GUJARAT TECHNOLOGICAL UNIVERSITY

Chandkheda, Ahmadabad.

A.D. PATEL INSTITUTE OF TECHNOLOGY,

KARAMSAD
An IDP
Project Report
On

“Design and Analysis of Punch/tool for 200 ton Power Press”

Team Id - 73090

B. E. Semester – VII
(Mechanical Engineering)
Developed by:-
Group:-
1. Makwana Mukul K (160010119038)
2. Mohit S Naik (160010119042)
3. Nayan A Verma (160010119046)
4. Panicker Anish S (160010119055)

Guided by:-
Prof. Sankalp B Bhatia
Prof. Ayanesh Y Joshi

Head of the Department

Dr. Mitesh I Shah
Academic year
(2019-2020)
 COLLEGE CERTIFICATE

Date:

This is to certify that the project entitled “Design and Analysis of a punch/tool for 200 ton power
press” has been carried out by Makwana Mukul (160010119038), Mohit Naik (160010119042),
Nayan Verma (16001011946) and Anish Panicker (160010119055) under my guidance in partial

fulfillment for the degree of Bachelor of Mechanical Engineering (7 th Semester) of Gujarat

Technological University, Ahmedabad during the academic year 2019-20.

Internal Guide Head of Department

Prof. Sankalp B Bhatia Dr. Mitesh I Shah

Seal of Institute
 Undertaking of Originality of Work

We hereby certify that we are the sole authors of this IDP project report and that neither
any part of this IDP project report nor the whole of the IDP project report has been
submitted for a degree by other students to any other University or Institution.

We certify that, to the best of our knowledge, the current IDP/UDP project report does
not infringe upon anyone’s copyright nor violate any proprietary rights and that any
ideas, techniques, quotations or any other material from the work of other people
included in our IDP project report, published or otherwise, are full acknowledged in
accordance with the standard referencing practices. Furthermore, to extent that we have
included copyrighted material that surpasses the boundary of fair dealing within the
meaning of the Indian Copyright (Amendment) Act 2012, we certify that we have
obtained a written permission from the copyright owner(s) to include such material(s)
in the current IDP/UDP project report and have included copies of such copyright
clearances to our appendix.

We declare that this is a true copy of our report, including any final revisions, as
approved by our supervisors.

Date:

Place:

Enrollment No. Name Signature

(160010119038) Makwana Mukul

(160010119042) Mohit Naik

(160010119046) Nayan Verma

(160010119055) Anish Panicker

INDEX

Title Page No.

ACKNOWLEDGEMENT 3

CHAPTER 1: INTRODUCTION

1.1 Problem Summary 4

1.2 Aim and Objective of the Project 4

1.3 Problem Specifications 5

1.4 Brief literature review 6

1.5 Plan of project 7

1.6 Materials / Tools required 7

CHAPTER 2: DESIGN
2.1 AEIOU, Empathy, Ideation and PD canvases 8

CHAPTER 3: IMPLEMENTATION
3.1 Snapshot/Picture of Modelling Image/Diagrams 13

CHAPTER 4: SUMMARY

4.1 Conclusion 17

4.2 Advantages 17

4.3 Scope of Project 17

4.4 Features of Project 17

REFERENCES 18
ACKNOWLEDGEMENT

We, the members of project are highly thankful for introducing such an exciting
way of developing our knowledge regarding project development. We take pleasure
in presenting the report on development our project entitled as - Design and
Analysis of a Punch/Tool for 200-Ton Power Press.

First and foremost, we would like to express our deepest sense of gratitude and
sincere thanks to our Project guide Prof. Sankalp B Bhatia and Prof. Ayanesh Y
Joshi for his support and timely co-operation.

We are extremely grateful for the help and support from other faculties and staff,
who directly or indirectly helped us in project.

At last, we are thankful to Dr. Mitesh I Shah, Head of Department, Information

Technology for his constant encouragement, co-operation and support.

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CHAPTER 1: INTRODUCTION

1.1 Problem Summary

Punching being an integral operation of many manufacturing processes requires or calls for better
tooling features and setups for obtaining desired output.

Now, punching works on the principle of shearing, thus need for a material with optimum strength
and higher toughness becomes a necessity. Incase the tool specifications like tool design, material,
tool tip shape is not appropriately chosen, this results in the wear and tear of the tool or the
workpiece which ultimately leads to the failure of the system. Due to this the tool may lose its
performance and dimensional qualities which further decreases the productivity and efficiency of
the machine.

As per the project manager’s guidance, the company experiences frequent tool failure during the
punching operations i.e., while manufacturing various types of chains the tool shears off within
60-70% of its average lifetime.

1.2 Aim and Objective of the project

Aim
Our primary goal is to design a punch tool for a 200-ton power press with better strength and
material qualities that resists shear stress under various loading conditions.

Objectives

 Reduce lead time and material handling

 Reduce purchase of new punch tool
 To Increase productivity
 Increase the quality of chains produced

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1.3 Problem Specification

Among general industrial equipment, machine parts with punching are required to have wear
resistance and durability, especially for the tools operating under high stress conditions. As
mentioned in statement 1.1 the punch tool currently used gives result only about 60-70% of its
average life cycle. This causes the tool to be replaced frequently, which increases the time spent
on assembly of tool, and also increases the quantity of tools used for operation which causes in
increase in inventory cost.

During the punching operations on chain links made of steel grades like EN-8, EN-19, etc. A heavy
load of 200 ton is to be applied to achieve the required punch. But such high force leads to
concentration of stress on the punch head, which leads to wear of punch from that particular point.

Images of worn out punches are taken from the industry are given below.

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1.4 Literature Review
We have read certain documents and reviews over the technology that we are going to use, the
past projects over this and also refers to some videos to innovate the past projects. The following
are the different literatures that we referred:

No. Title Author(s) Topic

1. Punch Performance Can Be Arnold H. Deutchman Coating
Improved With Precision
Coatings
2. Comparison of HCHCr Steel and K. Nagendran , S. Punch materials
Carbide Punch and Die Increase its Sathish and J. David
Strength and Life by Tin & Rathnaraj
Ceramics coating
3. Study and Analysis of Press Tool Dr. D. N. Raut Punch design
Design
4. Design study of the geometry of U.P.Singh, Punching and
a punching/blanking tool A.H.Streppel, Blanking operations
H.J.J.Kals

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1.5 Plan of Work

Initially, we fetched the data regarding existing tool material, design, setup, etc. We also collected
the data regarding various workpiece materials and their designs as well as working conditions
prevailing in the company.

After collecting the data and analyzing it, we found problems related to existing tool material and
its design for which we searched for various solutions.

As a solution, we provided the company a new tool design with few dimensional modifications.
As an option we also suggested for a new tool material having better properties compared to
existing material

1.6 Tools Required

Our system requires following tools:

(1) Worn out punch (for analysis)

(2) Actual tool dimensions
(3) Simulation Software

Designing Software: Solid works, Creo parametric

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DESIGN ENGINEERING CANVASES

2.1 AEIOU Canvas:

Fig 2.2

The AEIOU canvas helps to get the ideology about five main elements: Activities, Environment,
Interaction, Objects, and Users.

Activities
Activities are the task and methods or actions that are related to the users and those that would be
available to them.

Environment
Environment is nothing but the arena or platforms in which the activities would be used and
implemented.

Interaction
Interaction provides the activities that occur between people and between people and the
environment. Interaction between our product and user will provide the user features.

Objects
Objects are the building blocks of the environment and occur in the environment with
respective to their usage.

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Users
Users are the people who use and develop the system, that is the intended people or group for
which the product is

2.2 Empathy Summary Canvas:

Fig 2.3
2.3 Ideation Canvas:

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 Fig 2.4

In ideation canvas we try to generate, develop and communicate about new ideas related to
the product and try to improve it. Cases that we need to ideate are:

People
In this case we grouped the people for which we are interested in solving the problem.

Activities
In this case we mentioned the activities that are required by the people and the features
that will be provided the users.

Situation/Context/Location
This case is related to activities. Every activity that is mentioned in the ideation canvas may be
done in various situations, locations and contexts. Our system will be used for shopping.

Props/Possible Solutions
In this case all the possible ideas and solutions are grouped in accordance to the defined project
and challenges in the project.

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2.4 Product Development Canvas:

Fig 2.5

Product Development Canvas is used to design, challenge and develop the product strategy. It
consists of:

Purpose
The purpose groups the main idea over which the project is defined.

People
Here the specific group of people that are closely related to the product are grouped.

Product Experience
Here the product feedback or review and the problems solved is grouped. The product was
feasible in terms of the Cost, intuitive, Easy to use.

Product Function
Here the main function that solves the problem is mentioned.

Product Features
Here the fundamental features of the project are grouped. The important features of the project
include User friendly and time effective.

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Components
Here the components that will be used are grouped.

Customer Revalidation
Here the requirements of the customer are taken into considerations. The customer wanted the
system to be cost effective, easy to use and the most important was the life of the product.

Reject, Redesign & Retain

This part of the canvas depends upon the customer satisfaction, and the product features would be
required to redesign and retain if rejected by the customer.

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CHAPTER 3: IMPLEMENTATION

The implementation phase consisted of designing the punch with its actual dimensions and
applying von mises theory and calculating the shear stress acting on the tool from the region where
it breaks the most.

Then as per study and observation the taper angle of the tool which was previously 45⁰ was varied
to obtain increase in the resistance of shear. Hence the value of the taper angle was increased and the results
were studied. This simulation was carried out in Solid works and the results are given below.

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3.2 Diagrams

(a) Actual diagram of punch

Fig1. Punch having 45⁰ taper angle

We applied the Von mises theory of failure because it states the failure criterion for ductile material
subjected to uniaxial loading. After measuring the dimensions of the actual and creating a part
model in solid works shown in Fig2, the part was subjected to 200 Ton force which showed
accumulation of stress in the neck of punch.

This stress region is indicated in various colors, red being the most affected region and blue being
the least. By various studies done to reduce the stress affecting, we opted to solve it by reducing
the taper angle at the neck, by this way the punch head will become more rigid from the joint.
Which lowers the probability of wear without any major changes in dimensions of the whole tool.

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 Fig2. Image of punch carrying dimensions

Fig3. Stress analysis of punch for 45⁰ taper angle

After 45⁰ the punch angle was increased to 60⁰ and again stress was calculated and noted.

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(b) Modification 1: Punch angle is 60⁰

Fig4. 60⁰ taper angle with other dimensions

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 Fig5.Stress analysis of tool for 60⁰ taper angle

As seen in Fig5. By increase in the taper angle, instead of stress being accumulated at one region
it is distributed along the whole surface area of the punch. Here it has to be noted that by increasing
the taper angle there is minor decrease in the diameter of punch body.

By difference of angle to 60⁰ from 45⁰ shows the change of radius from 24mm to 21.04mm as seen
Fig4.

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(c) Modification 2: For this the punch angle is taken 70⁰

Stress analysis of tool for 70⁰ taper angle

20
(d) Modification 2: For this the punch angle is taken 70⁰

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CHAPTER 4: SUMMARY

4.1 Conclusion

Blanking is one of the inevitable operations that cannot be avoided most often in the industries. If
the life of the blanking tool can be improved somehow, then the reliability and the quality of the
components will also be improved. In order to do that the rigidity must be maintained throughout
its life time. Based on the study of punch and other critical components that are prone to failure
using FEM, the durability is found to be improved at elevated temperature.

From the above results obtained from the implementation of our data, we found that for the punch
provided by increasing the taper angle to some extent the stress concentration at a region can be
reduced by which the wear of punch can be reduced significantly. But also it has to be noted that
the angle can only be extended up to certain limit because by changing there is change in the
diameter of the punch. Which may lead to huge dimensional changes and which may lead to
variations in the whole design of the punch.

4.2 Advantages
 Overall cost is reduced as the rework cost is reduced.
 Time of rework is reduced.
 Quality of the punch is increased.

4.3 Future Scope

Our project was accepted by the industry and is providing better solution for them. This work can
be implemented in various fields of production engineering and it also provides platform for
further expansion by choosing a punch material having better properties then that of the currently
used material.




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REFERENCES:

1) A decision support for sheet metal blanking process parameter selection
[Journal of material Processing Technology]

2) A mechanical device for measuring the displacement and Rotation of a blanking or forging press
[Journal of material Processing Technology]

3) Blanking tool wear modeling using the finite element method. The prediction of tool wear in sheet metal
blanking/punching processes is investigated in this paper using the finite element method
[https://www.researchgate.net/publication/232399518_Blanking_tool_wear_modeling_using_the_finite_e
lement_method]

4) Design of Progressive Draw Tool
[http://www.ijsrp.org/research-paper-0813/ijsrp-p2032.pdf]

Design study of the geometry of a punching blanking tool
[https://www.sciencedirect.com/science/article/pii/0924013692902703]

6) Improving the wear resistance of tools for stamping

[https://www.sciencedirect.com/science/article/abs/pii/S0043164810002528]

7) Press tool Design by P.H. Joshi

8) Wear of advanced cemented carbides for metal forming tool materials

[https://www.sciencedirect.com/science/article/abs/pii/S0043164803005854]

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