1.

INTRODUCTION
Sheet metal is metal formed by an industrial process into thin, flat pieces. It is one of the
fundamental forms used in metalworking and it can be cut and bent into a variety of shapes.
Thicknesses can vary significantly; Extremely thin thicknesses are considered foil or leaf, and
pieces thicker than 6 mm are considered plate. Sheet metal is available in flat pieces or coiled
strips. The coils are formed by running a continuous sheet of metal through a roll slitter. The
larger the gauge number, the thinner the metal. In todays practical and cost conscious world,
sheet metal parts have already replaced many expensive cast, forged and machined products. The
common sheet metal products are metal desks, file cabinets, appliances, car bodies, aircrafts
fuselages. Mechanical toys and beverage cans. Due to its low cost and generally good strength
and formability characteristics, low carbon steel is the most commonly used sheet metal. For
aircraft and aerospace applications, the common sheet materials are aluminium and titanium.

The design and manufacture of press tool, or punches and dies is a branch of production
technology that has extended in to lines of engineering manufacture over the past seventy years.
There is no doubt that the accuracy achieved by new ideas in design and construction applied by
the tool design engineer, coupled with increased speed and rigidity of the presses etc.; used have
all contributed towards maintaining this form of metal tooling well to force as a mean of
obtaining, Yet strong, durable articles that can with stand severe day to day usage.

More and more it has become the practice to produce from sheet metal by some form of
pressing process, work piece that would have been made from bar, forging or casting two or
three decades ago. Also the handling of both strip material and semifinished component has
assumed an importance simply because fast and efficient movement means cheap products from
operators who do not suffer fatigue from the handling of awkward or heavy components.
However it should not be forgotten that press design has made many advance in recent years in
common with ,for example, the machine tool industry, and machines are now available that are
capable of withstanding the heavy stresses set up in many modern production process.

The modern car, radio and television sets, clocks and watch, house hold wares and office
furniture are all examples where press tools are used in varying degrees permitting the marketing
of a complete series of products quickly and cheaply to bring them with in the purchasing power
of the public.From this encouraging picture it may come something of a surprise to realize that in
press work there are often factors, particularly in bending and drawing process where successful
results are obtained only through the extensive experience of a tool designer contribution to first-
class press work.

1
 1. Good operation planning
2. Excellent tool design
3. Accurate tool design
4. Knowledge press setting
5. Operation planning

Tire balance, also referred to as tire unbalance or imbalance, describes the distribution of
mass within an automobile tire or the entire wheel including the rim to which it is attached.
When the wheel rotates, asymmetries of mass may cause it to hop or wobble, which can cause
ride disturbances, usually vertical and lateral vibrations. It can also result in a wobbling of the
steering wheel or of the entire vehicle. The ride disturbance due to unbalance, usually increases
with speed. Vehicle suspensions can become excited by unbalance forces when the speed of the
wheel reaches a point that its rotating frequency equals the suspensions resonant frequency.
Tires are balanced in factories and repair shops by two methods: static balancers and dynamic
balancers. Tires with high unbalance forces are downgraded or rejected. When tires are fitted to
wheels at the point of sale, they are measured again on a balancing machine, and correction
weights are applied to counteract the combined effect of the tire and wheel unbalance. After sale,
tires may be rebalanced if driver perceives excessive vibration.

Every year, millions of small weights are attached to tires by automotive technicians
while balancing them. Traditionally, these weights have been made of lead; it is estimated that
up to 500,000 pounds of lead, having fallen off of car wheels, ended up in the environment.
According to the US Environmental Protection Agency, worldwide these total more than 20,000
tons of lead annually, and encourage the use of less toxic materials. In Europe, lead weights were
banned in 2005; in the US, some states have banned them. Alternatives are weights made of lead
alloys that include zinc or copper, or weights that are altogether lead free.

Fig 1.1: Counter weight clip with zinc casted

2
 The weights added to the rim for wheel balancing with the help of clip, this clip is made
of spring steel. Spring steel is a name given to a wide range of steels used widely in the
manufacture of springs, prominently in automotive and industrial suspension applications. These
steels are generally low alloy, medium carbon steel or high carbon steel with a very high yield
strength. This allows objects made of spring steel to return to their original shape despite
significant deflection or twisting.
.
Spring Steel is typically used because of its high yield strengths, resistance to
deformation and its ability to return to its original shape. Our spring steel and spring steel strips
are available as heat treatable annealed, which allows the forming to occur prior to the heat
treatment or as heat-treated, having been previously hardened, tempered or sprung. Precision
Steels inventory of annealed spring steel can easily be formed, tempered, heat treated, blanked
or shaped. In addition to the annealed and heat-treated spring steel, Precision Steel also carries
large inventories of stainless spring strip steel. Stainless Spring steel is known for being resistant
to water, environmental, and pollution exposure. With two main groups, stainless spring steel
can either be austenitic or martensitic. The austenitic stainless spring steel strips like 301 and 302
are temper rolled for light springs versus the martensitic spring steels, such as the 420 stainless
strips that are heat treatable for high hardness and toughness and are typically used for hardened
tools.

Fig 1.2: Counter weight clips

3
2. THEORY
The metal stamping process can alter the sheet metal material in many ways. Parts may
be blanked, pierced, drawn, formed, or embossed, just to name a few basic operations. Each of
these processes exerts its influence upon the structure of the material: that of the part and that of
the scrap. Often, a congested piercing can cause stresses that will produce an increase in area
measurements of that particular section, which is called bulging, or oilcan effect. Forming or
drawing, on the other hand, can produce wrinkling, tearing, ironing, or undesirable folding of
metal.

During the forming or deforming process, any metal material, with all its mechanical
properties, will go through a transformation from its elastic state to plastic. These changes are
forced upon its structure by various stresses, temperature changes, and speed of the forming
application, among others. The changes may occur either along the plane of the highest
concentration of potential energy, or along the plane of maximum shear stress. Naturally, such an
array of influences cannot fail to produce considerable changes in the part's structure and
appearance. Some changes may have been originally planned for, and for that reason these can
be considered beneficial.

2.1 Operations performed by the press tool

2.1.1. By Shearing

Piercing: An operation in a die which cuts out a slug (usually scrap) in sheet or Plate
material.

Blanking: The operation of cutting or shearing a piece out of stock to a predetermined

contour.

Perforating: An operation in a die in which a number of holes are pierced or punched

Simultaneously or progressively in a single stroke of the press.

Notching: The operation of cutting out of various shapes from the edge of a strip, blank or
part.

Cropping: an operation of shearing the contours at the side of strip stock and aids for
accurate Stopping of the strip while feeding.

Trimming: The operation of cutting scrap out of a partially or fully shaped part to an
established trim line.

4
Shaving: A secondary shearing operation in which the surface of the previously out edge is
finished or smoothened.

2.1.2. By Bending
Bending:

Bending is the process of folding a sheet about a straight line axis which lies in the
neutral plane. Bends are made in sheet metal to gain rigidity, to produce a part of desired shape
& perform a particular function etc. The cross section of the bend inward from neutral axis is in
compression, outward from neutral axis is in tension as shown in fig.

Fig 1.3: Bending operation

Bend allowance The length of the arc through the bend area at the neutral axis.

Bend angle The included angle of the arc formed by the bending operation.

Bend compensation The amount by which the material is stretched or compressed by the
bending operation. All stretch or compression is assumed to occur in the bend area.

Bend lines The straight lines on the inside and outside surfaces of the material where the
flange boundary meets the bend area.

Inside bend radius The radius of the arc on the inside surface of the bend area.

5
K- factor Defines the location of the neutral axis. It is measured as the distance from the inside
of the material to the neutral axis divided by the material thickness.

Mould lines For bends of less than 180 degrees, the mould lines are the straight lines where
the surfaces of the flange bounding the bend area intersect. This occurs on both the inside and
outside surfaces of the bend.

Neutral axis Looking at the cross section of the bend, the neutral axis is the theoretical
location at which the material neither compressed nor stretched.

Set back For bends of less than 180 degrees, the set back is the distance from the bend lines to
the mould lines.

Spring back During bending the metal nearer to the neutral axis is stressed to the values below
the elastic limit. This phenomenon creates a narrow elastic band on both sides of the neutral axis.
The metal further away from the neutral axis is stressed beyond the yield strength and is
plastically deformed and permanently set. When the bending force on the metal is released the
elastic band tries to return to the fully due to the restrictions of the plastically deformed zones.
Some slight return does occur as the elastic and plastic zones come to an equilibrium and this
return is known as spring back.
Hemming: An operation in die which folds the edge of the part back over on itself. The edge

may or may not be completely flattened to form a closed hem.

Seaming: The process of joining two edges of sheet metal by multiple bending.

2.1.3. By Forming
Forming: Making any change in the shape of a metal piece which does not intentionally
reduce the metal thickness.

Flanging: The operation of forming the edges of shell or hole square with the walls.

Embossing: A process that produces relatively shallow indentations or raised designs with
theoretically no change in metal thickness.

Curling: Forming an edge of a circular cross section along a sheet or at the end of a shell or
tube.

Bulging: The process of expanding the walls of a cup shell or tube with an internally
expanding segmental punch or a punch composed of air, liquids or semi-liquids.

Necking: Reducing the diameter of a portion of the length of a cylindrical shell.

6
Coining: A closed die squeezing operation in which all surfaces of work are confined or
restrained

2.1.4. By Drawing
Drawing: A process in which a punch causes flat metal to flow to a die cavity to assume the
shape of a seamless hollow vessel.

Redrawing: Second and following operations in which cup like shells are deeply drawn and
reduced in cross sectional dimensions.

Ironing: An operation in which the thickness of the shell is reduced and its surface
smoothened.

2.2 Types of Press tool

2.2.1 Simple tool:

Simple dies or single action dies perform single operation for each stroke of the press

Slide. The operation may be like piercing or blanking.

2.2.2 Compound tool:

In these dies, two or more operations may be performed at one station. Such dies are
considered as cutting tools since, only cutting operations are carried out. Compound dies are
more accurate and economical in production as compared to single operation dies.

7
 Fig 2.1: Compound tool

2.2.3: Combination tool:

In this die also , more than one operation may be performed at one station. It is different
from compound die in that in this die, a cutting operation is combined with a bending or drawing
operation, due to that it is called combination die.

Fig 2.2: Combination tool

8
2.2.4: Progressive tool:
A progressive tool has a series of operations. At each station an operation is performed on
the work piece during a stroke of the press. Between the strokes the metal strip is transferred to
the next station. A finished work piece is made at each stroke of the press. While the piercing
punch cuts a hole in the stroke , the blanking punch blanks out a portion of the metal in which a
hole had been pierced at a previous station.

Fig 2.3: Progressive tool

2.2.4.1. ELEMENTS OF PROGRESSIVE TOOL

Die Set-
It is one of the basic elements of the stamping industry which can be defined as a sub
press unit consisting of a bottom plate and top plate together with guide pillars and bushes by
means of which the top and bottom plates are aligned. The purpose of die set is to utilize the
entire die assembly.

Top Plate-
The upper working member of the tool is called the top plate. The punch assembly
including the punch holder and thrust plate is mounted on the top plate. The tool shank, which
locates the whole tool centrally with the press ram, is also screwed into the top plate.

Punch Back Plate-

While performing the cutting operation, the punch exerts an upward thrust. So a
hardened plate to prevent it from digging into the soft-top plate should back up punch. It is made
out of case hardened tool steels.

Punch holder -

9
 The punch is usually fixed to a plate with a light press fit. Punch holder holds all types of
cutting and non-cutting punches to ensure alignment between punch and die.

Punches-
A punch is the male member of a press tool to get a component from the strip. It is made
out of good quality alloy steel.

Stripper Plate-
When cutting action is over, the punch withdraws from the die but the stock strip also
will move along with punch. So for next operation strip cannot be moved forward. To facilitate
this function one plate is fixed above the die plate. This removes the strip from the punch is
called stripper. It guides punches and pilots in this plate to ensure alignment with punch and die.

Die Plate-
A die block is defined as the block or plate from which the die profile is cut. It is usually
lower member of the tool. It provides cutting edge. The die opening has different designs and the
design is selected after looking in the requirements and facilities available.

Bottom Plate-
Bottom plate gives cushioning effect to the die as well as provides enough space for the
tool to be clamped to the press bed. There may be opening in the base plate, which allows the
blank, or slug to fall and clear off from the tool. The die assembly including stripper, all bottom
elements are mounted on the bottom plate.

Guide Pillar and Guide Bush-

These are very important function in press-tool. Pillar and bushes guide the moving and
fixed half of the tool in the press and also it is used to ensure accurate alignment between the
punches an.

10
2.3 Press selection
Press tool designer has to make proper selection of the type of press to be used and also
the kind of press tools to be provided. It is more economical to use a tool, which will complete a
number of cheaper and simpler tests to stroke of the press than to employ a number of cheaper
and simpler tests to perform the same work in a series of operations. The design of the tools
should be simplest possible and the method of operation the most efficient one.

A brief presentation of press classify action is necessary. The press described is the
common types used for sheet metal shaping using dies. While selecting a press the following
points should be considered.

Force required to cut the sheet metal

Size and type of die

Stroke length

Method of feeding and size of blank

Shut height

Type of operation

2.4 Classification of presses

Presses can be classified as listed below:

Rated tonnage capacity

Power source

Number of independently moving rams

Method of transmitting power

Frame design

Intended purpose

11
2.4.1. Rated tonnage capacity:

The rated tonnage capacity of a press indicates the maximum pressure, which the press is
designed to safely accommodate. A part from naming the press by various other names, the
capacity of the press must be linked with the name so that a job requiring that much capacity
and no more should be assigned to it.

2.4.2. Power source:

According to this classification the press may be named as manual driven press,
Hydraulic press of pneumatic press.

Manual driven presses

The energy is supplied by human effort at the rim of a flywheel or the screw at the end of
a lever in the arbor press.

Mechanically driven presses

Are the most commonly used machines in the press shops. They are further classified
according to the method the ram is actuated. They are suitable for all types of press work except
deep drawing where a slow motion is desired. These presses range in capacity from 5 to 100
tons.

Hydraulic driven presses

Hydraulic driven presses are used for heavy duty jobs. Heavy capacity presses are widely
used for forging purpose.

Pneumatically driven presses

Are not widely used on sheet metal production work.

2.4.3. No of rams:

Depending up on the no of rams, the press may be a single action press, double action
press or triple action press. Single action has one ram only actuated by of the means. It is most
popular type of press for most of the stamping operations can use both compound and
progressive dies.

12
2.4.4. Method of transmitting power:

In a mechanical the power is driven from a motor driving a flywheel or gear and may be
delivered to the ram by means of a crank shaft, eccentric cum, Knuckle joint, toggle joint, rack
and pinion or power screw mechanism.

2.4.5. Frame design:

The frame of the press is fabricated by casting or by welding heavy steel plates. Cast
frames are quite stable and rigid but expensive. Welded frame are generally less expensive and
more resistant for shock loading because of greater toughness of steel plates.

2.5 General press information:

The tool designer must know certain fundamentals of press operation before he can
successfully design a press tooling.

Press tonnage-

The tonnage of the press is the force that the press ram is able to deliver safely. Press
slides exert greater than the rated tonnage because of the built in safety factor. The tonnage of
mechanical presses is determined by the size of the bearing for the crank shaft or eccentric.

Stroke-

The stroke of a press is the reciprocating motion of press slide, usually specified as the no
of inches between terminal points of the motion.

Shut height-

The shut height of a press is distance from the top of the bed to the bottom of the slide
with stroke down and adjustment up. The thickness of the bolster plate most always is taken in to
consideration when determining the maximum die height.

Die space

Is the area available for mounting dies in the press.

13
3. LITERATURE REVIEW

1. Ch.Mastanamma , K.Prasada Rao and Dr.M.Venkateswara Rao , Design and

Analysis of Progressive Tool --- Design and development of Progressive tools for the sheet
metal component is one important phase in sheet metal manufacturing. Sheet metal press
working process by progressive tools is a highly complex process that is vulnerable to various
uncertainties such as variation in progressive tools geometry, strip layout, die shear, material
properties, component and press working equipment position error and process parameters
related to its manufacturer. These uncertainties in combinations can induce heavy manufacturing
losses through premature die failure, final part geometric distortion and production risk.

2. J.C. Choi, Chul Kim, A compact and practical CAD/CAM system for the blanking or
piercing of irregular shaped-sheet metal products for progressive working ----- it describes
the development of a computer-aided design of blanking and piercing for irregular-shaped sheet
metal products and stator and rotor parts. An approach to the compact and practical CAD system
is based on the knowledge-based rules. Knowledge for the CAD system is formulated from
plasticity theories, experimental results and the empirical knowledge of field experts. The system
has been written in AutoLISP on the AutoCAD with a personal computer and is composed of six
main modules, which are input and shape treatment, production feasibility check, blank layout,
strip layout, die layout, and drawing edit module.

3. Sung-Bo Sim, Sung-Taeg Lee, Chan-Ho Jang, A study on the development of center
carrier type progressive dies for U-bending part process ------The Center carrier-type
progressive die for U-bending sheet metal production part is a very specific division. This study
reveals the sheet metal forming process with multi-forming die by Cut off type feeding
system.Through the FEM simulation by DEFORM, it was accepted to U-bending process as the
first performance to design of strip process layout.The next process of die development was
studied according to sequence of die development, i.e. die structure, machining condition for die
making, die materials, heat treatment of partially die components, know-how and so on.

4. S. Kumar, R. Singh, A low cost knowledge base system framework for progressive die
design---- This paper presents a low cost knowledge base system framework for progressive die
design. The task of building the system is divided into different modules for major activities of
progressive die design. Each module of the proposed framework is designed to interact with the
user through the user interface. A procedure for developing knowledge base system modules is
described at length. The rules of each module of the system are recommended to be coded in the
AutoLISP language and loaded into the prompt area of AutoCAD. This arrangement facilitates
interfacing of design process with modeling and can be operated on a PC/AT.

5. Raja shakarappa, Analysis and simulation of progressive die---The aim is to reduce the
cost of the progressive dies without compromising on the quality of output. Using the optimum
resources possible in designing the progressive dies frame can effect this reduction in the cost of
the progressive dies. One way of doing it will be optimizing the volume of material utilized for
building the structure. An attempt has been made in this direction to reduce the volume of
material. In this project work an industrial application project consisting of mass minimization of

14
the progressive dies is considered. This progressive dies has to compensate the stresses acting on
the tools, top, middle & bottom plates and to fulfill certain critical constraints.

6. Vinay Kumar A V, D Ramegowda, Design of progressive press tool for an alpha meter
component ------ The design and manufacture of press tools, or punches and dies, is a branch
of production technology that has extended into many lines of engineering manufacture over the
past seventy years. There is no doubt that the accuracy achieved by new ideas in design and
construction applied by the press tool designer, coupled with increased speed and rigidity of the
presses etc, used have all contributed toward maintaining this form of metal tooling well to the
force as a means of obtaining pleasing, yet strong, durable articles that can withstand severe day-
today usage.

7. Vrushabh Mahaveer Ghosarwade, Chandradharappa, Finite Element Analysis of

progressive die--- Progressive die performs two or more operations at different stages in every
time the ram descends. The stock strip advance through a series of stations that perform one or
more die operation on work pieces stripe must move from first through each succeeding stations
to produce a complete work piece. The distance from one station to the next must be same that is
station to station distance is also same as the advance distance. Stripe moves in order to relocate
at each successive station when establishing sequence of operations for progressive dies.
Pearling operation must be placed first advantage should be take of any required holes in work
piece for piloting irregularly placed punches should be avoided by punching out a
portion of blank at one station and finishing it at another. The operation that required for bending
and forming must be done in lateral stations.

8. Tool engineering parameters book; Indian society of tool engineers.

15
4. PROBLEM STATEMENT:
Design of press tool for counter weight clip of wheel balancing of a 4 wheeler. by
considering the component dimension.
Idea is to develop progressive tool for doing five operations .The modeling is to be done
in solidworks.
Tonnage calculations for all operations.
Modeling and structural analysis on progressive tool Analysis of press tool parts like
punches, die and stripper to check there should not be any deformation while working.

4.1 Operations involved for counter weight clip:

The following five major sequences of operations are followed for manufacturing the
component by selecting proper press tool.

1. Piercing
2. Notching
3. Edge bending
4. Blanking
5. U bending

4.2. Objective of the project:

1. The primary objective is to design the press tool for counter weight clip.

2. The study of component has been done to design the tool in simplest form.

3. Nonstandard parts have been avoided to the maximum extent and care is taken to include
design consideration for safer die operation.

4. The project emphasis to correlate the curriculum and the designing practice carried out .The
study of selected materials has to be done to know its physical and mechanical properties that
influence tool design and tool life.

16
4.3. Component Material:

SPRING STEEL
Sheet thickness: 1 mm

Composition: carbon - 0.45 to 0.6%

Manganese - 0.6 to 0.8%

Silicon - 0.1 to 0.35%

Sulphur - 0.05% max

Phosphorous - 0.05%max

17
5. METHOD PLAN FOR COUNTER WEIGHT CLIP
5.1 Drawing the component 2d and 3d diagrams in solid works software.

5.2 Drawing the strip layout and specifying the press tool.

5.3 Stock utilization Factor

5.4 Calculation of tonnage required to form the component.

5.5 Selection of press for required tonnage.

5.6 Calculation of press tool components dimension.

5.7 Material selection for punch, die and inserts

5.8 Modeling the press tool in solid works.

5.9 Analysis of press tool components in Ansys.

18
5.1 Drawing the component 2d and 3d diagrams in solidworks
The counter weight clip 2d diagrams are drawn below as per the specified
Dimension.

Fig 5.1: 2d view of counter weight clip

19
Fig 5.2: 3D view of counter weight clip

20
5.2 Drawing the strip layout and specifying the press tool.

Fig 5.3: Strip layout of counter weight clip

By considering the shearing and bending operations involved in the component and
difficulty in the component the progressive die is selected for press working operation.

The component is required in large number ,as the mass production can be easily done by
progressive tool.

The progressive die performs a series of fundamental sheet metal working at two or
more stages during the press running to produce a production part as the strip stock
moving through the die surface. Press working from the optimum dies design and its
making has been the purpose of mass production in the manufacturing field.

21
5.3 Strip utilization factor

% of Stock strip utilization :

Area of component No of components
Stock strip utilization =
Area of strip before blanking

Area of component = Area of rectangle [4(Area of isosceles triangle)+2(Area of

first circle)+area of second circle]

= (20.315.8) [4(0.81) +28.26+25.13]

= 264.11mm

Considering for 10 components the area of strip before blanking = length width

= 20315.8

= 3207.4mm
264.11 10
% of stock strip utilization =
3207.4

= 82% of stock is utilized

22
5.4 Tonnage required to form the component
Tonnage = Total Shear force + spring force + lifting spring force

1. Total shear force = Shear force + Edge bending force + U bending force

Shear force Fsh =

K = Factor of safety=1.2

L = Shear length = 2(d) + d + 4Lc + Lb

= 51.86mm

T = Thickness = 1 mm

Sst =shear strength = 45 kg/mm2

1.2 51.86 1 45
Fsh = = 3 t ons
1000

.
Edge bending force Fe =

Su = ultimate tensile stress =57 kg /mm2

W = width = 15.8 mm

T = thickness = 1mm

L = 2.87 mm

0.33 57 15.8 1
Fe = = 0.12 tons
2.87

.
U bending force Fu =

Su = ultimate tensile stress =62 kg /mm2

W = width = 15.8 mm

T = thickness = 1mm

L = 7.05mm

0.66 57 15.8 1
Fu = = 0.084 tons
7.05

23
Total shear force =1.3 (Shear force + Edge bending force + U bending force)

= 1.3(3 + 0.12 + 0.084)

= 4.21 tons

2. Spring force = 20% of Total shear force

= 0.2 4.21

= 0.84 tons

3. Lifting spring force = 1% of Total shear force

= 0.01 4.21

= 0.042 tons

Tonnage = Total Shear force + spring force + lifting spring force

= 4.21 + 0.84 +0.042

= 6 tons

24
5.5 Selection of Press for required tonnage
Available press

AMETEEP Machine Tools Pvt Ltd

Model 0B1G

Pressure 40 t ons

Stroke of slide 25-102mm

Shut height 500mm

Bed area 700 495 m m

No of strokes per minute 12

Power required 5 HP

Fly wheel or belt pulley - 50 rpm

25
5.6 Calculation of press tool components dimension

Die block thickness Td = Ftsh

Ftsh = total shear force = 4.2 tons

For design safety purpose Td = 3.0 cm

= 30 mm

Piercing punches

1. Size of punch Dp = 3 mm

Size of die Dd = Dp + 2c

Where c = at ; t = thickness ; a = % of clearance

c = 6% t = 0.06 1 = 0.06 mm

Dd = Dp + 2c

= 3 + (2 0.06) = 3.12 mm

2. Size of punch Dp = 3 mm

Size of die Dd = Dp + 2c

Where c = at ; t = thickness ; a = % of clearance

c = 6% t = 0.06 1 = 0.06 mm

Dd = Dp + 2c

= 4 + (2 0.06)

= 4.12 mm

Punch holder thickness Tph = 0.9 td

= 0.9 30

Tph = 28 mm

26
Bottom bolster thickness T b.b = 1.16 td

= 1.16 30

= 35 mm

Top bolster thickness Ttb = 1.5 td

= 1.5 30

= 45 mm

Stripper plate thickness Tsp = 1.4 td

= 1.4 30

= 43 mm

27
5.7 Material selection for punch, die and inserts
Cold work tool steels include the high-carbon, high chromium steels or group D steels.
These steels are designated as group D steels and consist of D2, D3, D4, D5 and D7 steels. These
steels contain 1.5 to 2.35% of carbon and 12% of chromium. Except type D3 steel, all the other
group D steels include 1% Mo and are air hardened. Type D3 steel is oil-Quenched; though
small sections can be gas quenched after austenitization using vacuum. This makes tools made
with type D3 steel brittle during hardening. Type D2 steel is the most commonly used among the
D steels, D2 steel is selected for all shearing punches and die plates of press tool. AISI D2 is
high carbon high chromium tool steel (HCHCR) alloyed with molybdenum and vanadium.
Chemical composition, physical properties and mechanical properties are given in table 5.1, 5.2
and 5.3 respectively.

Table 5.1: Chemical Composition of D2 steel

Element Content %
C 1.40 - 1.60
Mn 0.60
Si 0.60
Co 2.50 3.50
Cr 11.00 13.00
Mo 0.70 1.20
V 1.00
P 0.03
Ni 0.30
Cu 0.25
S 0.60

Table 5.2: Physical properties of D2 steel

Density 7.7 8.03 1000 kg/m3
Melting point 1426 C

Table 5.3: Mechanical properties of D2 steel

Hardness 62 HRC
Poissons ratio 0.27 - 0.3
Elastic modulus 190 210 Gpa

28
Fabrication and Heat Treatment:
D2 steels should be preheated very slowly to 8050C and then temperature can be
increased to 10100C. They are then held at 10100C for 20 to 45 minutes and air cooled (air
quenched).

Forging:
D2 steels can be done from 10650C down to 9540C. Do not forge below
9260C.
Annealing:
D2 steels should be done at 8710C to 8980C followed by slow furnace cooling at 4.4 per
hour or less.

Tempering:
D2 steels can be tempered at 2040C for achieving Rockwell C hardness of 62 and at
5370C for a Rockwell C hardness of 54.

29
5.8 Modeling of press tool components in solid works

Solid works

To model the progressive tool I used solid works 2013

Fig 5.4: Top plate assembled with punch holder and punches

30
Fig 5.5: Stripper plate with inserts

31
Fig 5.6: Bottom plate assembled with die block and strip guide

32
Fig 5.7: Assembly of progressive tool

33
5.9 Analysis of press tool components

Material HCHCR
Density : 7700 kg/m3

Elastic modulus : 190 210 Gpa

Poisson ratio : 0.27 -0.3

5.9.1 Theoretical and Analytical deflection and stress calculation of piercing

punch for 4 mm hole
The blanking punch is considered as one end fixed and the compressive force acting on
other end.

Deflection =

F = shearing force = 5654 N

L = length of punch = 83 mm
A = Area of punch = 12.5 mm2
E = Youngs modulus = 210 103 N/mm2

= (5654 * 83) / (12.5 * 210 103)

= 0.17 mm

Stress = F / A

F = Shearing force = 5654 N

A = Area of punch = 12.5 mm2

= 5654 / 12.5 = 452 N/mm2

34
Fig 5.8: Total Deflection of 4mm hole piercing punch

Fig 5.9: Von-Mises stress of 4mm hole piercing punch

35
5.9.2 Theoretical and Analytical deflection and stress calculation of piercing
punch of 3 mm hole
The blanking punch is considered as one end fixed and the compressive force acting on
other end.

Deflection =

F = shearing force = 3001 N

L = length of punch = 83 mm
A = Area of punch = 7.06 mm2
E = Youngs modulus = 210 103 N/mm2

= (3001 * 83) / (7.06 * 210 103)

= 0.16 mm

Stress = F / A

F = Shearing force = 3001N

A = Area of punch = 7.06 mm2

= 3001 / 7.06 = 425 N/mm2

36
Fig 5.10: Total Deflection of 3mm hole piercing punch

Fig 5.11: Von Mises stress of 3mm hole piercing punch

37
5.9.3 Theoretical and Analytical deflection and stress calculation of bending
punch
The bending punch is considered as one end fixed and the compressive force acting
on other end.

Deflection =

F = bending force = 840 N

L = length of punch = 92 mm
A = Area of punch = 49.77 mm2
E = Youngs modulus = 210 103 N/mm2

= (840 * 92) / (49.77 * 210 103)

= 0.007 mm

Stress = F / A

F = bending force = 840 N

A = Area of punch = 49.77 mm2

= 840 / 49.77
= 17 N/mm2

38
Fig 5.12: Total Deflection of bending punch

39
Fig 5.13: Von Mises stress of bending punch

40
5.9.4 Theoretical and Analytical deflection and stress calculation of noutching
punch
The noutching punch is considered as one end fixed and the compressive force acting on
other end.

Deflection =

F = shearing force = 1620 N

L = length of punch = 88 mm
A = Area of punch = 11.4 mm2
E = Youngs modulus = 210 103 N/mm2

= (1620 * 88) / (11.4 * 210 103)

= 0.059 mm

Stress = F / A

F = Shearing force = 1620 N

A = Area of punch = 11.4 mm2

= 1620 / 11.4
= 142 N/mm2

41
Fig 5.14: Total Deflection of bending punch

42
Fig 5.15: Von Mises stress of bending punch

43
5.9.5 Theoretical and Analytical deflection and stress calculation of die block
The die block is considered to be as fixed beam.

Deflection = ( F L3) / (192*E*I )

F = shearing force = 4.2104 N/mm2

L = length of die block = 220 mm
E = youngs modulus = 210 103 N/mm2
I = Moment of Inertia = b h3 / 12
I = 100 *30 /12 = 7500 mm4

= (4.2104 * 2203) / (192 * 210 * 103 *7500 )

= 0.014 mm

Stress = F / A

F = Shearing force = 4.2104 N

A = Area of die = 3000 mm2

= 4.2104 / 3000
= 140 N/mm2

44
Fig 5.16: Total Deflection of die block

45
Fig 5.17: Von Mises stress of die block

46
5.9.6 Analysis Results
The following table shows the comparison of calculated to theoretical values.

Table 5.4: Comparison table

Sl .no Description Analysis Results Calculated value

Deflection Von mises Deflection Stress

mm Stress mm N/mm2
N/mm2
1 4mm hole piercing punch 0.045 330.45 0.177 449

2 3mm hole piercing punch 0.079 304.5 0.16 425

3 Bending punch 0.001 16.6 0.007 18

4 Notching punch 0.003 118.8 0.059 142

5 Die block 0.003 80.7 0.0149 140

The results plotted in the table are theoretical and analytical values. There is a slight
difference between theoretical value and analytical value.

47
6. COST ESTIMATION

Tool cost :
Raw material HCHCR = Total weight of HCHCR in the tool in Kg raw material
cost per Kg

= 45 290

= Rs 13050/-

Raw material OHNS = Total weight of OHNS in the tool in kg raw material cost
per kg

= 63 120

= Rs 7560/-

Raw material EN-31 = Total weight of EN-31 in the tool in Kg raw material cost
per kg

= 17 110

= Rs 1870/-

Raw material MS = total weight of MS in the tool in Kg raw material cost per Kg

= 150 70

= Rs 10500/-

Total material cost = 13050 + 7560 + 1870 + 10500 = Rs 45000/-

Machining cost = {(Turning hrs Rs/hr) + (milling hrs RS/hr)+(drilling hrs Rs/hr)+
(surface grinding hrs Rs/hr)+(jig boring hrs Rs/hr)+( CNC milling
hr Rs/hr ) + ( CNC turning hr RS/hr) + (pre machining hr Rs/hr)

= {(15 * 250) + ( 52 * 300) + ( 10 * 200 ) + ( 15 * 380 ) + ( 15 * 550) + (84 *

450 ) + ( 24 * 400 ) + (30 * 200)

= RS 98700/-

Machining cost = Rs 98700/-

48
Design cost = Total design hours cost/hr

= 72 500

= Rs 36000/-

Tool assembly = Assembly hr labor cost

= 8 * 150

= Rs 1200/-

Maintenance cost = Rs 35000/-

Standard items cost = Rs 6000/-

Total cost = (raw material cost + Machining cost + Design cost + Standard items cost +
Maintenance cost + Tool assembly cost + Trial cost)

= (45000+98700+3600+6000+35000+1200+4000)

= Rs 2,01,500/-

49
7. RESULTS
Progressive tool for counter weight clip for wheel balancing has been designed
successfully.

Calculated tonnage is 7 tons which required for producing the counter weight clip from
this tool.

Theoretical and Analytical deflection and stress valves are formulated.

The estimated tool cost Rs 2,01,500.

FUTURE SCOPE

Automatic feeding of stock strip can be adopted to increase production rate.

50
REFERENCES
1. Ch.Mastanamma, K.Prasada Rao , Dr. M.Venkateswara Rao, Design and Analysis
of Progressive Tool International Journal of Engineering Research & Technology
(IJERT) Vol. 1 Issue 6, August 2012.

2. J.C. Choi, Chul Kim.,A compact and practical CAD/CAM system for the blanking or
piercing of irregular shaped-sheet metal products for progressive working Journal of
Materials Processing Technology, Volume 110, Issue 1, March 2001 .

3. Sung-Bo Sim, Sung-Taeg Lee, Chan-Ho Jang, A study on the development of center
carrier type progressive dies for U-bending part process Journal of Materials
Processing Technology, Volumes 153154, November 2004.

4. S. Kumar, R. Singh A low cost knowledge base system framework for progressive die
design Journal of Materials Processing Technology, Volumes 153154, 10 November
2004.

5. Raja shakarappa, Analysis and simulation of progressive die- International Journal

of Engineering Research & Technology (IJERT) 03 | May-2014.

6. Vinay Kumar A V, D Ramegowda, Design of progressive press tool for an alpha

meter component International Journal of Engineering Research & Technology (IJERT)
06 | June-2015.

7. Vrushabh Mahaveer Ghosarwade, Chandradharappa, Finite Element Analysis of

progressive die International Journal of Engineering Research & Technology (IJERT)
09 December-2015.

8. Tool engineering parameters book; Indian society of tool engineers.

51