Technical Report on Slip Free Sheet

Place: Belgaum, Date: 1st Dec 2010 to 11th Dec 2010

 
Diamond Metal Screens, Udyambag, Belgaum
Mr. Satish M Patil – Technical Director
Mr. Alhad S Patil – Technical Manager
 

JAL
Mr. Utpal Upadhyay.

Machine Detail
Make:- Trumpf
Model :- Tru Punch 3000
Type:- Press Punch
Sheet Handling capacity :- 3000mm x 1500mm
Max Tonnage of machine :- 18T

Tool Detail
Tool type :- Punch with Stripper
Punch size :- 28.5mm x 10mm
Die Size :- 28.5mm x 10mm
Clearance :- NIL

1
Tool Rectification
 The clearance between punch and die was not maintained resulting in
excessive load on machine.

 It was suggested to give a clearance of 0.25 mm per side on Punch.

 A radius of 0.5mm should be provided around the punch for avoiding sharp
edge.

 Material (D2, Die Steel) suggested for punch & Die.

 Hardness of Punch & Die was suggested up to 50 - 55 HRC.

 Punch should be more harder than Die.

2
Tool Detail
Punch Holder

PU, Previously height

was 8 mm, modified to 6
mm

Punch

sharp corner changed to

Punch Detail
chamfer of 1x30⁰
Punch profile size
27.5mmx9.5mm Die, Profile size
28.5mmx10mm

3
Trial 1
 After Correction on Tooling Trial was held.
 Load on the machine was minimized after necessary rectification
on tooling.

 The warpage on first trial was observed 450mm.

4
Rectification on tool & Pitch of profile
 To control the warpage the pitch was changed from 31.2 mm to 33.5 mm.

 A proper chamfer of 1 x 30⁰ provided around the punch.

 Nesting of the profiles were rearranged as per modified pitch.

 Actuation of the stripper was increased 2mm by decreasing the PU (Poly

Urethane) height to provide better grip while punching on the sheet .

 Two Different punching sequence was decided for trial. One is Horizontal
punching and another is From centre to outer punching.

 Instead of full sheet two pieces where sheared from the sheet having size of
1250x500 mm for trial.

5
Trial 2
 After Re correction of tool and pitch the warpage decrease to13mm and
further after rolling up to 6mm which is under tolerance.

Before Rolling Process After Rolling Process

6
Operation & Tooling Detail

• Final Punch & Die Detail

Punch size :- 27.5mm x 9mm

Die Size :- 28.5mm x 10mm
Clearance :- 0.25 mm
PU Height :- 5 mm
Chamfer of 1 x 30⁰ on punch

• Pitch between profile should be 33.5mm.

• Punching pattern will be horizontal punching.
• All the parameter of machine at the time of successful trial were noted and
discussed with Mr. Shreekant (Project leader) and agreed to be strictly followed in
further process.

7
Conclusion

CHECK SHEET FOR SLIP FREE SHEET

Sl No Description Parameter Tol. Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
1 LENGTH 3200 + 2 /- 0 3204/3205 2203/2204      
2 WIDTH 1250 + 2 /- 0 1250/1251 1250/1250      
3 EMBOSS HEIGHT 1.25 ±0.2 1.1/1.12 1.25/1.28      
4 PITCH (HORIZONTAL) 33.5 ±0.1 ok ok      
5 PITCH (VERTICAL) 33.5 ±0.1 ok ok      
6 DIAGONAL LENGTH 1 3436 + 3 /- 0 3437 2536      
7 DIAGONAL LENGTH 2 3436 + 3 /- 0 3440 2535      
Remark:- sample 2 having size of 2200x1250 mm

 Each of the above characteristics was discussed with Mr. Satish Patil (Technical Director)
and mutually agreed to be maintained.
 Leveling has to be done on each sheet after punching.
 Shearing of sheet before punching should be done for maintaining the sheet size (3200mm x
1250mm) & diagonal length.
 Proper packaging to be done for avoiding any material damages / scratches.