nother kind of press is a set of plates with a relief, or depth-based design, in them.

The metal is placed between the plates, and the plates are pressed up against each other, deforming the metal in the desired fashion. This may be coining or embossing or forming. A punch press is used for forming holes. Capping Presses form caps from rolls of aluminium foil at up to 660 per minute. Progressive stamping is a manufacturing method that can encompass punching, coining, bending and several ways of modifying the metal, combined with an automatic feeding system. The feeding system pushes a coil of metal through all of the stations of a progressive stamping die. Each station performs one or more operations until a finished part is made per the requirements on the print. The final operation is a cut-off operation, which separates the finished part from the carrying web. The carrying web, along with metal that is punched away in previous operations, is considered scrap metal.

STATEMENT OF THE PROBLEM

Design, Manufacture & Analysis of Press tools as a set of stage tools for Front Right/Left Disk Protector is the subject considered for this project work. A new component is usually manufactured without giving enough attention to simulation & analysis aspects, by trial & error process in order to obtain a part without defects. Even the previous experience of designers is not enough to decrease the number of trial, rework on tool & redesign cycles.

OBJECTIVE OF THE STUDY

The prime objective of the study is to design a set of tools to produce the component that exceeds the expectations of the customer in Aspects like Quality, Cost & On time delivery, it holds out the strong probability of achieving the following: 1. A die or set of dies that combines maximum production and least maintenance with lowest feasible cost, for the desired or expected life. 2. Maximum utilization of the least expensive stamping material that will satisfactorily function. 3. Most efficient press working practices.

4. A stamped product that consistently meets sales and service requirements of shape, dimensions, strength, finish, style and utility.

SCOPE OF WORK
The basic concept involved in this method to attain the objective is the systematic and correct tool design, a well planned approach has been employed. The methodology consists of the following as detailed here and in the subsequent chapters.
Component analysis. Step by step approach to die design. Selection of tooling materials. Tool fabrication. Tool assembly and tryout, Tool cost estimation.

The most economical manufacturing of fineblanking tools can be done if the die sets and their components are manufactured in series. Therefore, SCHMID has designed a standard line of die sets, which is available from stock. A full set of detailed drawings is provided with each press. For each type of press, SCHMID has different sizes of standard die sets. The choice depends on the size of the fineblanking component.

1. Top die shoe 2. Bottom die shoe 3. Guide plate 4. Top back-up block 5. Bottom back-up block 6. Guide pin 7. Punch 8. Punch retainer with adjusting plate 9. V-Ring plate 10. Guide bushing 11. Adjusting plate 12. Punch retainer with adjusting plate 13. Ejector 14. Die 15. Piercing punch retainer 16. Guide bushing