Faculty of Mechanical Engineering

SMR 4712 TOOLING FOR PRODUCTION

GROUP ASSIGNMENT: DIE DESIGN 2011/2012-SEM 1

LECTURER PM ZAINAL ABIDIN

SECTION 02

NO. 1. 2.

GROUP MEMBERS EDWIN LEONG FUH ZHENG JAZIZ AMIRUDDIN B. JAMALUDDIN

MATRIX NO AM080173 BM083002

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE

INTRODUCTION 1.1 Part 1.2 Station and Operation Sequence

1 1 2

CUTTING FORC 2.1 Station One 2.1.1 Blanking (Oval Contour) 2.1.2 Piercing (2 holes of 4 mm) 2.2 Station Two 2.2.1 Embossing (Rectangular Offset Embossing) 2.2.2 Slotting (Square Fillet Feature) 2.3 Station Three 2.3.1 Embossing (5 Interior Offset Emboss of 12) 2.3.2 Embossing (2 Interior Offset Emboss of 16) 2.3.3 Piercing (5 holes of 4 mm) 2.3.4 Piercing (2x Pre-pierced Holes) 2.3.5 Beading (V-Bead) 2.4 Station Four 2.4.1 Extruding

3 3 3 4 5 5 6 6 7 8 9 10 12 13 13

Stripper 3.1 Stripping Force 3.2 Calculation of Stripping Force

14 14 15

PUNCH AND DIE 4.1 Clearance 4.2 Determining Size 4.2.1 Station One 4.2.2 Station Two 4.2.3 Station Three 4.2.4 Station Four

16 16 16 16 17 18 19

DIE COMPONENT 5.1 Thickness of Punch Holder and Die Holder 5.1.1 Station 1 5.1.2 Station 2 5.1.3 Station 3 5.1.4 Station 4

20 20 20 21 22 23

PRESS CAPACITY 6.1 Calculation for Press Capacity of Each Station

24 24

SCRAP STRIP LAYOUT 7.1 7.2 7.3 7.3.1 7.3.2 7.3.3 The Scrap Strip Layout Scrap Strip Allowances Strip Area per Blank Calculations Single Row, One Pass Positioning Number of Blanks per Strip End Waste of Single Pass Strip

25 25 25 26 26 26 27

Appendices

Drawing etc.

28

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

1.2 Station and Operation Sequence

Station

Operation

Feature Blank Contour 2x 4mm Rectangular Offset Emboss 2x Square Fillet 5x 14mm 2x 16mm

Station 1 Blanking Piercing Station 2 Emboss Slotting Station 3 Emboss

Piercing

5x 4mm 2x 3.16mm

Beading

1x 83mm V Bead 2x 43mm V Bead

Station 4 Extruding

2x 2.5mm Wall

CHAPTER 2

CUTTING FORCE

2.1 Station One

2.1.1 Blanking (Oval Contour)

Perimeter

= 632.84 mm

Area to be Cut

= Perimeter x Thickness = 632.84 mm x 0.5 mm = 316.42 mm2

Blanking Force

= SR x A = 32 kgf/mm2 x 316.42 mm2 = 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

Piercing Force

= SR x A = 32 kgf/mm2 x 12.57 mm2 = 402.12 kgf

Total Cutting Force at Station One = 10125.44 kgf + 402.12 kgf = 10527.56 kgf

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

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/mm2 x 37 mm2 = 1184 kgf

Total Cutting Force at Station Two = 6308.2 kgf + 1184 kgf = 7492.2 kgf

2.3 Station Three

One of the features of the plate required a special operation that first emboss, punch and extrude. We need to calculate the initial diameter of the pierce holes before we extrude to the dimension needed.

2.3.1 Embossing (5 Interior Offset Emboss of 12 mm)

Sectional View of Interior Offset Emboss

Perimeter

= 5 x 2r = 5 x 2 x 6mm = 188.5 mm

Embossing Force

= TS x t x L = 40 kgf/mm2 x 0.5 mm x 188.5mm = 3770 kgf

2.3.2 Embossing (2 Interior Offset Emboss of 16 mm)

Sectional View of Interior Offset Emboss

Perimeter

= 2 x 2r = 2 x 2 x 8mm = 100.53 mm

Embossing Force

= TS x t x L = 40 kgf/mm2 x 0.5 mm x 100.53mm = 2010.6 kgf

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/mm2 x 31.42 mm2 = 1005.31 kgf

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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 Bending Radius = 0.5 mm = 1.0mm

Bend Radius Bending Allowance 0.75 1.00 1.50 0.97 1.08 1.29

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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

13

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 force 2. Smaller clearances need higher force 3. Cutting near sheet edge required less force since the sheet can be deflected away from the punch 4. Cutting at higher speeds results in a hotter punch with greater chance of welding and higher force 5. Lubrication can reduce force 6. Grinding punch and die steel vertically rather than the conventional cylindrical grind will reduce force

15

3.2 Calculation of Stripping Force

Stripping Force = 0.1 x Cutting Force

Station 1 2 3 4

Cutting Force (kg f) 10527.56 7492.2 14339.59 879.65

Stripping Force (kg f) 1052.8 749.2 1434.0 88.0

16

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 3rd Edition Die Design Fundamental C = 0.0011 inch ~ 0.02794 mm

4.2 Determining Size

Operation Blanking Piercing

Die Size Part Size Part Size + 2C

Punch Size Part Size 2C Part Size

4.2.1 Station One

Blanking:

Die Size Punch Size

= =

Part Size Part Size 2(0.02794)

17

Piercing:

Die Size Punch Size

= =

4mm + 2(0.02794) = 4.056 mm 4mm

Die

Punch

4.2.2 Station Two

Slotting:

Die Size Punch Size

= =

Part Size + Offset Clearance Part Size

Die

Punch

18

4.2.3 Station Three

Piercing:

Die Size Punch Size

= =

4mm + 2(0.02794) = 4.056 mm 4mm

Die

Punch

Piercing:

Die Size Punch Size

= =

3.16mm + 2(0.02794) = 3.216 mm 3.16mm

Die

Punch

19

4.2.4 Station Four

Extruding:

Die Size Punch Size

= =

6mm + 2(0.02794) = 6.056 mm 6mm

Die

Punch

20

CHAPTER 5

DIE COMPONENT

5.1 Thickness of Punch Holder and Die Holder

5.1.1 Station 1

Blanking Force (Blank Contour) Piercing Force (2x 4mm) Total Cutting Force at Station 1

= 10125.44 kgf = 402.12 kgf = 10527.6 kgf = 10.5276 tonnes

21

Punch Holder Thickness Die Holder Thickness

= 44.50 mm = 51.00 mm

5.1.2 Station 2:

Embossing Force (Rectangular Offset) Piercing Force (2x Square Fillet)

= 6308.2 kgf = 1184 kgf

Total Cutting Force at Station 2

= 7492.2. kgf = 7.4922 tonnes

Punch Holder Thickness Die Holder Thickness

= 31.75 mm = 38.10 mm

22

5.1.3 Station 3:

Embossing Force (5x 14mm) Embossing Force (2x 16mm) Piercing Force (5x 4mm) Piercing Force (2x 3.16mm) Beading Force (3x V-bead)

= 3770 kgf = 2010.6 kgf = 1005.31 kgf = 317.68 kgf = 7236 kgf

Total Cutting Force at Station 3

= 14,339.59 kgf = 14.34 tonnes

Punch Holder Thickness Die Holder Thickness

= 44.50 mm = 51.00 mm

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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 Die Holder Thickness

= 31.75 mm = 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

Station 1 2 3 4

Cutting Force (kg f) 10527.56 7492.2 14339.59 879.65

Stripping Force (kg f) 1052.8 749.2 1434.0 88.0

Press Capacity (kg f) 11580.36 8241.42 15773.55 967.62

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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

Curved Outlines Type

26

Curved outlines:

For these, dimensions A are given a minimum allowance of 70% of the strip thickness T.

T A A

= = =

0.5mm 70% of 0.5mm 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

Assume S = 1500 mm N=
[ . ( . )]

+1

N = 5.850 N~5

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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

28

Appendices 1. Scrap Strip Layout 2. Die Set Station 1 3. Die Set Station 2 4. Die Set Station 3 5. Die Set Station 4

PART DRAWING

STATION ONE

STATION TWO

STATION THREE

STATION FOUR