Project Die Design Tooling UTM 20112012

7/30/2019 Project Die Design Tooling UTM 20112012

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SMR 4712

TOOLING FOR PRODUCTION

GROUP ASSIGNMENT: DIE DESIGN

2011/2012-SEM 1

LECTURER

PM ZAINAL ABIDIN

SECTION 02

NO. GROUP MEMBERS MATRIX NO

Faculty of

MechanicalEngineering


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TABLE OF CONTENTS

CHAPTER TITLE PAGE

1 INTRODUCTION 1

1.1 Part 1

1.2 Station and Operation Sequence 2

2 CUTTING FORC 3

2.1 Station One 3

2.1.1 Blanking (Oval Contour) 3

2.1.2 Piercing (2 holes of 4 mm) 4

2.2 Station Two 5

2.2.1 Embossing (Rectangular Offset Embossing) 5

2.2.2 Slotting (Square Fillet Feature) 6

2.3 Station Three 6

2.3.1 Embossing (5 Interior Offset Emboss of 12) 7

2.3.2 Embossing (2 Interior Offset Emboss of 16) 8

2.3.3 Piercing (5 holes of 4 mm) 9

2.3.4 Piercing (2x Pre-pierced Holes) 10

2.3.5 Beading (V-Bead) 12

2.4 Station Four 13

2 4 1 E tr ding 13


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4 PUNCH AND DIE 16

4.1 Clearance 164.2 Determining Size 16

4.2.1 Station One 16

4.2.2 Station Two 17

4.2.3 Station Three 18

4.2.4 Station Four 19

5 DIE COMPONENT 20

5.1 Thickness of Punch Holder and Die Holder 20

5.1.1 Station 1 20

5.1.2 Station 2 21

5.1.3 Station 3 22

5.1.4 Station 4 23

6 PRESS CAPACITY 24

6.1 Calculation for Press Capacity of Each Station 24

7 SCRAP STRIP LAYOUT 25

7.1 The Scrap Strip Layout 25

7.2 Scrap Strip Allowances 25

7.3 Strip Area per Blank Calculations 26

7.3.1 Single Row, One Pass Positioning 26

7.3.2 Number of Blanks per Strip 26

7.3.3 End Waste of Single Pass Strip 27


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CHAPTER 1

INTRODUCTION

1.1 Part

Assumption Made: Material is made of Soft Steel 0.3% C

Shear Resistance (SR) = 32 kgf/mm2

Tensile Strength (TS) = 40 kgf/mm2

Thickness = 0.5 mm

1


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1.2 Station and Operation Sequence

Station Operation Feature

Station 1 Blanking Blank Contour

Piercing 2x 4mm

Station 2 Emboss Rectangular Offset Emboss

Slotting 2x Square Fillet

Station 3 Emboss 5x 14mm

2x 16mm

Piercing 5x 4mm

2x 3.16mm

Beading 1x 83mm V Bead

2x 43mm V Bead

Station 4 Extruding 2x 2.5mm Wall

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CHAPTER 2

CUTTING FORCE

2.1 Station One

2.1.1 Blanking (Oval Contour)

3


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Blanking Force = SR x A

= 32 kgf/mm2x 316.42 mm

2

= 10125.44 kgf

2.1.2 Piercing (2 holes of 4 mm)

Perimeter = 2 x 2r

= 2 x 2 x 2mm

= 25.13 mm

Area to be Cut = Perimeter x Thickness

= 25.13mm x 0.5 mm

= 12.57 mm2

4


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2.2 Station Two

2.2.1 Embossing (Rectangular Offset Embossing)

Perimeter = 315.41 mm

Embossing Force = TS x t x L

= 40 kgf/mm2

x 0.5 mm x 315.41mm

= 6308.2 kgf

5


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2.2.2 Slotting (Square Fillet Feature)

Perimeter = 74 mm (measured using UG software)


= 74 mm x 0.5 mm

= 37 mm2

Piercing Force = SR x A

= 32 kgf/mm2x 37 mm

2

= 1184 kgf

Total Cutting Force at Station Two = 6308.2 kgf + 1184 kgf

= 7492.2 kgf

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2.3.1 Embossing (5 Interior Offset Emboss of 12 mm)

Sectional View of Interior Offset Emboss

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2.3.2 Embossing (2 Interior Offset Emboss of 16 mm)

Sectional View of Interior Offset Emboss

Perimeter = 2 x 2r

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2.3.3 Piercing (5 holes of 4 mm)

Perimeter = 5 x 2r

= 5 x 2 x 2mm

= 62.83 mm


= 62.83 mm x 0.5 mm

= 31.42 mm2


= 32 kgf/mm2x 31.42 mm

2

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2.3.4 Piercing (2x Pre-pierced Holes)

Comparing from both diagram above and determined the parameter:

A = 1.5 mm B = 4.5 mm h = 2.5 mm BR = 1.0 mm

Determine BA from Table:

Material Thickness = 0.5 mm

Bending Radius = 1.0mm

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By taking Interpolation BA = {[(1.29-0.97) / (1.50/0.75)] x (1.5-1)}+0.97 = 1.08

Determined Pre-pierced Holes Diameter:

Dpre-pierce = 2[B-(A+h-BA)]

= 2 [4.5mm (1.5mm + 2.5mm 1.08)]

= 3.16 mm

Piercing Force:

Perimeter = 2 x 2r

= 2 x 2 x (3.16/2) mm

= 19.85 mm


= 19.85 mm x 0.5 mm

= 9.93 mm2


= 32 kgf/mm2 x 9.93 mm2

= 317.68 kgf

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2.3.5 Beading (V-Bead)

Perimeter = 361.8 mm

Beading Force = TS x t x L

= 40 kgf/mm2

x 0.5 mm x 361.8 mm

= 7236 kgf

Total Cutting Force at Station Three = 3770 kgf + 2010.6 kgf + 1005.31 kgf +

317.68 kgf + 7236 kgf

= 14339.59 kgf

12


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2.4 Station Four

2.4.1 Extruding

Perimeter = 2 x 2r

= 2 x 2 x 3.5mm

= 43.98 mm

Extruding Force = TS x t x L

= 40 kgf/mm2

x 0.5 mm x 43.98mm

= 879.65 kgf

Total Cutting Force at Station Four = 879.65 kgf

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CHAPTER 3

STRIPPER

3.1 Stripping Force

When sheet metals are punched or blanked, the metal surrounding the punch steel

clings tightly and must be removed by some mechanical means.

Harder and thinner metals require very small stripping forces, and in some

instances none at all. Most die design rules recommend a stripper capable of exerting 10

percent of the cutting force. Technique Of Press Working Sheet Metal, 1974

General rules regarding stripping force are

1. Softer metals need higher force2. Smaller clearances need higher force3. Cutting near sheet edge required less force since the sheet can be deflected away

f h h

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3.2 Calculation of Stripping Force

Stripping Force = 0.1 x Cutting Force

Station Cutting Force (kg f) Stripping Force (kg f)

1 10527.56 1052.8

2 7492.2 749.2

3 14339.59 1434.0

4 879.65 88.0

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CHAPTER 4

PUNCH AND DIE

4.1 Clearance

Assumption: Material is made of Soft Steel 0.3% C

Thickness = 0.5 mm ~ 0.020 inch

By referring to the table at page 228 of 3

rd

Edition Die Design FundamentalC = 0.0011 inch ~ 0.02794 mm

4.2 Determining Size

Operation Die Size Punch Size

Blanking Part Size Part Size 2C

Piercing Part Size + 2C Part Size

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Piercing: Die Size = 4mm + 2(0.02794) = 4.056 mm

Punch Size = 4mm

Die Punch

4.2.2 Station Two

Slotting: Die Size = Part Size + Offset Clearance

Punch Size = Part Size

Die Punch

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4.2.3 Station Three

Piercing: Die Size = 4mm + 2(0.02794) = 4.056 mm

Punch Size = 4mm

Die Punch

Piercing: Die Size = 3.16mm + 2(0.02794) = 3.216 mm

Punch Size = 3.16mm

Die Punch

`

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4.2.4 Station Four

Extruding: Die Size = 6mm + 2(0.02794) = 6.056 mm

Punch Size = 6mm

Die Punch

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CHAPTER 5

DIE COMPONENT

5.1 Thickness of Punch Holder and Die Holder

5.1.1 Station 1

Blanking Force (Blank Contour) = 10125.44 kgf

Piercing Force (2x 4mm) = 402.12 kgf

Total Cutting Force at Station 1 = 10527.6 kgf

= 10.5276 tonnes

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Punch Holder Thickness = 44.50 mm

Die Holder Thickness = 51.00 mm

5.1.2 Station 2:

Embossing Force (Rectangular Offset) = 6308.2 kgf

Piercing Force (2x Square Fillet) = 1184 kgf

Total Cutting Force at Station 2 = 7492.2. kgf

= 7.4922 tonnes

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5.1.3 Station 3:

Embossing Force (5x 14mm) = 3770 kgf

Embossing Force (2x 16mm) = 2010.6 kgf

Piercing Force (5x 4mm) = 1005.31 kgf

Piercing Force (2x 3.16mm) = 317.68 kgf

Beading Force (3x V-bead) = 7236 kgf

Total Cutting Force at Station 3 = 14,339.59 kgf

= 14.34 tonnes

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5.1.4 Station 4:

Extruding Force (2x 2.5mm Wall) = 879.65 kgf

Total Cutting Force at Station 4 = 879.65 kgf

= 0.88 tonnes

Punch Holder Thickness = 31.75 mm

Die Holder Thickness = 38.10 mm

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CHAPTER 6

PRESS CAPACITY

6.1 Calculation for Press Capacity of Each Station

Press Capacity = Total Cutting Force + Stripping Force

StationCutting Force

(kg f)

Stripping Force

(kg f)

Press Capacity

(kg f)

1 10527.56 1052.8 11580.36

2 7492.2 749.2 8241.42

3 14339.59 1434.0 15773.55

4 879.65 88.0 967.62

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CHAPTER 7

SCRAP STRIP LAYOUT

7.1 The Scrap Strip Layout

In this design, we had chosen the single-row one-pass layout method for our scrap

strip layout. For part positioning, we choose narrow-run positioning. All the calculation

below will use this scrap strip criteria.

7.2 Scrap Strip Allowances

A

AA

AA

25

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Curved outlines: For these, dimensions A are given a minimum allowance of 70%

of the strip thickness T.

T = 0.5mm

A = 70% of 0.5mm

A = 0.35mm

7.3 Strip Area per Blank Calculations

7.3.1 Single Row, One Pass Positioning

As = AB

Where:

As = area of the strip per one blank

A = width of strip

B = length of one piece

As = 125.7 256.35

As = 32223.195 mm2

7.3.2 Number of Blanks per Strip

N =()

+ 1

26

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7.3.3 End Waste of Single Pass Strip

D = S [B (N1) + X + Y + 2E]

D = 1500 [256.35(51) + 128 + 128 + 2(0.35)]

D = 217.9mm

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Appendices

1. Scrap Strip Layout2. Die Set Station 13. Die Set Station 24. Die Set Station 35. Die Set Station 4


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PART DRAWING


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STATION ONE


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STATION TWO


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STATION THREE


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STATION FOUR

Project Die Design Tooling UTM 20112012

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