SUMMER TRAINING REPORT

HONDA SIEL CARS INDIA LTD.

SPL-1, Tapukara Industrial Area, Khushkhera Distt. Alwar, Rajasthan 301707. INDIA

PROJECT REPORT ON
Die Maintenance Study and Chip-Dent Reduction

TraineePrakul Bansal

MentorMr. Harsh Vardhan

Mr. Pankaj Shrivastava HOD, Press Shop -1-

Details of the Trainee:Name of Trainee Fathers Name Date of Birth Course Name & Trade Name of Institute / Collage Session Name of Guide (if any) Referred by Permanent Address E mail Contact No. Previous project details (If any):Project Name Name of the Organization Duration Details related to current project:Project Name Dept. / Section Training Duration Die Maintenance Study and Chip-Dent Reduction Press Shop 8th June to 20th July Production of Goods Trucks and Buses Ashok Leyland, Alwar 1 month 3/530, KALA KUAN, ALWAR Grvchaudhary01@gmail.com +91-7206108388 GAURAV CHAUDHARY Mr. RAM GOPAL CHAUDHARY 01-08-1991 B.Tech, Mechanical Engineering NIT KURUKSHETRA 2012-13 Mr. Harsh Vardhan

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Acknowledgement
Gratitude is the hardest of emotions to express often one doesnt find adequate words to convey the feeling of gratefulness. There were many people whom I would like to thank for their support. I sincerely feel that credit of this work could not be narrowed down to any one individual, by which I have achieved its completion. Words will not suffice to express my deepest feeling of sincerest gratitude to my revered Mentor Mr. Harsh Vardhan for his guidance, constructive criticism and inspiring attitude resulting in the successful completion of my Project. Some persons certainly have more capacity to help others and I should not loose any opportunity to extend my feeling of profound gratitude to Mr. Rakesh, Mr. Dipin, Mr. Mandeep, Mr. Puneet, Mr. Deepak, Mr. Abhishek, Mr. Shiv Narayan for unstinted encouragement which inspired me to do better. I wish to acknowledge the sincere co-operation and moral support rendered to me by HR Department. In the end it would not be out of place to express sincere thanks to my Parents for their moral support and encouragement.

(__________) Dated
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TO WHOM IT MAY CONCERN

This is to certify that GAURAV CHAUDHARY a student of National Institute of Technology, Kurukshetra has undertaken a summer training project on Die Maintenance Study and Chip-Dent Reduction under my guidance and mentorship. I assure all the contents, research work, analysis, and interpretations are genuine attempt on her/his part. This is also to certify that this project is neither submitted nor published else where.

I have ensured that this summer training report does not contain any information which will be detrimental to the interest of the company.

Mentor:Mr. Harsh Vardhan

HOD:Mr. Pankaj Shrivastava Press Shop

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Table of Contents
Sr. 1. 2. 3. Company profile Executive Summary Project 1:- Study of Die Maintenance a. Background of project work Repair Tools and Use of Standard Hand b. Tools c. Remedy Procedures for Press Die d. Die Design 4. Project 2:- Chip-Dent Reduction a. Background of project work b. Problem identification c. Situation analysis using 7 QC tools d. Countermeasure proposal 59-60 61-64 65 66 23-31 32-40 41-50 51-58 Description Page No. 6-15 16-22

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COMPANY LAYOUT & PROCESS FLOW

HONDA PRODUCTS
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HSCI PRODUCTS
Updated as on 2010

TO SHARE HONDA PHILOSOPHY

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The driving force behind Hondas growth was the leadership of its founders Mr. Soichiro Honda and Mr. Takeo Fujisawa. philosophy. The most valuable legacy which our founders gave to our company is Honda This Honda Philosophy will continue to serve as the basis of our daily business action and judgment for all companies and associates within the Honda Group. It is critical that Honda Philosophy be fully understood, respected, shared and translated into action by every Honda associate around the world. HONDA PHILOSPHY The Honda Philosophy expressed in this illustration shows the Company Principle, Management Policies and the Honda Way based upon the fundamental beliefs of Respect for the Individual and The Three Joys :

COMPAN Y
COMPANY PRINCIPLES PRINCIPL

ES

THE THREE JOYS RESPECT FOR THE INDIVIDUAL

HONDAS MISSION
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Respect for the Individual

Each individual is unique, independent and possesses initiative

Initiativ e
All associates are encouraged to take initiative while understanding that they must take responsibility for the results of those actions

Equalit y

Trust
The relationship among associates at HSCI to be based on mutual trust

All associates are treated fairly and equal opportunities given to each individual.

THE THREE JOYS JOYS

THE JOY OF BUYING
The joy of buying is achieved by providing products and services that exceed the needs and expectations of the customer.

THE JOY OF SELLING

The joy of selling is attained when those engaged in selling and servicing Honda products develop relationships with the customer based on mutual trust.

THE JOY OF CREATING

The joy of creating occurs when Honda Associates and Suppliers involved in the design, development , engineering and manufacturing of products recognize a sense of joy in our customers using the product and dealers selling them.

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MANAGEMENT POLICIES

anagement Policies

Company standards for carrying out Daily Operations are based upon the

Proceed always with ambition and youthfulness. Respect sound theory, develop fresh ideas and make the most effective use of time. Enjoy work, and encourage open communications. Strive constantly for a harmonious flow of work. Be ever mindful of the value of research and endeavor.

5S
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KAIZEN

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HONDA SIEL CARS INDIA, TKR PLANT

Honda Siel Cars India Ltd., (HSCI) was incorporated in December 1995 as a joint venture between Honda Motor Co. Ltd., Japan and Siel Limited, a Siddharth Shriram Group company, with a commitment to providing Hondas latest passenger car models and technologies, to the Indian customers. The total investment made by the company in India till date is Rs 1620 crores in Greater Noida plant and Rs 784 crores in Tapukara, Bhiwadi plant. HSCIS first state-of-the-art manufacturing unit was set up at Greater Noida, U.P in 1997. The green-field project is spread across 150 acres of land (over 6,00,000 sq. m.). The annual capacity of this facility is 100,000 units. The companys second manufacturing facility is in Tapukara, Rajasthan. This facility is spread over 600 acres and will have an initial production capacity of 60,000 units per annum, with an investment of about Rs. 1,000 crore. The first phase of this facility was inaugurated in September 2008.

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The companys product range includes Honda Jazz, Honda City, Honda Civic and Honda Accord which are produced at the Greater Noida facility with an indigenization level of 77%, 76%, 74% and 28% respectively. The CR-V is imported from Japan as Completely Built Units. Hondas models are strongly associated with advanced design and technology, apart from its established qualities of durability, reliability and fuelefficiency.

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KEY FEATURES OF THE TAPUKARA PLANT PHASE 1 PRESS FACILITY

The Press Facility comprising of 1500 ton tandem lead press and 3 other tandem press of 1000 ton each maintain a tact time of 7 seconds and is equipped with advanced features like Auto de-stack sheet feeder & online sheet cleaning Robotized part pick-up and transfer Safety sensors that stop robot and machine operation in case of breach of safety fence. Underground scrap conveyer.

MODERN POWER TRAIN UNIT

30% of the machines in the Power Train Unit have been procured from local suppliers Crankshaft operation. Unique Big end robotized cracking machine for connecting rod. line having GSN (Gas Soft Nitriding)

GREEN PLANT
The new plant is modeled on the lines of Hondas latest global plants with great emphasis on environment protection and safety. Zero Discharge Plant
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 25% of the land in plant with green cover

Plantation of 20,000 trees in 1st year. Maximum usage on Natural Lighting for energy saving and healthy environment.

Rain water harvesting.

ASSOSIATES
The new plant employed 250 associates in the starting which has reached up to 700 in the present year.

SUPPLIERS CLUSTER
The suppliers cluster is spread over 150 acres having space for 8 critical and bulky part suppliers. Proximity to the HSCIs car plant and use of most updated techniques and features by these suppliers will make the overall process of car production more efficient.

DEPARTMENTS IN HSCI TAPUKARA PLANT

Power Train Engine Control Parts Quality (PQ) Power Press Utility IPDD
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 PLC

INTRODUCTION TO PRESS SHOP

HSCI(TKR) is producing Sheet metal parts for car body. The department had automatic tandem press line with first press machine having capacity of 1500 tonnes followed by 3 Press machines with capacity of 1000 tonnes each. Besides this, Press line has 5 Robots for parts movement from one process to next process and a Destackfeeder assembly for automatic feeding of blanks in press line for processing.

RPSC supplies blanks as raw material as per PRT system controlled by Production Control Department. The blanks are stored and preserved press dept. end and loaded on the press line according to the plan. The blanks are processed in dies depending upon the number of operations and converted into parts. The parts are packed in trollies according to their packing standard after going through check on conveyer by online quality inspector. The repair parts are shifted to H/W area for repair and N/G parts put in red coloured scrap bin. The OK parts trollies are stocked at Trolley stock area. The PLC dept. receives the OK quality parts from trolley stock area according to dispatch plan. The parts are packed in PLC trollies from press production trollies according to their packing standard and delivered to GNU plant.

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Press dept. has sub dept. of Planning and Production, Quality Control, Machine Maintenance and Die Maintenance and New Model.

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PERSONAL PROTECTIVE EQUIPMENTS

Helmet

Goggles

Ear Plugs
Nose Mask

Gloves

Arm Sleeves

Boot Cover

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Safety Shoes

PARTS INTRODUCTION 2AP PRESS PART DETAILS

13 11 9 15 7 14

2PS

2AP

3 10 12

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SRNO

2PS PARTS NAME

2AP PARTS NAME

1. 2. 3. 4. 5. 6. 7 8. 9.

Hood Skin Hood Frame Front Fender R/L Panel Roof Side Panel RH Side Panel LH Panel Rear Inside Front Floor Rear Floor

Hood Skin Hood Frame Front Fender R/L Panel Roof Side Panel RH Side Panel LH Panel Rear Inside

Rear Floor

10.

Front Door Skin R/L

Front Door Skin R/L

11.

Front Door Panel R/L

Front Door Panel R/L

12.

Rear Door Skin R/L

Rear Door Skin R/L

13.

Rear Door Panel R/L

Rear Door Panel R/L

14. 15.

Tail Gate Skin 20 Tail Gate Frame

Tail Gate Skin Tail Gate Frame

DRAWING:
Drawing is a metal working process which uses tensile forces to stretch the sheet metal by which hollow shapes are formed.

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Die and punch are used in drawing operation. Drawing is usually done at room temperature, thus classified as a cold working process. The flow of material is controlled through pressure applied to the blank and lubrication applied to the die or the blank. If the form moves too easily, wrinkles will occur in the part. To correct this, more pressure or less lubrication is applied to the blank to limit the flow of material and cause the material to stretch or thin. If too much pressure is applied, the part will become too thin and break. Drawing metal is the science of finding the correct balance between wrinkles and breaking to achieve a successful part. Drawing leads to wrinkling and puckering at the edges where the sheet metal is clamped. This is usually removed by a separate trimming operation.

TRIMMING:
Trimming is the operation of cutting away excess metal in a flange or flash from a piece e.g. when holes are produced in a sheet manually, first circular blank is cut with a chisel and hammer. Then fine shapes are trimmed with the help of a sher or snip. This operation i.e. cutting by snip is called trimming.

FORMING (FLANGE & RE-STRIKE):

Forming is the process of producing contoured parts by stretching metal sheets. Forming strains the metal beyond the elastic limit, to give the work piece a permanent set. Forming is similar to bending. Complex parts such as U-sections and channel sections of different profiles can be produced by doing multiple bends.
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There is no change in thickness. Good dimensional repeatability as well as close tolerances is possible with this process. Complex bending and re-strike operations can be accomplished using Cams in dies. Complicated flanges can be split in different operations.

Study of Die Maintenance

Role of Die maintenance Technicians:1.

Troubleshooting and repair of dies

Draw dies.

Trim and piercing dies, cam trim and pierce dies. Flange and Re-strike correction in forming dies. Blanking dies.

2. Preventive maintenance of dies Conducting weekly PM as per schedule Conducting monthly PM as per schedule Conducting yearly PM as per schedule

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Die opening and Closing

Die opening is a process of parting two halves of the die. Generally, the top die is parted from the bottom die using a over head crane.

Die opening procedure: Centralize the crane to the die centre Place all four noose of the crane rope in the rope slot of the top die. Lock the rope in the slot using die pins. Confirm that the die pins are locked rigidly Raise the crane hoist in inch mode. Once the top die is disengaged from the guide. Raise the hoist in rapid mode till there is a gap of ft between the die halves. Place the top die on the die cot wood. Do not place the die on floor without die cot wood.

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Die closing is a process of assembling the two halves of the die. Generally, the top die is assembled on the bottom die using a over head crane.

Die closing procedure: Centralize the crane centre to the top die centre Place all four noose of the crane rope in the rope slot of the top die. Lock the rope in the slot using die pins. Confirm that the die pins are locked rigidly Raise the crane hoist upto 2mt from ground level. Check the flow direction of the top and bottom dies are pointing towards same direction Move the top die to the center of the bottom die. Check if locators are hitting against the top die. Move the crane hoist down in inch mode till the gauides are engaged. Bring the hoist down till the distance block is touched. Remove the crane ropes from the slot

DIE WASHING
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Why do we need to wash dies ?

To remove atmospheric dirt which causes quality issues like dent and bumps. To remove the grits which gets deposited on the die surface after polishing or after carrying out repairs? If the dies are not cleaned it will result in scoring on die surface, which in turn results in chrome peel off.

Procedure for die washing

Wash the die only on designated washing area Apply Kerosene on the guides and panel area of the die Wash the die with warm water 60-80 deg Blow air and ensure that the die is 100 % moisture free Apply a thin uniform layer of anti corrosion oil on the die surface before closing the die.

Die Grinding
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Grinding is a highly skilled operation, where the required dimensions or form is achieved. It requires a tremendous amount of skill and concentration for grinding. Grinding is often a secondary or finishing operation. The quality of the ground surface depends on the selection of type of grinder and type of wheel. The next few pages illustrates how to finish a hexahedron block by grinding.

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Dos and Donts of Grinding

Dos
Dress the wheel straight. Grind in criss cross direction. Lubricate the grind periodically. Keep the grinder nozzle away from dust. Grind in swinging motion to avoid deep grinding marks. Use the max length of the wheel while grinding.

Don'ts
Using damaged mounted wheels. Tighten the wheel with full force. Grind using undressed wheel. Blow off grinding dust using compressed air.

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TYPES OF REPAIR TOOLS:Tool Name

Air Porter Air Porter (mini) Angle Grinder Angle grinder (mini) Hex Wrench T Handle Wrench Copper Hammer Steel Hammer Wrench Angle Wrench Screwdriver (+) Screwdriver (-) Plier Chisel Adjustable Wrench Dowel pin puller File Compass Vernier caliper Thickness gage Radius gage Impact wrench Pipe wrench Vise plier Shears

Use
Finishing of counter and cutting edge. Finishing small counter, holes, cutting edges Rough finishing counter, cutting edge. Rough finishing small counter, cutting edge. Tightening and loosening socket bolts. Tightening and loosening socket bolts. Driving dowel pins, blocks, etc. Peening, Chisel, etc. Tightening ad loosening nuts. To replace offset Tightening, loosening cross recess screws. Tightening and loosening socket bolts. Holding, Gripping, cutting parts Cutting, chipping Tightening, loosening nuts Dowel pin pulling, driving Finishing contour Scribing lines General measurement Measuring clearances Measuring radius Tightening, loosening, socket bolts Holding, tightening, loosening round parts.. Clamping Parts Cutting steel, copper sheets
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Tap handle Die stock Flashlight Diamond file Dresser Oilstone Carbide cutter Emery paper Offset Emery wheel Buff Emery compound Copper Bar

Tapping holes Threading parts Working in dark areas Finishing hardened areas Dressing emery wheel Polishing contours, cutting edge Rough cutting with porter Polishing contours, general surface Rough cutting with angle grinder Finishing with porter Finishing with porter Rough polishing contour, general surface Die disassembly, driving large part

Use of Standard Hand Tools:Tool Name

Hex Wrench, T handle wrench 1. Preparation for work

Description

Handling Pointers

Inspect and wear specified protective gears. Inspect conditions of tools. Set wrench fully into the bolt head Prevent over/under torquing

Cotton gloves

Do not use cracked tools or those worn in excess of 10% or oversize tools, check weld in the T handle. Use the proper size wrench and seat fully into the head. Check the weld of T handle wrench. Torque value will differ for bolt material and diameter.
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2. Tool Usage

3. Completion of operation

Check wrench for wear and crack. Clean and orderly arrange work area (especially oil) Refrain from using any damaged tools found.

4. Others

Replace or repair before using, or dispose

Copper Hammer, Steel Hammer 1. Preparation for work

Inspect and wear specified protective gears. Inspect conditions of tools.

2. Tool Usage

Do not use gloves. Wear safety goggles if necessary. Do not use hammer with loose handle, missing wedge Do not use copper hammer with greater than 20% flared head Do not use hammer without an anti slip end. Do not use hammer with an oily hand.

Caution of injury to other workers. Refrain from using excessive force.

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3. Completion of operation

Check condition of hammer head Replace or repair before using, or dispose. and handle. Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect and wear specified protective gears. Inspect conditions of tools. Prevent overtorquing or undertorquing . Check wrench for wear and crack. Clean and orderly arrange work area (especially oil)
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4. Others

Wrench, Offset wrench 1. Preparation for work

Wear cotton gloves.

Do not use wrench with worm opening(greater than 5%) or with cracks. Use proper tightening torque.

2. Tool Usage

3. Completion of operation

4. Others

Refrain from using any damaged tools found.

Replace or repair before using, or dispose.

Screwdriver (+), Screwdriver 1. Preparation for work

Inspect and wear specified protective gears. Inspect conditions of tools. Do not hammer the screw driver. Check for loose handle. Check for cracked or chipped blade. Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect and wear
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Wear cotton gloves.

Do not use tool with loose handle or with chipped, cracked, worn tip.

2. Tool Usage

3. Completion of operation

4. Others

Replace or repair before using, or dispose.

Plier 1. Preparation for work

Wear cotton gloves.

specified protective gears. Inspect conditions of tools. 2. Tool Usage 3. Completion of operation Check for cracks, loose pin Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect and wear specified protective gears. Inspect conditions of tools. Caution for flying of broken chips. Check for cracks, loose pin Clean and orderly arrange work area.
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Do not use tool with excessively worn grip area or loose pin.

4. Others Chisel 1. Preparation for work

Replace or repair before using, or dispose.

2. Tool Usage 3. Completion of operation

Wear cotton gloves and safety goggles. (However, do not wear gloves when using set chisel) Do not use tool with flared head, chipped or cracked point. Hardness of point shall be less than HRC 55.

4. Others

Refrain from using any damaged tool found.

Replace or repair before using, or dispose.

Adjustable wrench, pipe wrench 1. Preparation for work

Inspect and wear specified protective gears. Inspect conditions of tools. When using the tool apply force in the direction of the adjusting slide. Do not use as a hammer. Check for cracks and looseness. Clean and orderly arrange work area. Refrain from using any damaged tools found. Inspect
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Wear cotton gloves.

Do not use cracked tools or tool with loose adjusting screw or slide.

2. Tool Usage

Apply proper torque.

3. Completion of operation

4. Others

Replace or dispose.

Pin Puller

Wear cotton gloves.

1. Preparation for work

and wear specified protective gears. Inspect conditions of tools.

Length of main unit shall be less than 300mm. Sliding weight hole diameter should be less than 15% of the diameter of the main unit slide. Flare of the main unit head section shall be less than 35%. Main unit and head shall be single piece. Normally, the pin screw end should not be welded.

2. Tool Usage

Caution, prevent pinching the finger. Check the condition of the pin puller welded bolt. Clean and orderly arrange work area. Refrain from using any damaged tools found. wear specified protective gears. Inspect conditions of
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3. Completion of operation

4. Others

Repair before use.

File 1. Preparation for work

Length shall be at least 150mm.

Wear cotton gloves only on

tools. 2. Tool Usage Apply force only on the forward cutting strike. Work in a weld balanced attitude. When cutting edge becomes dull, clean the teeth with a wire brush. Check condition of handle and the crack stopper ring. Clean and orderly arrange work area. Refrain from using any damaged tools found.

hand which holds the tip. Do not use tool with loose handle or cracked handle.

3. Completion of operation

Wire brush

4. Others

Replace or repair before using, or dispose.

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REMEDY PROCEDURE FOR PRESS DIE (DRAWING DIE)

SYMPTOM
1. 2. Overall wrinkles Localized wrinkles 3. Crack or tear along part periphery

CAUSE
Blank holder pressure low Blank holder not level Blank holder not flat. Blank stock improperly positioned Blank holder pressure low Blank holder pressure too large Punch/Die radius too small

REMEDY
Adjust blank holder pressure Adjust blank holder Grind blank holder flat Adjust blank positioner Adjust blank holder pressure Adjust blank holder pressure Increase Die/Punch radius (observe part dimension) Adjust clearance C= t+ (2/10 6t/10) Adjust blank positioner Polish Adjust timing Defective stock

4.

Radial tear

Insufficient clearance between punch and die. Incorrect positioning of blank stock Scoring on the bead and die radius Incorrect slit timing Defective blank stock(work hardened) Defective blank stock Blank holder
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Defective stock Regrind holder

 5. 6 Radial scratches Shiny spots on drawn surface 7. 8. 9. Drawn surface depression Inside scratches Streak depression along drawn surface (Starting mark)

pressure low due to unevenness Blank stock improperly positioned Scoring on the bead and die radius Insufficient clearance Improper shut height Improper die setup Excessive clearance

Adjust blank position

Polish Adjust clearance C=1.21.5t Adjust shut height Reset up Adjust clearance between punch and die. Polish Adjust die radius Polish Adjust bead (observe part) Adjust cushion Replace stock Reduce pressure increase bead pull force Correct bend surface Adjust cushion pressure Adjust bead Adjust slit timing

10 Les along . drawn surface

11 Line shift .

Groove scratches on flange holder and bead Insufficient ie radius Poor material slip property Bead lacks pull Excessive cushion pressure Defective blank stock Insufficient blank pull Defective die bend surface Improper cushion pressure Improper blank pull force (improper bead) Slit improperly timed
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12 Insufficient . flange width

13 Caused by . vacuum created during die separation 14 Develops . during pressing due to uneven distribution of stress during press operation. 15 Depression .. develops during processing due to insufficient pull on the material 16 Excessive . curvature develops during processing due to insufficient pull on the material.

Excessive shut height Insufficient material Insufficient cushion pressure Insufficient blank pull force (bead) Punch rise speed too high Improper air bleed hole size, quantity Uneven clearance Unbalance tension produced by the bead.

Adjust shut height Replace material Adjust cushion pressure Adjust bead Reduce punch speed. (double action) Change size, number, location of air bleed. Adjust stretch ratio Adjust oiling condition. Adjust clearance. Adjust location and height of the bead. Adjust processing and cushion pressure. Straightening process. (by use of jig during assembly) Reinforcement of bead. Adjust the blank holder pressure Repair of blank holder surface

Insufficient bead pull Insufficient blank holder pressure. Uneven blank holder surface Insufficient blank holder pressure Punch contour

Adjust blank holder pressure Improve finish of the punch

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17 Irregular . spots formed by foreign objects on the die surface. 18 Crease . develops along the corner during drawing and bending due to concentration of stress 19 Condition that . develops on the inside surface of the sheet due to uneven distribution of stress.

Foreign objects on the die. Foreign objects on the blank stock. Burrs on sheared edge. Insufficient bead pull and blank holder pressure Excessive clearance

Clean the die. Clean the blank stock Remove burrs. Adjust bead shape and blank holder pressure Adjust clearance

Large die corner radius Excessive clearance Insufficient spring back allowance Insufficient blank holder and cushion pressure. Insufficient material Irregular radius on the die and punch surface Improper bead pull

Remedy due corner radius Adjust clearance Adjust spring back allowance Adjust blank holder and cushion pressure Use material of larger dimension

20 During initial . drawing phase the friction of the die caused excessive material stretch at the radius and subsequent increase in rigidity produced a

Improve he finish of the die and punch radii (smooth) Adjust the bead timing Increase the profile radius with consideration to blank holder contour, pressure direction.

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marked line.

REMEDY PROCEDURE FOR PRESS DIE (TRIMMING DIE)

SYMPTOM
1. Burrs

CAUSE
Excessive clearance Insufficient clearance Primary cutter wear Protruding secondary edge. Punch and die off center Dull or worm punch Damaged or chipped cutting edge of punch Damaged or chipped cutting ede of die. Part not properly set in the die. Bushing surface too low. Incorrect drawing depth Stripper not set parallel. Loose punch Punch off center
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REMEDY
Hardface C= t*5/100~7/100 Adjust cutter edge clearance Hardface the cutter edge Grind secondary edge. Remedy die offset.

2.

3. 4. 5.

Edge condition different for sides. Material not sheared square Projection along the cutting edge. Depression along cutting edge Depression of the normally flat surface

Build up worm area by hardfacing Regrind or build up by hardfacing the punch cutter Regrind or build up by hardfacing the die cutter. Check the matching of the dies and make correction Install spacer and regrind height of bushing Adjust stripper Enlarge mounting diameter of the punch to provide good fit. Realign the punch

6.

7.

Punch breaks

8.

Scrap clogging

9.

Part adheres to upper die

10 Shift of cut . line

Interference with reverse hold down Incorrect material or hardening Restriction of the hole. Scrap chute hole requires polishing Burrs Weak stripper spring or damage to the urethane Excessive cutting stroke causing part to bind Contour not matched between drawn part and trimming punch Punch and stripper contour not matched Damaged reverse holder spring

Adjust Change material or heat treat to proper hardness. Provide proper clearance Polish hole Lap punch and bushing Replace Adjust stroke

Match punch to the part contour Match stripper to punch contour Replace spring.

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REMEDY PROCEDURE FOR PRESS DIE (HOLE PIERCING)

Symptom
1. Burrs

Cause
Worn slide core Loose punch mount Incorrect secondary finish Incorrect clearance Clogged scraps Loose fixed cam Loose back up block Insufficient stroke.

Remedy
Adjust slide core clearance Correct mount to proper diameter Remedy Adjust clearance Match the punch, clean scrap escape hole Tighten bolt, install key Tighten bolt, install key Adjust stroke

2.

Blocked hole

REMEDY PROCEDURE FOR PRESS DIE (BURRING DIE)

SYMPTOM
1. Ragged hole edge

CAUSE
Pilot hole too small. Ragged hole during pilot hole piercing Defective material Punch and die off center. Hole in part not aligned to the die. Incorrect burring hole bushing radius Improper drawing depth Improper burring
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REMEDY
Increase size of pilot hole so as to reduce the amount of burring Match the punch Adjust

2.

Incorrect burring height

Adjust shut height Match pilot to shape of

pilot shape.

part hole.

REMEDY PROCEDURE FOR PRESS DIE (CURLING DIE)

SYMPTOM
1. Reverse bend

CAUSE
Binding in the curling groove Curling groove off center Punch and bushing misaligned Punch over hardened Worn guide

REMEDY
Polish groove Reposition curling groove by build up facing Align punch and bushing Temper to proper hardness Replace guide, post, bushing

2.

Broken punch

Periodic Inspection and Maintenance

GENERAL:The purpose of periodic inspection and maintenance (hereafter referred as periodic maintenance) is to perform control of the dies to prevent them from aging and wear so that the accuracy of the parts they produce will be maintained at the specified uniform quality. Basic for die control is by press shot (number of parts produced). Refer to the separate sheets for the details on preventive maintenance for the respective processes.

PERIODIC MAINTENANCE CONTROL METHOD:-

ESTABLISHING SHOT QUANTITY BASED ON MAINTENANCE INFORMATION:Durability of the dies will depend upon many factors such as shape of product, sheet thickness, die design, die material. Normally, it would be desirable to maintain die accuracy for each product by the respective process, or to perform control within the range that products of uniform quality (acceptable product quality) can be supplied. However, based
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on past experience with die repair, control is established for each process based on the number of press shots.

PERIODIC MAINTENANCE CYCLE:PROCES S Type, repair DRAW Normal Importan t Plating TRIM Normal Importan t PIERCE Normal Important SIDE CUT Normal Important BEND Normal Important 70,000 140,00 210,00 280,00 350,00 REMARKS Shots 0 0 0 0 Shots Shots shots shots Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Bead Wear countermeasure

Cutter Wear countermeasure Adjust accuracy of shoulder punch fit section

Y Y Y

Y Y Y

Y Y Y

Y Y Y Y

Bend punch wear countermeasure

1. Normal Periodic Maintenance:- Perform- check of the steel

dies for defects and damages In accordance with the maintenance procedure specified in the following attached sheets, and make any repairs as necessary. 2. Important Periodic Maintenance:- In addition to the periodic maintenance, look for areas of the steel die that indicate excessive wear from die aging, and perform the designated preventive maintenance. 3. Plating:- Check the hard chrome plated areas for the loss (peeling) of the plating as the result of polishing and galling. Perform repair by building up the worn surface with welding and then replating. Replating will restore excellent wear resistant
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property of the die (minimizing the depressions and scratches) and enable the continued production of quality products. Furthermore, the drawing property of the die is improved by the smoothness of the plated surface.

FEEDBACK:-

The information derived from the periodic maintenance provides valuable information on the characteristics of each die (die design inadequacies, repairs) which can be used in the design and manufacture of future steel dies.

KEEPING OF DIE MAINTENANCE AND REPAIR RECORDS:All the periodic maintenance record sheets, and repair and modification record sheets shall be kept in the file by parts (process) and in the order of maintenance performed.

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DIE DESIGN
1.

STEEL DRAWING DIE:-

Draw die- The rolled steel sheet is formed into the shape of the die by applying a force perpendicular to the surface of the sheet.

Ref.
a. b. c. d. e. f. g. h. i.

Part Name
Die set Die Bead Balancer block Blank holder Punch Cushion Pin Pilot Guide

Function
To simplify the mounting of the die (some are made integral with the die) Forces the sheet stock to form around punch contour. Prevents wrinkles and distortion of press part, prevents slipping Used for adjusting the holding force of the die and blank holder. Used mainly for motorcycle. Maintains the blanked stock in place and holds the stock during drawing (prevents wrinkles) Forces the sheet stock into the die to form the shape. A component of the press which function as a support for the blank holder Performs the positioning of the stock sheet Performs the positioning of the blank holder to
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the die.

Draw Die Periodic Maintenance Inspection Standard:S.No.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Inspection Points
Guide post Guide bushing Punch, Die, Blank Holder, guide, plate Guide plate mounting bolt Punch Die Die plating Die mounting bolt Bead Bead mounting bolt Ejector retainer pin Ejector spring Pilot pin Scrap chute box Upper/lower holder Hook hole Mounting bolts

Description of Inspection
Galling, wear, bend Galling, wear, crack Galling, wear Galling, wear Break, loosening Worn radius, galling Worn radius, galling Peeling Break, loosening Galling, crack, wear Break loosening Galling, deformation Break, bend Break, deformation, looseness Damage deformation Surface condition Screw thread war Break, looseness

Inspection Standard
0.1-0.2 0.1-0.2 0.05-0.1 0.05-0.1 None permitted 0.5max. 0.5max. None permitted None permitted Determine from Die and None permitted Not permitted Not permitted Not permitted Not permitted 60-70% contact 1mm max. Not permitted

Inspection Method
Micrometer, Inspection jig Cylinder gage Thickness gage Thickness gage Wrench Section gage Section gage Visual Wrench Part Wrench Visual Visual Visual Visual Straight edge Vernier caliper Wrench

Maintenance Method
Replace with new parts Replace with new parts Grind, Liner repair Grind, Liner repair Replace with new parts Weld build up worn spot Weld build up worn spot Plating Replace with new parts Weld build up worn spot or replace Replace with new part Replace with new part Replace with new part Replace with new part Replace with new part or repair Grind Machine new hole Replace with new parts

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2. STEEL SHEAR DIE ( Blanking, Trim, Pierce):Trim-pierce die For cutting off excess material

Ref. a. b. c. d. e. f. g. h. i. j. k. l. m. n.

Part Name Die set Dowel pin Stripper Guide bushing Stroke end pin Guide post Punch plate Spring ellipse (Spring urethane) Shoulder punch Bushing Die cutter Punch cutter Punch Scrap cutter

Function Upper die mounting plate (Some are made integral with the die) For the die positioning (accuracy 0.15-0.24) Holding the part in position, prevent part from lifting For aligning upper and lower die, to maintain die accuracy Die reference (normally 0.5mm clearance exists) For matching the upper and lower die, maintain die accuracy Shoulder punch mounting plate, maintains punch position Serve as auxiliary punch function. (When large force required in small space) Mate with the bushing and performs hole piercing Mate with Shoulder punch and performs hole piercing Mate with punch cutter and performs punching Match with die cutter and performs punching Serve as positioner for drawn parts

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Trim Die Periodic Maintenance Inspection Standard:No. Inspection Description of points inspection
1. 2. 3. 4. 5. 6. 7. Guide post Guide bushing Heel guide Wear plate Wear plate mounting bolt Male cutter, Flat Male cutter, Vertical Cut Male cutter head pipe Male cutter countered section Female cutter flat Female cutter vertical cut Female cutter head pipe Female cutter countered section Punch block mounting bolt Die block mounting bolt Punch Punch holder Bushing Bushing holder Ejector Ejector Spring Galling, Wear, Bend, Cracks Galling, Wear, Bend, Cracks Galling, Wear Galling, Wear Break, looseness Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Chip, Clearance, Wear, Over-cut Break, Looseness Break, Looseness Chip, wear, overcut, loose mounting Loose mounting, Galling Chip, Wear, Overcut, Loose mounting Loose mounting, Galling Damaged contour Break, bend, Deform

Inspection Standard
0.05-0.1 0.05-0.1 0.05-0.1 0.05-0.1 Not permitted Chip not permitted Clearance 0.05-0.08 of sheet thickness Sagging edge not permitted Overcut 0.52.0 + sheet thickness Chip not permitted Clearance 0.05-0.08 of sheet thickness Sagging edge not permitted Overcut .5-2.0 + sheet thickness Not permitted Not permitted Chip not permitted Edge sag Overcut = t + 0.5~2.0 Looseness 0.01 max Not permitted Not permitted

Inspection method
Micrometer, in inspection jig Cylinder gage Thickness gage Thickness gage Wrench Visual Thickness gage Check product shear edge Scale Visual Thickness gage Check product shear edge scale Wrench Wrench Visual Visual Vernier Calliper Cylinder gage Visual Visual

Maintenance Method
Replace with new part. Replace with new part. Repair wear Repair worn liner. Replace with new part Repair by weld build-up Repair by weld build-up Jig model repair Jig model repair Weld build up wear area Repair by welding Repair by welding Scale repair by welding Replace with new part Replace with new part Wear replace Repair by jig boring Weld build-up, Replace with new part Jig boring machining Repair by welding Replace with new part

8. 9. 10. 11.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

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22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Ejector Urethane Lifter Cylinder Knock out pin Knock out spring Scrape chut Upper/Lower holder Upper/Lower mounting bolts Hook hole Jig model

Break, Bend, Deform Deform, Bend, damage Air leak, Operating condition Malfunction Break, Bend, Deform Damage, Deform Surface condition Break, Looseness Screw thread condition Defective contour, Chip

Not permitted Not permitted Normal operation Deform not permitted Not permitted Not permitted 60-70% contact Not permitted 1mm max wear Not permitted

Visual Visual Test Stand Visual Visual Visual Straight edge Wrench Vernier caliper Visual

Replace with new part Replace with new part or repair Replace with new part or repair Replace with new part Replace with new part Replace with new part or repair Grind Replace with new part Drill new hole Repair or make new

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Steel Bending Die (Bend) & Steel Form Die (Restrike, Curling, Burring):Bend die is used to produce bend to the stock material with the die.

Curling die is used bend up the flange of stock material

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Pierce/Burring die periodic maintenance Inspection Method:No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Inspection points Guide Post Guide bushing Punch Punch holder Bushing Bushing holder Burring punch Burring holder Burring bushing Burring holder Ejector Slit male cutter Description of Inspection Galling, wear, bend Galling, wear, crack Chip, wear, overcut, hole looseness Galling, Mounting looseness Chip, wear, mounting hole looseness Galling, mounting looseness Galling, wear, bend Mounting looseness, Galling Galling, wear Mounting looseness, Galling Contour damage Chip, galling, wear Inspection Standard 0.05-0.1 0.05-0.1 Chip not permitted Overcut = t+ 0.5~2.0 Looseness 0.01 max. Clearance t 0.05~0.08 Galling not permitted Looseness 0.01 max. Wear 0.05 max. Wear 0.05 max. Not permitted Determine from die and part sheared edge Determine from die and part sheared edge Determine from die and part sheared edge Not permitted Determine from die and part sheared edge None permitted None permitted Inspection method Micrometer, inspection jig Cylinder gage Visual Vernier Caliper Cylinder gage Visual Visual Cylinder gage Micrometer Micrometer Visual Maintenance Method Replace with new part Replace with new part Grind, Replace Jig boring Repair by welding, replace Jig boring Grind, Replace Jig boring Replace with new part Jig boring Repair by welding Repair by welding

13.

Slit female cutter

Chip, galling, wear

Repair by welding

14.

Blank holder

Galled surface, wear

Weld build-up worn spot

15. 16.

Blank plating Blank bead groove

Peeling Galling, wear

Visual

Plating Weld build-up spot

17. 18.

Blank mounting bolt Blank set pin

Break, loosening Break, bend, looseness

Wrench Visual

Replace with new part Replace with new part

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19. 20.

Blank bottom surface Ejector

Depression Damaged contour, worn radius

0.5 max. Determine from die and part sheared edge None permitted Pin free from bend None permitted Not more than 1mm wear 60-70% surface contact None permitted

Vernier caliper

Grind Repair by welding

21. 22. 23. 24. 25. 26.

Ejector mounting bolt Knockout Knock spring Hook hole Upper, lower holder Upper mounting bolt

Break, loosening Malfunction Break, bend, deform Worn threads Flatness, irregular surface Break, looseness

Wrench Visual Visual Vernier caliper Straight edge Wrench

Replace with new part Replace with new part Replace with new part Machine new hole Grind Replace with new part

E F E F F E F C E T C T O O N N A A P P P P E E A A R R A A N N C C E E :: A A F F T T E E R

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A P IA N I T, N D T TO RESOLVE CHIP-DENT PROBLEM TO E , N D INCREASE THE QUALITY T E IN S T C L WHAT IS CHIP DENT?I E S A R C OK PANEL L L CHIP EFFECT ON Y E APPEARANCE: V LOWER DENT PANEL A EFFECT ON IR AFTER PAINT, APPEARANCE: AFTER DENT IS S L PAINT, DENT IS IY CLEARLY UPPER DENT PANEL CLEARLY VISIBLE VISIBLE WHICH B WHICH AFFECTS OUR CHIP AFFECTS OUR L V CBU APPEARANCE CBU E I QUALITY W APPEARANCE S QUALITY H I IB HOW IT GENERATE: WHEN DURING DRAW OR TRIM OPERATION C L SOME DUST OR CHIP PARTICLE COMES ON THE DIE,GENERATE H E THE DENT A F W F H E I C C T H S EFFECT ON APPEARANCE: AFTER PAINT, DENT IS CLEARLY O VISIBLE WHICH AFFECTS OUR CBU APPEARANCE QUALITY A U F R F C E B C U T Hand Work Contribution, All Models May12 A S P P O E U - 59 A R R A EFFECT ON APPEARANCE: EFFECT ON AFTER PAINT, APPEARANCE: AFTER DENT IS PAINT, DENT IS CLEARLY CLEARLY VISIBLE VISIBLE WHICH WHICH AFFECTS OUR AFFECTS OUR EFFECT ON APPEARANCE: AFTER PAINT, CBU APPEARANCE CBU DENT IS CLEARLY VISIBLE WHICH AFFECTS QUALITY APPEARANCE OUR CBU APPEARANCE QUALITY QUALITY

MODEL 2PS 2AP 2CV TOTAL

TOTAL PRODUCTION 79661 36396 96686 212743

B C U E Q A U P A P HANDWORK L E IA T 1050 R 690 Y 1760 A N3500 C E

2AP 36396 Q U1.84 A L I T Y

% H/W 1.32 1.90 1.82 1.65

NOS REJECTED 82 137 186 405

% REJECTION 0.10 0.38 0.19 0.19

CRACK NOS 51 82 62 195

% CRACK 0.06 0.23 0.06 0.09

2PS 79661 1.32

2CV 96686 1.81

2 CV HandWork Trend May'12

AVERAGE 1.8

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S. NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Part Name ROOF RR DR PNL L SPO L/H SPO R/H RR DR PNL R FR DR SKIN R HOOD SKIN FR DR SKIN L HOOD FRAME FR FNDR L RR DR SKIN L RR DR SKIN R FR FNDR R T/L SKIN FR DR PNL R FR DR PNL L FR FLOOR RR IN SIDE L RR IN SIDE R RR FLOOR T/L FRAME

ACTUAL 12.0 9.6 7.7 5.8 4.2 3.5 3.2 2.9 2.5 2.4 2.2 1.4 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

TARGET 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

Defect Wise
PART NAME HOOD SKIN TOTAL 108 DENT 54 DING 54 SCRATC H 0 OTHER S 0 RUST 0 SCRAP JAM 0 WRINKLE 0 BURR 0

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HOOD FRAME FR FENDER R FR FENDER L ROOF PANEL S P OUT R/H S P OUT L/H PANEL RR IN SIDE R PANEL RR IN SIDE L FR FLOOR RR FLOOR FR DOOR SKIN R FR DOOR SKIN L FR DOOR PANEL R FR DOOR PANEL L RR DOOR SKIN R RR DOOR SKIN L RR DOOR PANEL R RR DOOR PANEL L SPOI.LER SKIN SPOILER FRAME

85 0 107 445 244 232 0 0 0 0 105 88 0 0 35 56 150 347 0 0 2002

0 0 53 311 164 166 0 0 0 0 60 44 0 0 17 26 0 0 0 0 895

0
0 54 134 80 66 0 0 0 0 45 44 0 0 18 30 0 0 0 0 525

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 SCRAP JAM 85

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 SCRATC H 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

85 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 85 OTHER S 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 150 347 0 0 497

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

TOTAL
TOTAL 2002

DENT 895

DING 525

WRINKLE 497

RUST 0

BURR 0

2CV Hand Work

PART NAME HOOD SKIN HOOD FRAME FR FENDER R FR FENDER L MARCH 2.42 0.67 1.35 1.62 APRIL 3.01 0.00 1.89 1.47 MAY 3.16 2.49 0.00 2.45

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ROOF PANEL S P OUT R/H S P OUT L/H PANEL RR IN SIDE R PANEL RR IN SIDE L FR FLOOR RR FLOOR FR DOOR SKIN R FR DOOR SKIN L FR DOOR PANEL R FR DOOR PANEL L RR DOOR SKIN R RR DOOR SKIN L RR DOOR PANEL R RR DOOR PANEL L T/L SKIN T/L FRAME

12.55 7.16 9.29 0.00 0.00 0.61 0.00 1.57 1.67 0.92 0.52 1.75 1.25 27.00 4.10 0.00 0.00

6.46 3.69 7.14 0.00 0.00 0.00 0.00 1.48 1.73 0.30 0.00 2.69 2.64 6.63 12.75 0.40 0.00

11.97 5.81 7.74 0.00 0.00 0.00 0.00 3.50 2.94 0.00 0.00 1.40 2.24 4.17 9.64 0.00 0.00

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