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Design and Analysis Progressive Tool Design

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Design and Analysis Progressive Tool Design International Journal of Research ISSN NO:2236-6124 DESIGN AND ANALYSIS PROGRESSIVE TOOL DESIGN #1SETTI NOOKARAJU, PG STUDENT #2MRS.VENKATA LAKSHMI, ASSISTANT PROFESSOR DEPARTMENT OF MECHANICAL ENGINEERING KAKINADA INSTITUTE OF ENGINEEING AND TECHNOLOGY, KAKINADA ABSTRACT Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the material. Thicknesses can vary significantly, although extremely thin thicknesses are considered foil or leaf, and pieces Fig.1.Shearing Operations: Punching, Blanking and thicker than 6 mm (0.25 in) are considered plate. Perforating Design of sheet metal dies is a large division of tool engineering, used in varying degree in manufacturing industries like automobile, electronic, house hold wares and in furniture. In our project we have learnt about different sheet metal dies, sheet metal operations and studied the design of progressive press tool. I. INTRODUCTION TO SHEETMETAL Fig.2.Common Die-Bending Operations Various Bending Operations Introduction Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the material. Thicknesses can vary significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate. Sheet metal processing Fig.3.Schematic illustration of a stretch-forming process. The raw material for sheet metal manufacturing processes is the output of the rolling process. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin and very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is to cut the correct shape and sized ‘blank’ from larger sheet. Fig.4. Schematic of the Drawing process. Volume 7, Issue XII, December/2018 Page No:474 International Journal of Research ISSN NO:2236-6124 Dies and Punches Simple- single operation with a single stroke Compound- two operations with a Fig.5. Eight-roll sequence for the roll forming of a box single stroke channel Combination- two operations at two stations Finishing processes Progressive- two or more operations at Material properties, geometry of the starting two or more stations with each press material, and the geometry of the desired final product stroke, creates what is called a strip play important roles in determining the best process. development Equipments Basic sheet forming operations involve a press, punch, or ram and a set of dies Presses Mechanical Press - The ram is actuated using a flywheel. Stroke motion is not uniform. Ref fig.6 Hydraulic Press - Longer strokes than Fig 8 Progressive dies Punches mechanical presses, and develop full force Tools and Accessories throughout the stroke. Stroke motion is of The various operations such as cutting, uniform speed, especially adapted to deep shearing, bending, folding etc. are performed drawing operations. Ref fig.7 by these tools. Marking and measuring tools Steel Rule - It is used to set out dimensions. Try Square - Try square is used for making and testing angles of 90degree Scriber – It used to scribe or mark lines on metal work pieces. Divider - This is used for marking circles, arcs, laying out perpendicular lines, bisecting lines, etc Fig.6 Mechanical Press Marking and measuring tools Cutting Tools Straight snip - They have straight jaws and used for straight line cutting. Ref fig.10 Curved snip - They have curvedblades Fig.7 Hydraulic Press for making circular cuts. Ref fig.10a Volume 7, Issue XII, December/2018 Page No:475 International Journal of Research ISSN NO:2236-6124 Grade 316 offers more corrosion resistance and strength at elevated temperatures than 304. It is commonly used for pumps, valves, chemical equipment, and marine applications. Available finishes are #2B, #3, and #4. Grade 410 is a heat treatable stainless steel, but does not offer as good corrosion resistance. It is commonly used in cutlery. The only available finish is dull. fig.9.Straight snip Aluminium The four most common aluminium grades available as sheet metal are 1100-H14, 3003-H14, 5052-H32, and 6061-T6. Grade 1100-H14 is commercially pure aluminium, so it is highly chemical and weather resistant. It is ductile enough for deep drawing and weldable, but low strength. It is commonly used in chemical Fig.10. Curved Snip processing equipment, light reflectors, and jewelry. Striking Tools Mallet - It is wooden-headed hammer of round or Grade 3003-H14 is stronger than 1100, while rectangular cross section. The striking face is made maintaining the same formability and low cost. It is flat to the work. A mallet is used to give light blows corrosion resistant and weldable. It is often used in to the Sheet metal in bending and finishing. Ref stampings, spun and drawn parts, mail boxes, fig.11 cabinets, tanks, and fan blades. Grade 5052-H32 is much stronger than 3003 while still maintaining good formability. It maintains high corrosion resistance and weldability. Common applications include electronic chassis, tanks, and pressure vessels. Grade 6061-T6 is a common heat-treated structural aluminium alloy. It is weldable, corrosion resistant, and stronger than 5052, but not as formable. Note that it loses some of its strength when welded. It is Fig.11 Types of Mallets used in modern aircraft structures, generally replacing the older 2024-T4 alloy. II. MATERIALS GAUGE Stainless steel The sheet metal gauge (sometimes spelled gage) The three most common stainless steel grades indicates the standard thickness of sheet metal for a available in sheet metal are 304, 316, and 410. specific material. For most materials, as the gauge number increases, the material thickness decreases. Grade 304 is the most common of the three grades. It offers good corrosion resistance while maintaining Sheet metal thickness gauges for steel are based on formability and weldability. Available finishes are the weight of steel, allowing more efficient #2B, #3, and #4. Note that grade 303 is not available calculation of the cost of material used. The weight in sheet form. of steel per square foot per inch of thickness is 41.82lb (18.96kg), this is known as the Manufacturers' Standard Gage for Sheet Steel. For Volume 7, Issue XII, December/2018 Page No:476 International Journal of Research ISSN NO:2236-6124 other materials, such as aluminium and brass, the The variety in press specification gives the thicknesses will be different. liberty to the designer to think innovative. The Safety Provisions has reduced the accidents and the productivity has been increased. “Simulation Software’s” give the designer freedom from taking risky decisions. The use and availability of Standard Elements has reduced the design and development period The concept of “Flexible Blank Holder” has given the scope to control the flow of the material in a better way. Hardened and toughened new martial & heat treatment process made the design easy. The latest machining process made the complex designs made easy, like wire cut, EDM, Profile Grinding. Four factors are essential contributions to first class presswork are Good operation planning Excellent tool design Accurate tool design Knowledge press setting Design of any Press Tool involves the following Steps 1. Determination of force (Press Tonnage) required for the operation 2. Selection of Press for requisite force, work piece size and shape 3. Determination of shut height of the tool 4. Computing die thickness, and margins (minimum cross-section) 4. Drawing Strip Layouts and comparing Material utilization 6. Design of locating Elements 7. Selection of Locating Elements 8. Selection of Hardware 9. Drawing die plan and selection of pillar die set 10. Deciding punch length and mounting III. DESIGN OF SHEET METAL DIES 11. Finding Centre of Pressure and Checking INTRODUCTION scrap Disposal 12. Drawing Details Design of sheet metal dies is a large division of tool engineering, used in varying degree in manufacturing industries like automobile, electronic, TYPES OF PRESS TOOLS house hold wares and in furniture. There is no doubt that accuracy achieved by Press tools are commonly used in hydraulic and the new ideas in design and construction applied by mechanical presses to produce components at a high the press tool designer, coupled latest development productivity rate. Generally press tools are made in related fields made more productive, durable categorized by the types of operation performed and economical. using the tool, such as blanking, piercing, bending, These are forming, forging, trimming etc. The press tool will Volume 7, Issue XII, December/2018 Page No:477 International Journal of Research ISSN NO:2236-6124 also be speciopified as blanking tool, piercing tool, Shaving tool bending tool etc. Shaving removes a small amount of material around CLASSIFICATION OF PRESS TOOLS the edges of a previously blanked stampings or piercing. A straight, smooth edge is provided and Press tools are classified into: therefore shaving is frequently performed on instrument parts, watch and clock parts and the like. STAGE TOOLS Shaving is accomplished in shaving tools especially designed for the purpose. Blanking tool Bending tool When a component is produced with one single punch and die were the entire profile is cut in single Bending tools apply simple bends to stampings. A stoke is called Blanking tool. simple bend is done in which the line of bend is straight. One or more bends may be involved, and Piercing Tool bending tools are a large important class of pres tools. Piercing involves cutting of clean holes with resulting scrape slug. The operation is often called piercing, In Forming tool general the term piercing is used to describe die cut holes regardless of size and shape.
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