Project Die Design Tooling UTM 20112012
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Transcript of 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
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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)
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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
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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
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2.2.2 Slotting (Square Fillet Feature)
Perimeter = 74 mm (measured using UG software)
Area to be Cut = Perimeter x Thickness
= 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
Area to be Cut = Perimeter x Thickness
= 62.83 mm x 0.5 mm
= 31.42 mm2
Piercing Force = SR x A
= 32 kgf/mm2x 31.42 mm
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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
Area to be Cut = Perimeter x Thickness
= 19.85 mm x 0.5 mm
= 9.93 mm2
Piercing Force = SR x A
= 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
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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
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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
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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