUCTION IN DRAWING AND RE-DRAWING It is also known as reduction ratio. This should also be determined for successive reduction to produce a final component. i) Percentage Reduction (P) = 100 (1 d/D) Where, d = Internal diameter of the cup D = Outer Diameter of the Cup

t0 X t ii) Reduction ratio (%): Ri = --------------- X 100 t0 Where, t0 = Thickness of cup wall before Ironing

t = Thickness of cup wall after Ironing iii) Possible number of reductions for a given ratio of shell height with respect to the diameter Ratio H/d Upto 0.8 0.8 - 1.5 1.5 - 3.0 3.0 - 4.5 No. of draws 1 2 3 4 I draw % 40 40 40 40 II draw % 25 25 25 III draw % 15 15 IV draw % 10 10

3. DRAW CLEARANCE It is the intentional gap provided between draw punch and die for successful draw operation. Depending upon the type of metal and operation generally this allowance range from 7% - 20% of material thickness.

4. DRAW FORCE or CUPPING FORCE This force is a function of the strain factor and other variables required to select appropriate capacity press. Usually, Hydraulic presses are proffered for draw operations. Cupping force (Fc) = Aw x Sy x nc x In Ec Where, Fc = Cupping force Aw = Cross sectional area of the cup (Aw = phi X dt) Sy = Yield strength of material nc = Deformation efficiency of cupping In Ec = Natural logarithm of strain factor Ec Deformation efficiency (nc) is a factor varies from 0.6 0.7

DRAW FORCE or CUPPING FORCE (FD): [SU + SY] FD = X d X t X ------------ X h = ----- Kg

Where,

2 d = Punch diameter h = Height of the cup t = Stock thickness

Blank holding pressure (Fb): Fb = 0.2 to 0.4 X Fb Total Draw force: FN = 1.3 FD Draw force for Cylindrical cup (FCD): FCD = 0.9 X FD X h LUBRICATION Lubricant is a substance, when applied between two surfaces provides friction free movement with lubrication effect. A lubricant for draw operation plays a very important role. Lubricants are used to reduce friction between surfaces and assist material flow during the draw operation. While selecting the lubricant for a particular type of draw, consider the following points carefully.

POINTS TO BE CONSIDERED WHILE SELECTING AN APPROPRIATE LUBRICANT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Depth of draw Contour or profile of the component Mode of transport used Material flow Material specification (thickness, ductility, cupping property, treatments required before and after the draw operation Type of material: ferrous or non-ferrous Drawing speed (speed of the ram head) Pressure exerted on the blank holder plate Function or application of the component (in its final shape) Approximate time of producing the component and its dispatch time Packing methods and mode of transport used

LUBRICANTS PROPERTIES The lubricant film must cover both surfaces in the areas required throughout the operation. A lubricant in addition to preventing metal to metal contact will also reduce friction and generation of heat. LUBRICATION DURING DRAW OPERATION A good lubricant when applied on punch and die, stops direct contact of the component with the punch and die. Any lubricant that breaks down after a short period of use is obviously useless for drawing sheet material. The load applied by the punch and die is transferred to the component material without directly contacting but via through the lubricant. Because of the elongation of the lubricant medium a shining surface occurs on all the drawn components. Due to friction too much of heat is generated. To dissipate this hot water soluble lubricant has to be used. APPLICATION OF LUBRICANTS 1. Lubricating oil This is suitable only for drawing small cylindrical cups and not advisable for larger and thicker components. This evaporates easily and also creates local nonlubricated zones. 2. Graphite powder Even though graphite is self lubricating, not much used in practice and may be useful for small diameter drawn components. 3. Zinc oxide This is a very fine powder white in color widely used for all general draw operations. Zinc oxide is available easily in the market with reasonable price compared to other lubricants.

4. Molybdenum Sulphide powder This is a black powder and best lubricant medium used for draw operations. When compared with zinc oxide this is superior but very expensive. This is best suited for sheet material of thickness 2 mm and above. 5. Lubricant solution (Mixture) For Steel: 3% colloidal compound with 67% water For Brass and Copper: 5% soap flakes, 28%, colloidal compound with 67% water For Tin: Lubrication not required since this material is self- lubricating Most common methods of applying lubricant 1. Using a Brush 2. Swabbing 3. Using Roller-coating 4. Dipping the blank or stock in a lubricant bath 5. Spraying on the area where maximum draw force is concentrated

DAY TWO: 3RD HOUR

DEFECTS IN DEEP DRAWING OPERATION 1. 3. 5. 7. 9. 11. Burr collection at the draw die Cracking Ejection problems Wrinkling Material and its influence Wrong tool setting 2. Thinning 4. Score marks 6. Puckering 8. Earring 10. Surface finish 12. Operators negligence

REASONS AND REMEDIES FOR DEFECTS IN DEEP DRAWING OPERATION 1. BURR COLLECTION AT THE DRAW DIE Fine powder like particles gets collected at the bottom of the die due continuous use. Causes:

1. Type of sheet material used for producing the component 2. Thickness of the sheet material used Remedies: 1. Polish the draw die and draw punch and smoothen the flow radius and inside surface and use good lubricant such as Molybdenum sulphide 2. THINNING It is a frequent problem which occurs during draw operation. Due to this thickness of the component steeply reduce and give rise to its height.

Causes: 1. 2. 3. 4. Clearance is insufficient Lubrication problem Insufficient die radius or punch radius Reduction ratio: h/d is not properly calculated and maintained in the tool 5. Drawing speed is more Remedies: 1. Appropriate clearance is to be given in each draw stage 2. Use good lubricants such as molybdenum sulphide, so that the material flows evenly during draw operation 3. Check the draw die radius. If it is less, increase it to the required size. Maintain it with in 4t to 8t, where,t is the sheet thickness 4. Check the reduction ratio. If it is more, introduce one more intermediate draw operation, so that the reduction ratio is within the limit

3. CRACKING Splitting of wall surface of a finished component is known as Cracking. It invariably occurs after thinning

Causes: 1. 2. 3. 4. Draw clearance is insufficient Lubrication problem Insufficient die radius or punch radius Reduction ratio: h/d is not properly calculated and maintained in the tool 5. Drawing speed is more Remedies: 1. Appropriate clearance is to be given in each draws 2. Use good lubricants such as Molybdenum sulphide, so that the material flows evenly during draw operation 3. Check the draw radii of both punch and die. Maintain them properly throughout the profile. If it is less increase them (i) For die = 4t to 10t (ii) For punch = 3t to 5t 4. Check the reduction ratio. If it is more, introduce one more intermediate draw tool so that the reduction ratio is within limit 5. Decrease the draw speed 6. Polish the die and punch for better and even flow of stock material 4. SCORE MARKS These are marks formed on the component or on punch and die due to fouling of parts or particles of the sheet material.

Causes: 1. Lubricant used is not effective. 2. Fouling is caused by the building up of particles of the sheet material from the drawn cup on both the punch and the die and leads to scoring of the surface of the end product. Remedies: 1. Dismantle the tool. Clean the punch and die surfaces, lubricate and reset them. 2. Polish the draw punch and draw die. 5. EJECTION PROBLEM The component is struck either to the draw punch or with the draw die and is not getting ejected for consistent production. Causes: 1. Insufficient draft on punch or die 2. Lubrication problem 3. Any abnormal change in punch and draw radii due to stock material hardness Remedies: 1. 2. 3. 4.

Check the draft on draw punch and draw die radii Rectify by providing positive draft on die Provide good lubricant such as molybdenum suplhide Polish the draw punch and draw radii properly

6. PUCKERING This is a defect mostly found in shallow drawing and less frequent in deep drawing. This is similar to wrinkling but takes place inside the die, after the metal has begun to form inside the die aperture. Due to this wall of the component gets damaged.

Causes: 1. Poor die design and providing too much draw clearance 2. Stresses in the material are the underlying cause of this phenomenon 3. Lack of ductility (sheet material may be hard and not accepting the operation) Remedies: 1. It is difficult to set right the die 2. Redesign the tool 3. Trial to be made with draw quality stock material 7. WRINKLING It is defined as the deformation of material into ups and downs on the surface. This defect takes place between the pressure plate (blank holding plate) and the die face.

Causes: 1. Insufficient pressure on the pressure pad that holds the blank 2. Increase in the stress or stress concentration in the stock material of the component Remedies: 1. Appropriate pressure is to be applied on the pressure pad which holds the blank with use of suitable springs or air cylinder or die cushion 2. Once wrinkling is been occurred on a component nothing can be done in subsequent operations. So effort must be made in design itself to prevent this 3. Use of draw beads on the die 8. EARRING These are the extra projections caused by the directional properties in the sheet material from which the cups are drawn.

Causes: 1. Cold working tends to produce preferred orientations in sheet materials 2. When rectangular blank is drawn to a rectangular shallow bowl Remedies: 1. Earring can be minimized by avoiding excessive deformation in the deep drawing process

2. Shape and size of the ears can be controlled to some extent by varying the shapes of the blank (oval or even squared instead of circular). 3. Increase draw clearance 4. By conducting tests to find the most suitable orientation of the major axis relative to the sheet in order to reduce earring to a minimum 5. Trim the ears in case of rectangular or shallow bowl at the edges by a secondary cutting operation called Trimming 9. MATERIAL AND ITS INFLUENCE The type or quality of stock material is a very important factor controlling the technique employed to produce any given article. Causes: 1. When tool is used for other materials to manufacture same components. 2. Inferior quality of material supplied in the subsequent batch of material supply Remedies: 1. A good quality of material is essential if success is concerned 2. Different tools to be used for different types of materials. 10. SURFACE FINISH Surface quality of the deep drawn component depends largely on the grain size of material of the sheet material, from which it is blanked and drawn. Causes: 1. Due to coarse grains (Larger size of grains) 2. Coarse grains do not come into contact with the die face 3. The surface often resembles as orange peel (flakes). Hence, it is also called as ORANGE PEEL EFFECT Remedies: 1. Adequate control of grain size in the sheet to be drawn, is necessary 2. Final annealing process must be standardized and carried out for every subsequent draw operations and annealing at too high temperature or for too long period leads to formation of coarse grains

3. In case of mild steel normalizing the drawn cup at 910C, instead of annealing at 650C, leads to re-crystallization of material with fine grain size 11. WRONG TOOL SETTING Some times the tool setter does not have the knowledge of proper procedure of loading the tool, which may lead to many types of serious damage to the tool. Cause: 1. The tool setter sets the tool wrongly without following the procedure 2. He may be over confident or ignorant or not knowing the procedure 3. He may try to use the available facility Remedies: 1. Having once obtained all the relevant information and procedure of tool setting, the tool is to be set properly by the tool setter 2. Few of the things include proper clamping of the tool, lubrication, setting of proper shut height, screws on pressure plate to be checked twice, tightening of punch and die etc 12. OPERATORS NEGLIGENCE In many instances the operators are inexperienced or experienced by just assisting the senior operators and proclaiming themselves as skilled operators. By this the basic problem what the industry faces is the high risk on valuable tools and equipments. Causes: 1. Conversation with another operator 2. Disobeying the instructions 3. Lack of knowledge in the draw tool operation Result: 1. 2. 3. Remedies: 1. 2. 3. Sometimes complete destruction of the tool Production will be held up for many days till the tool is rebuilt Product become scrap Operator must be cautious about the work Operator has to obey the instructions Safety instructions have to be strictly followed

4. The supervisor must be vigilant and has to supervise all of these functions

DAY TWO: 4TH HOUR STRIP LAYOUT

There are two important methods of rolling in practice

HOT ROLLING Hot rolling is the core production process between melting and finishing operations. It is the main transformation stage where the billets are processed into bars wires, sheets or foils. If the sheets are rolled in hot condition, it is called as hot rolled sheets. COLD ROLLING Hot billets are cooled, cleaned, surface ground and Cold rolled to specific thickness on latest computer controlled mills, which continuously monitor the material for uniform gauge. TYPES OF SHEETS AVAILABLE Sl. No. Type of Sheet Metal CRCA (Cold Rolled Close Annealed) 1 HR (Hot Rolled) Aluminum 2 Brass

Available size 4 X 8 12 X 48,

Copper Phosphor bronze UTILIZATION OF STRIP

14 X 48 & Coil form

During the production of stampings, major consideration is very often given to the economical use of the raw material and blank lay-out in general is planned with minimum scrap. UTILIZATION FACTOR It is the percentage of the raw material (stock material) used in the component. Represented by:

Where, (Surface area) Area of the material in the component (Surface area) Area of material required to produce the component K W = Utilization factor 100 = To convert the value into percentage Ex: Blank size = 20mm x 30mm and the value of Scrap bridge and Side scrap = 1.75mm Pitch = 21.75mm and Strip width = 33.5mm fo K W = ---------- x 100 f1 fo = 20 X 30 = 600 mm2 = 21.75 X 33.50 = 7728.62 mm2 KW = (600 / 728.62) X 100 KW = 82.34% fo = f1=

f1

1000 No. of components per meter = ---------Pitch 1000 No. of components per meter = --------------- = 45.97 21.75 No. of complete components = 45 METHOD OF CALCULATING NUMBER OF COMPONENTS PER SHEET WITHOUT ANY SCRAP Ex: Component dimension = 15mm x 45mm Sheet dimension = 4 x 8 (4 Feet x 8 Feet) [Standard size of CRCA steel sheet] 1st step: Convert Feet to Millimeters [mm] We know that, 1feet (1) = 12 Inches (12) 1 Inch (1) = 25.4mm 4 Feet = 1219mm and 8 Feet = 2438mm (Decimal values are neglected) 2nd Step: In a sheet of 1219mm x 2438mm 2438 Number of pieces produced of size 45mm = ------------------ = 54 45 1219 Number of pieces produced of size 15mm = ------------------ = 81 15 3rd Step: Number of pieces from the sheet (1219mm x 2438mm) = 54 x 81 = 4374 [Conclusion: From a sheet of 4 Feet x 8 Feet, number of pieces produced are 4374]

Important note: Practice the above calculation for other sheet sizes with different blank dimensions. As per thumb rule the Scrap bridge and Side scrap is as follows: 1.5 X sheet thickness for metallic materials 2.0 X sheet thickness for non-metallic materials BLANK LAY-OUT The initial preparation of tool design, involves deciding the position of cutting tool, stopping positions, direction of feed and its value, instruction of feeding the strip and operations in the tool. DEFINITION It may be defined as the plan of cutting the blanks from the stock with optimum economy which is being influenced by many factors. Sometimes when there is no provision for deciding precise and economical strip lay-out for irregular contours, blank lay-outs are more preferred. STRIP LAY-OUT Strip lay-out is very important as it serves as the basis for designing and manufacturing of press tool. DEFINITION It may be defined as complete plan of producing the component in a progressive tool from the stock material. In a strip lay-out, the sequence of operation, the location of tool limit at each station, press operation taking place at each station, feeding direction etc, are clearly indicated. Generally there are different alternative methods of blanking out the given shape. Before the tools are designed it must be decided which method is to be adopted.

Blanking Side Scrap Piercing Scrap Bridge Strip width

End Stopper

Pitch

Side Scrap

The following important points are to be considered while designing a strip lay out. Sl. No. Strip lay out points 1 2 3 4 5 6 7 8 9 Stock material from which blanks are cut Direction of burr on the component Grain direction in the stock material Direction of feeding the stock strip Production quantity of components required Tool cost Specification of press Tool making possibilities and facilities Scrap and Utilization factor of stock material

DAY TWO: 5TH HOUR GROUPS ACTIVITY WORK SHOP ON DESIGN OF STRIP LAY OUT
Participants have to form few groups among themselves and does the strip lay out design for the given components.

DAY TWO: 6TH HOUR OBJECTIVE TEST

[Note: Each question carries one mark] Duration: 30 Minutes

FILL IN THE BLANKS WITH APPROPRIATE WORDS 1. Press tools are generally ____________ working tools. i) Cold, ii) Hot, iii) Neither Cold nor Hot Press tools are manufactured to produce sheet metal components in ___________ quantity i) Large, ii) Medium, iii) Small Punch back plates are ______________hardened. i) Full hardened, ii) Half hardened, iii) Case hardened Daylight means ______________________________________________ _______________________________________________________________ _________________________________________________________ i) Distance between the top surface of the bottom plate to the bottom surface of the top plate when the tool is in closed condition. ii) Distance between the bottom surface of the bottom plate to the top surface of the top plate when the tool is in closed condition. iii) Distance between the top surface of the bottom plate to the bottom surface of the top plate when the tool.

2.

3.

4.

5.

Shut height in a press tool means _______________________________ _______________________________________________________________ _________________________________________________________ i) Distance between the top surface of the bottom plate to the bottom surface of the top plate when the tool is in closed condition. ii) Distance between the bottom surface of the bottom plate to the top surface of the top plate when the tool is in closed condition. iii) Distance between the top surface of the bottom plate to the bottom surface of the top plate when the tool. Guide bushes generally are _______________ hardened. i) Full, ii) Half, iii) Case _________________operation cuts out various shapes from the edge of work piece material. i) Blanking, ii) Piercing, iii) Notching ____________ is a combined bending and cutting operation along a line in a work material. i) Lancing, ii) Lovring, iii) Fine blanking All cutting punches are made out of ____________________ material. i) (HCHCr) T 215 Cr12 W90, ii) (HSS) High speed steel, iii) Mild steel

6.

7.

8.

9.

10. Material used for manufacturing Cutting Die is ___________________. i) (HCHCr) T 215 Cr12 W90, ii) (HSS) High speed steel, iii) Mild steel 11. Shaving and trimming are_____________________ operation. i) Primary, ii) Secondary, iii) None of these two 12. Punch back plate is also called as ______________________. i) Thrust plate, ii) Stripper plate, iii) Die insert 13. Swaging operation is also called as ________________________. i) Necking, ii) Lancing, iii) None of these two 14. Piercing punch has a hardness of _________________. i) 52-55 HRc, ii) 60 -62 HRc, iii) 45 52 HRc

15. Die shoe means __________________________. i) Bottom plate, ii) Back plate, iii) None of these two 16. Type of fit between surface contact of pillar and bush in a press tool is called __________________________________. i) Sliding fit, (ii) Press fit, iii) Transition fit 17. Top plate is made with __________________ material. i) St-42, (ii) High Carbon High chromium steel, iii) OHNS 18. Non-Cutting die and punch are made with ______________ material. i) St-42, (ii) High Carbon High chromium steel, iii) OHNS 19. Spring loaded strippers are made with ______________ material. i) St-42, (ii) High Carbon High chromium steel, iii) OHNS 20. Bottom plates are also called as ___________________. i) Thrust plate, ii) Stripper plate, iii) Base plate or Die shoe 21. Dowels are used for _______________. i) Aligning, ii) Fastening, iii) None of these two 22. Screws are used for _______________. i) Aligning, ii) Fastening, iii) None of these two 23. The IS Codification of HCHCr material is i) T 215 Cr12 W90, ii) T 110 Cr1 W2, iii) 17 Mn1 Cr95 24. The material normally used for Bending punch is _________________. i) T 215 Cr12 W90, ii) T 110 Cr1 W2, iii) 17 Mn1 Cr95 25. To prevent the punches from penetration into the top _______________________ is used. i) Punch holder plate, ii) Punch back plate, iii) Stripper plate 26. The effect of Ironing the material results in. i) Tearing, ii) Shearing, iii) Thinning plate

27. Embossing is a _______________ operation. i) Drawing, ii) Forming, iii) Bending 28. The power source of Fly press is _________________. i) Hydraulic, ii) Manual, iii) Mechanical 29. Lancing punch is the best example for _____________ type of punch. i) Cutting, ii) Hybrid, iii) Bending 30. ______________ operation is a combined bending and cutting operation along a line in the work material. i) Blanking, ii) Lancing, iii) Bending 31. Formula for calculating blank diameter in drawing is _____________. _______ _ i) D = d2+ 4dh, ii) D = 0.01 x t fs, iii) D = D2 d2/h 32. Press tools are required to produce component in _________ quality. i) Mass, ii) Batch, iii) Repetitive 33. Insufficient clearance results in ____________________ type of burr. i) Tensional, ii) Compressive, iii) None of these two 34. Pilots are made out of __________________________ material. i) T110 W2 Cr1 (OHNS), ii) T215 W90 Cr12 (HCHCr), iii) St - 42 35. _________________ is provided in the die to have a free fall of the piece parts. i) Angular clearance, ii) Spring, iii) Pressure pad 36. _____________ formula is used for calculating the utilization factor. i) D = 0.01 x t fs, ii) D = D2 d2/h, iii) K.W = fo / f1 x 100 37. Generally the land portion in a die will be around 3 to 5 mm. i) 1 to 2mm, ii) 3 to 5 mm, iii) None of these two 38. Cutting clearance will be given on _________in a piercing operation. i) Die, ii) Punch, iii) For both

39. Tools which perform only one operation are called as _____________ i) Single action tool, ii) Progressive tool, iii) Compound tool 40. Utilization factor is expressed in terms of __________________ i) Percentage [%], ii) Millimeters, iii) Grams

DEAR PARTICIPANT, HOPE YOU HAD A NOVEL JOURNEY WITH US IN THE FIELD OF PRESS TOOLS. WE HAVE SINCERELY PUT OUR EFFORTS TO COMPILE THIS COURSE MATERIAL WITH OUR EXPIRIENCE AND KNOWLEDGE. WE HAVE PUT SINCERE EFFORTS IN THE PREPARATION OF THIS COURSE MATERIAL. IN CASE IF ANY ERRORS OR MISTAKES ARE FOUND, WE APPRECIATE YOUR FEEDBACK.

GTTC, DHIO and Pannaga EXTEND THEIR THANKS TO YOU AND TO YOUR
SPONSORERS FOR HAVING GIVEN AN OPPURTUNITY TO SHARE OUR THINKING AND AQUIRED KNOWLEDGE.

WISHING YOU GOOD LUCK

Contact Santhosh N L, Director

DHIO Research & Engineering Pvt Ltd., No 277, 1st Floor, Above Central Bank, 8th main, 4th Block, Basaveshwaranagar, Bangalore- 560 079 India Ph/Fax: +91 080 42151310 Cell: +91 9591994642 Email: santhosh@dhio.in web: www.dhio.in Head Office DHIO - Center for Excellence #91/46, 8th Cross, Wilson Garden, Bangalore 560 027, India