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1. INTRODUCTION
The development of the power press gave rise to a demand for another form of tooling,
the “PRESS DIE / DIE TOOL” the function of which is to cut and form sheet metal into
predetermined shapes and configurations. The work of fabricating press dies is similar to, but
not identical with, that of producing jigs, fixtures, and other tooling, which led to many of the
specialized machine shops labeling themselves tool and die shops. Sheet metal press work
methods date back longer than one can imagine when speaking of automated processes. The
technology of sheet metal press work emerge with the development of steel industry, and to a
large degree we owe our present standard of living to the production of stamped metal parts.
The numerically controlled machine tool is an important contribution for sure, but the punch
press and its relatives in the far end of the plant are still considered our bread and butter.
Die tool design is a specialized phase of tool engineering. The basic task of the die tool
designer is to provide drawings of a die or set of dies to produce the workpiece. He will be
provided with a blueprint of the workpiece to be manufactured, the name and specifications of
the machine to produce the workpiece, and the number of workpieces required. If large number
of workpieces are needed, an expensive tool may be justified else the tool must be inexpensive.
In all the cases, the dies must be made as economical as possible for the required service.
In order to complete the task, a complete set of drawings showing
1. An assembly drawing.
2. One or more sub assemblies, if the design is complex.
3. A detail drawing of each part
4. A complete list of parts needed to make the tool.
are to be produced.
A knowledge of standards and procedures is required for die tool designing. The greatest
economy can be effected where standard parts can be worked into new tools. Since they are
made in large numbers, standard parts can be manufactured at a lower cost than special jobs.
The tool designer must understand how tools perform their function. He should also know the
physical properties of materials used in making tools. These are mostly steel, but since there are
now large variety of alloy steels, each with its own individual properties, this subject is a
comprehensive one.

1.1. Fundamentals of Die tool operations:

Before beginning the study of die making it is necessary to attain a clear understanding of the
following terms:
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Piece part:
A piece part is the product in itself (the draftsman’s erasing shield and a bottle cap opener are
examples of this kind of product) or it may be only one component of a product consisting of
many and different parts, such as an electrical terminal used in a television set. The die may or
may not produce the piece part in a finished state.
Stock material:
General term for any of the various materials from which the piece part is made.
Die:
The word "die" has several definitions. We utilize two: (a) a complete production tool, the
purpose of which is to produce piece parts consistently to required specifications, and (b) the
female part of a complete die.
Punch:
A punch is a male member of a complete die which mates or acts in conjunction with the female
die to produce a desired effect upon the material being worked. A die can be a simple tool
composed of punch, die block, and stripper, or it can be an extremely complex mechanism
which performs many and various operations.
Die Clearance:
It is the intermediate gap between the punch and die cutting. It depends upon the physical
properties of the material to be sheared.
Table 1.1 Clearance given for materials

Compound tool:
A die in which two cutting operations are accomplished in one press stroke, the most common
type of compound die blanks and pierces a part.
Progressive tool
A die in which two or more sequential operations are performed at two or more stations upon
the work which is moves from station to station.

Stripper:
It acts as ejector that easily removes the work piece struck to the punch. Thus called as stripping
device.
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Function of Stripper:
 To hold the raw material against the die.
 Guide the punches.
 It strips out the material that sticks to the punch
Shedder:
It acts as ejector that removes the work piece from the die.
Knock-out:
It acts as ejector that removes the work piece from the die, which directly acts on the work
piece.
EN:
Abbreviation for EN is ENGLISH NUMBER or EMERGENCY NUMBER. It is the British
standard used for referring to the materials (steels).
STD: It refers to the STANDARD available in the market.
CRS: It refers to the Cold Rolled Steel.

1.2. Piece Parts Produced by blanking and/or piercing:

The piece part in Fig 1.1 is produced by blanking. It is shown in relation to the stock
strip from which it was blanked.

Figure 1.1: Stock Strip that shows the strip layout.

The terms used describe the various aspects of the work are indicated. The stock strip is
stock material of the required thickness T which has been cut to strips of suitable width for the
particular job. The stock strip in this instance is fed through the die from right to left, as

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indicated by the feed direction arrow. The advance is the distance the stock must be fed
(advanced) to allow a clean blanking operation at each press stroke. The scrap bridge is the
scrap remaining between the openings in the stock strip after blanking. The advance distance is
equal to the scrap opening plus the scrap bridge.

The back scrap is so called because it is located toward the back of the press (away from
the operator). The front scrap is on the side toward the front if the press (toward the operator).
The lead end of the stock strip is the end that is fed into the die first. The opposite end of the
strip is called the tail.

The piece part Shown in Fig 1.1 would be called a blank if further work were required to
complete it. This is illustrated in Fig 1.2, where the piece part is the same as the first one expect
that there is an opening in a blank or piece part, the operation is called piercing. The slug is the
material that is cut out of the blank or piece part by the piercing operation.

Figure 1.2: piece part left after piercing operation.

To summarize, the piece part illustrated in Fig. 1.1 is produced by blanking. The piece
part in Fig. 1.2 is made by blanking and piercing, and the slug is a result of the piercing
operation.

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 An endless number and variety of stampings are produced by blanking and/or piercing.
In addition, there is another endless variety of piece parts in which blanking and/or piercing
complement other press working operations.

1.3. Basic Blanking or Piercing Operation

Figure 1.3: basic blanking or piercing operation under the press.

Whether the die shown in Fig. 1.3 is a blanking die or a piercing die depends solely
upon its intended use. It is called a blanking die if it is meant to produce blanks B of a desired
contour and size by cutting them out of the required type of material A. The blanks are desired
product (piece parts) made by the die. In most cases, the material remaining after the blanks
have been cut out is considered scrap.

If the purpose of the die is to make openings of a desired contour and size in the required
material a, it is called a piercing die. In this case A represents the piece part and B is called the
slug. The slug is usually considered scrap.
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 The basic elements of both dies are identical. The name of the die is derived form its
intended use. The physical effects of the tool upon the stock material are the same whether it is
punching out slugs in order to produce a desired opening in a piece part or whether it is
punching out blanks which are the desired product of the die.

1.4. Description of Blanking or Piercing dies:

Figure 1.3 shows the basic elements of a blanking or piercing die. These elements are
the die block in which the proper female die opening has been made, the punch, and the stripper.
(The back gage which locates the back edge of the stock material is, in this instance, a part of
the stripper). They are mounted on a die set in order to achieve and return proper matching of
the punch and the die opening. The die block and stripper are secured to the die shoe by means
of screws and dowels. The punch is screwed and doweled to the punch holder. When the die
is set up or mounted in the punch press, the punch holder is secured to the ram of the press and,
of course, moves with the ram. The die shoe is secured to the press bed and remains stationary.

Action of Blanking or Piercing Die

Refer to Fig 1.3 the stock material A is fed or loaded in the proper position on the top
surface of the die block. When the press is tripped, the ram drives the punch through the stock
material A into the die opening, thereby producing an opening in the stock material by cutting
out the blank or slug B. This blank or slug remains in the die opening when the punch is
withdrawn and is pushed through the die by the blanks or slugs produced subsequently.

Stripping:
After the blanking or piercing has taken place, the punch is returned to the open position by the
press ram as it completes its cycle. The stock material clings to the punch and will prevent it.
This is the function of the stripper: it keeps the stock material from traveling with the punch on
the return stroke. Because the stock material is held back by the stripper, the punch is withdrawn
from the material on the return stroke.

1.5. Reaction of the stock material: Shearing action

The result of the forces imposed on the stock material by the working of the blanking or
piercing dies is a shearing action. This shearing action may be considered in three stages which

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are important to the die maker because of their direct relationship to the dimensional qualities
and appearance of piece parts.
They are also related to the effective working and life of the die. These stages showing the
reaction of the stock material are illustrated progressively below.
Critical stages of shearing action on metal.

Figure 1.4(A): first stage – plastic deformation

Figure 1.4(B): second stage – penetration (shear)

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 Figure 1.4(C): third stage - Fracture

First stage – plastic deformation, View A: The stock material has been placed on the die, the
press has been tripped, and the punch is being driven towards the die. The punch contacts the
stock material and exerts pressure upon it. When the elastic limit of the stock material is
exceeded, plastic deformation takes place.

Second stage – penetration, View B: As the driving force of the ram continues, the punch is
forced to penetrate the stock material and the blank or slug is displaced into the die opening a
corresponding amount. This is the true shearing portion of the cutting cycle, from which the
term “shearing action” is derived.

Third stage – fracture, View C: Further continuation of the punching pressure when causes
fracture to start at the cutting edges of the punch and the die. These are the points of greatest
stress concentration under proper cutting conditions the fractures extend towards each other and
meet. When this occurs, the fracture is complete and the blank or slug is separated from the
original stock material. The punch then enters the die opening, pushing the blank or slug slightly
below the die cutting edge.
These three stages of shear action are responsible for the characteristic appearance of
piece parts produced by blanking and piercing

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 Figure 1.5: cutting operation with optimum clearances

Typical appearance characteristics:

The appearance characteristics of material that has been blanked or pierced are factors of
significance to the tool and die maker. A visual check or examination of these characteristics
tells him whether or not the punch and die have the proper amount of clearance between them.
He can also tell whether the punch is properly aligned with the die opening.

Optimum cutting clearance: In the above figure, the blank or slug has been made under
optimum cutting conditions. The edge radius is the result of the initial plastic deformation which
occurred during the first stage of the shear action.
The highly burnished band, resulting from the second stage (penetration) of the shearing
action, is the cut band. The width of the cut band is approximately 1/3 the thickness T of the
stock material .the balance of the cut is the break, which results from the third stage (fracture) of
the shearing action.
Cutting clearance is the space between a side of the punch and the corresponding side of the die
opening at the cut edge when the punch is entered in the die opening. Therefore, the cutting
clearance should always be thought of and expressed as the amount of clearance per side.

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Burr side: The burr side is adjacent to the break. The burr side is so called because, if a
noticeable burr condition develops, it will occur on this side. Burrs should be practically
nonexistent if the cutting clearance between the punch and die is correct and if the cutting edges
are sharp. In fact, when a dies is running in production, the degree of burr on the piece parts is
an indication whether the die is ready for sharpening.
Characteristics of the blank or slug and the punched opening are inversely identical. The
burr side of a blank or slug is always towards the punch. The burr side of a punched opening is
always towards the die opening.

Excessive cutting clearance: The comparatively large space between the punch and die cut
edges allows the stock material to react to the initial punch pressure in a manner approaching
that of forming rather than cutting.
The edge radius becomes larger and does not blend smoothly into the cut band. The cut band
becomes smaller, sometimes degenerating to a mere line of demarcation between the break and
the edge radius. The break shows greater irregularities due to tearing. These irregularities may
extend into the cut band and occasionally into the edge radius.
The stock material has been forced into the clearance space, and when the break occurs, large
burrs are present at the break edge.
Residual incomplete fractures may sometimes be found in the finished piece parts. This
is because the material starts to fracture in the normal way, beginning at the cut edges, but
cannot complete a normal fracture due to the excessive clearance, which allows a new path of
least resistance to be set up.

Insufficient cutting clearance: When the cutting clearance is slightly too small, the condition
may be identified by a greater width and irregularity of the cut band. If however, the
proportional cutting clearance is further decreased, the stock material may react by showing two
or more cut bands.
This is somewhat idealized concept of the actual condition, but it serves to typify the reaction
of the stock material to insufficient cutting clearance. Because of the steeper angel between the
punch and die cut edges, the resistance of the stock material to fracture is increased. The

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resulting accumulation of pressure may cause the initial fractures to originate in the clearance
rather than at the cut edges.

1.6. Theory of Bending

Basics of Bending

When used in reference to stamping dies, the term bending is restricted to a definite type
of forming operation. In bending operations, the material is formed around a straight axis which
extends completely across the material at the bend lines. A bending operation produces a plane
surface which is at an angle to the original plane of work piece (or stock strip).
The illustration serves also to depict fundamental elements of bends. Shown here are the bend
radiuses, bend lines, and bend axis. Refer to view A and note the following relationship:
1. The bend radius is tangent to the inner plane surfaces of the piece part.
2. The bend lines occur at the tangency of the bend radius with the inner plane surfaces.
3. At the bend lines, the bend radius is perpendicular to the inner plane surfaces.
4. The bend axis is located at the center of the bend radius.

Figure 1.6: Bending nature of material.

Bending stresses:
Application of the force causes deflection of the sheet, creating an inner and an outer surface.
The inner surface tends to become shorter as the force is applied, and the outer surface tends to
lengthen. Somewhere between the outer and the inner surface, there exists a neutral plane which
does not change in length. Material inside the neutral plane is in compression; material outside
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The neutral plane is in tension. If the material is uniform in section, and if its elastic limit is not
exceeded, the neutral plane coincides with the center line of the material.
If the elastic limit of the material is not exceeded, plastic flow does not occur, and the material
will spring back to its original shape when the force is removed. If instead of being removed, if
the force is increased, the material will bend. Whenever the applied force becomes strong
enough, it causes the stresses to increase beyond the elastic limit of the material. Exceeding the
elastic limit forces of the material into a state of plastic flow within the bend area, resulting in
the permanent deformation of the material.

Plastic deformation due to bending:

As far as the press working of the metals is concerned, the shape of the material can be
changed. The volume of the material however is considered constant. (Volumetric change on the
order of a small fraction of 1 percent may occur, but this is ignored.)
Bending operations change the shape of the material in specific manner. Because the material
changes in shape but not in the volume, the act of bending causes the portion of the material
which is within the area of the bend to become distorted.
Actually some distortion, proportionate to the ductility of the material and the severity of the
bend, exists beyond the bend area. Since bending is a specific type of forming operation, all
bends are distorted in similar manner. This distortion is called plastic deformation because it is
associated with the characteristic plastic flow of the material with in the bend area.

The bending allowance curve:

The curved neutral plane of the bend area is called the bend allowance. Since the bend-
allowance curve is subtended by the bend angle, the length of the curve is directly in proportion
to the size of the angle. Precisely speaking, the bend-allowance curve is not a true arc described
about the bend axis. It approximates such a true arc so closely; however, that for all bending
calculations it is considered as one.
It is important for the die maker to be thoroughly conversant with the elements of bend and
how they are interrelated.

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 Figure 1.7: Parameters in bending

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 2. DIE TOOL - DESIGN METHODOLOGY

2.1. Systematic procedure followed for die making :

1. Study of Basics of Die making.

2. Analysis of the details of the component provided.
3. Study of material characteristics of the component
4. Listing the type of tools to be designed.
5. Blank opening up calculations of the component.
6. Force /Tonnage calculations
7. Springs selection
8. Designing and determining the dimensions of the individual parts of the tool.
9. 2- Dimensional and 3-Dimensional modeling of all the parts of the tools, assembled tools.
10. Preparing the final Bill of Material lists of the tools designed.

2.2. Analysis of the details of the component provided.

Chief objective of the project is to design sheet metal dies for Rear suspension mounting
bracket. such that it is 1. Easy and safe to operate, 2. Practical and attractive and 3. Economical.
Component material is CRS –D grade having thickness of 2 mm and bearing a weight of 361.8 gms
Brief details of the component:
It is a new component designed by the R & D dept of MLR Motors Ltd for their new 3- wheeler
project named “TEJA SUPER”. Till date, in this firm, these kinds of components were being made
using handy tools like shearing machines, hammers etc or being bought from the other larger firms.
Due to the hand made components, there is always a problem of quality, accuracy and assembling.
In order to overcome these drawbacks, to improvise the production process and the quality of the
component, it has been decided to go for sheet metal dies for this component. As a part of it, we
were being allotted the task of designing the sheet metal dies for this component analyzing its
requirements and material characteristics. The solid model of the component has been modeled in
Pro-e based on the component drawing and is shown in the fig 2.1.

3-D VIEW

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 Figure 2.1: 3-d view of component.

2.3. Thumb rules in the process of designing the dies

 Minimum value of the thickness of the die block for any operation should not be less
than 20mm.
 Die block thickness (td ) = cube root of Cutting force (rounded off) + 5 mm

 Stripper plates thickness = ½ td = ½ * 45 (rounded off)

 Lower and Upper plate’s thickness = 1.5 td ( for sheet metal greater than or equal to 2
mm )

 Thickness of the plates taken = 40 mm

(In order to save the material cost as it is not that required in this tool.)

 Stripper traveling = 2 + sheet thickness.

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3. BLANK OPENING UP CALCULATIONS AND STRIP LAYOUT

2-D View of the component

Figure 3.Basics of Bending.1: 2-Dimensional View of Component.

3.1. Division of component into sections :

The component has been divided into Sections as shown in the figure above.
They are,
1. Section ‘A’
2. Section ‘B’
3. Section ‘C’
4. Section ‘D’
5. Circular section
Length of the required work piece “in the flat” = length of its neutral plane.
To determine the Blank length, bend allowance ‘P’ is to be determined for each bend.
Estimated or Tentative Blank length =sum of lengths ‘L’ of the bend legs and the
allowances.
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 B = L1 + P + L2
‘P’ is called the bend allowance.
To find ‘P’
P = (R+C) 2**N/ 360.
N = angle of bend
R = Bend radius (Internal radius need to be taken)
C = Distance from the inner surface to the neutral plane.
‘C’ is a variable factor depending largely upon the Ratio of stock thickness ‘T’ to the bend
radius ‘R’. Optimum value for ‘C’ may be considered to be,
When

For the component we are dealing with,

Bend angle ‘N’ is 90° and
Thickness ‘T’ = 2mm.

3.1.1. Section ‘A’

Figure 3.Basics of Bending.2: Component View along Section A-A.

R1 = 2 ; R2 = 4 ; R3 = 2 ;
L1 = 4 ; L2 = 145.84 ; L3 = 46 ;
P1 = (2+ 0.33*2)*2**90/360 = 4.178.
P2 = (4+ 0.4*2)*2**90/360 = 7.539.
P3 = (2+0.33*2)*2**90/360 = 4.178.
Note: 1. Value of  is not rounded to 3.14.
2. All dimensions are in mm.
Total length for section A = L1 + P1 + L2 + P2 + P3+ L3
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 = 4 + 4.178 + 145.84 + 7.539 + 4.178 + 46
= 211.735.

3.1.2. Circular section :

Figure 3. Basics of Bending.3: Development of Circular Arc of Component.

3.1.3. Sections ‘B’,’C’ AND ‘D’:

Figure 3.Basics of Bending.4: Component View along sections B-B, C-C, D-D.

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 For Section B-B
L1= 4; L2= 105.92; L3= 4;
P1= (2+2*0.33) ([2**90]/360) =4.19;
P2= (2+2*0.33) ([2**90]/360) =4.19;
Total length of Blank = L1 + L2 + L3 + P1 + P2;
= 4 + 105.92 + 4 + 4.19 + 4.19;
= 122.3

For Section C-C

L1= 4; L2= 79; L3= 4;
P1= (2+2*0.33) ([2**90]/360) =4.19;
P2= (2+2*0.33) ([2**90]/360) =4.19;
Total length of Blank = L1 + L2 + L3 + P1 + P2;
= 4 + 79 + 4 + 4.19 + 4.19;
= 95.38

For Section D-D:

L1= 11; L2= 134.99; L3= 11;
P1= (2+2*0.33) ([290]/360) =4.19;
P2= (2+2*0.33) ([290]/360) =4.19;
Total length of Blank = L1 + L2 + L3 + P1 + P2;
= 11 + 134.99 + 11 + 4.19 + 4.19;
= 165.35.

The dimensions of the blank obtained are always considered the tentative values and not the
exact values as they may be changed as per the convenience after testing the forming tool
operation on the blank which is tested.

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3.2. Dimensions of the TEST BLANK obtained after the calculations.

Figure 3.Basics of Bending.5: Blank Dimensions after Development of component.

Strip Layout
Using the strip width calculation standards by the industry,
For sheet thickness of 2mm,
Length of front scrap and back scrap should not be more than 3 mm.
Bridge scrap = 2 * Thickness of the sheet + 0.5
= 2*2 +0.5 = 4.5 mm.

Figure 3.Basics of Bending.6: Strip Layout

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Manufacturing of the tools for this component is being done in the following order.
1. Forming Tool.
2. Blanking and Piercing Tool.
 Based on the dimensions of the blank obtained, the required blank is cut from the strip
using the laser cutting operation.
 This particular blank obtained is considered to be the “TEST BLANK”.
 Test Blank will undergo the forming operation on the forming tool and then the shape
and size of the component obtained is compared with the given standard drawing.
 Changes in the blank dimensions will then be made inorder to maintain the accuracy.
 These changed dimensions of the blank are again reflected in the design of the
Blanking and Piercing Tool.

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4. CUTTING AND FORMING FORCE CALCULATIONS
(AS PER THE THUMB RULES OF THE INDUSTRY)

4.1. Blanking and Piercing die tonnage calculation:

Cutting Force = S*p*t
= 40*649.29*2
= 51940 kgs
= 51.94 tonnes.
Where
S = shear strength of the sheet metal (kg/mm2).
(Here the material of the sheet metal is Cold Rolled Steel whose shear
Strength value is taken to be 40 Kg/mm2)
p = perimeter (mm).
t = thickness of the sheet metal (mm).
Top Stripper Force = 10% of the Cutting Force
= 51.94*(10/100)
= 51.94*0.1
= 5.194 tonnes.

Bottom Stripper Force = 10% of the Cutting Force

= 51.94*(10/100)
= 51.94*0.1
= 5.194 tonnes.
Total Tonnage for the Blanking and Piercing tool:
= Cutting force + Top stripper force + Bottom stripper force
= 51.94 + 5.194 +5.194
= 62.328
The press used for cutting operation is = total tonnage + 20% of total tonnage obtained
= 62.328 + [62.328*(20/100)]
= 62.328 + 12.46
= 74.788 tonnes
Standard mechanical press available in the above range is 80 Tonne press.

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4.2. Forming Die tonnage calculation:
Forming Force = 70% of the Cutting Force
= 51.94*(70/100)
= 51.94*0.7
= 36.35 tonnes.
Stripper Force = 10% of the Forming Force
= 36.35*(10/100)
= 36.35*0.1
= 3.635 tonnes.
Total tonnage = Forming Force + Stripper Force
= 36.35 + 3.63
= 39.98 tonnes.
The press used for this forming operation = total tonnage in forming + extra 20% of total
tonnage
= 39.98 + [39.98*(20/100)]
= 39.98 + 7.99
= 47.97 tonnes
Standard mechanical press available in the above range is 50 Tonne press.

4.3. Calculation of dimensions of the dies. (referring to thumbrules in pg.no.15,

chapter 2)

 Die block thickness = cube root of 51.94(in cms) + 5.

= 40 + 5
= 45.
 Stripper plate thickness = ½ * 45 (rounded off) = 25.

 Lower and upper plate thickness taken as 40 mm.

 Stripper travelling = 4 mm.

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5. SELECTION OF SPRINGS

A spring is an elastic member which store energy and provides a force over a distance by elastic
compression. Spring have ability to withstand relatively large compressions elastically. Today
springs find tremendous applications in engineering and other areas, which makes wide variety
of springs both in size and shapes. Springs are mainly used for following functions.
1. To cushion, absorb or springs or control the energy either due to shock or vibration as in
railway wagons, automobiles, shock absorbers, press tools etc.
2. To exert a force as in spring loaded safety valve clutches etc.
3. To support moving masses or to isolate vibrations.
4. To store energy, - that way spring find use in clocks, toys, machines etc.

5.1. Classification of springs :

Springs are classified according to their shapes and type of stress they have to withstand.
Following are main types of springs,
1. Compression Springs.
2. Tension Springs.
3. Spiral Spring.
4. Disc Spring.
5. Spring rings and bars

Figure 5.1: Spring Types by application.

We dealt with the compression springs used for press tool dies for sheet metal working.
The major types of springs used in tool and die industry -
 Helical Coiled Springs
 Polyurethane Springs
 Belleville (Washer) Springs
 Leaf Springs

Here, we deal with only helical coiled springs for these tools.
These springs are known as ' DIE SPRINGS'.
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5.2. Die springs :

Die springs are mainly made up with rectangular wire to generate high loads as well as high
compression. Die spring need proper selection. The first thing to be consider in the selection of
spring will be type of job spring will be called upon to perform such as short period, long
period, high speed, heavy load, high compression etc. In slow moving dies, at low load and low
compression, it is possible to achieve good performance of die springs. At high speed, heavy
load and high compression the life expectancy of die spring decreases. The most common
problem is the use of die spring too close to, or beyond, the springs, physical limitations. (Use
upto maximum operating conditions) To increase useful life of the die springs, use as many
springs as the die will accommodate to produce

The required amount of load with least amount of compression. This catalogue provides all
details of various die springs commonly used worldwide. Almost all die springs are identified
with color code, with reference to their load and compression.

Figure 5.2: Spring Notation

5.3. Types of Loads on springs

1. Static Loading
(E.g., Braking, Winding and accumulating springs)

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2. Dynamic Loading of Limiting Duration
(E.g., trigger mechanisms in fire arms, Shock absorbers)
3. Dynamic Loading of Indefinite Duration
(E.g., Valve springs of IC engines, springs in forging machines and presses)

Table 5.1: Spring Compression Table.

Load classification and corresponding colour coding for Helical Springs:

Figure 5.3: Color Coding of springs.

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5.4. Guide lines – Spring selection and Operating conditions

1. Select the spring carefully at the design stage.

2. For longer stroke - select light load or medium load spring.
3. For more load - select heavy load or extra heavy load springs.
4. Calculate spring stroke (required compression.)
5. Preloading compression should be equal to 5 % of the length.
6. Use guide pin, a locating bore as a guide - this is essential for spring having a free length /
diameter ratio exceeding 3.5.
7. If possible use longer springs for lower loadings.
8. Never compress springs beyond the average life load and compression.
9. Always check spring holder heights and working strokes of moving elements after die tools
has been reground.
10. Protect springs from corrosive agents.
11. Do not exceed a working temperature of 250 C, No significant load reduction occurs up to
120 C, beyond this temperature an average loss of 1 % for every 400 C must be calculated.
12. Do not replace one spring at a time, if they are multiple in use.
13. Do not alter physical characteristics of springs like cutting of coils, grinding of internal or
external diameter.

Selection of springs for Blanking and piercing tool:

 Based on the area of the blank, the number of springs with the diameter of our choice is
being selected.
 For this tool, based on the available area using the idea sketches.
 For the bottom stripper: 5 springs of 40 diameter are being used.
 For the top stripper: 6 springs of 40 diameter are being used.

5.5. Selection of springs for Blanking and Piercing die

Load calculation for the top stripper:
Stripper force that was obtained = 5.194 tonnes.
Number of springs used = 6
Each spring will carry a load of = 5.194 *1000/ 6
=865.66 kg.
Page | 27
Load calculation for the Bottom stripper:
Stripper force that was obtained = 5.194 tonnes.
Number of springs used = 5
Each spring will carry a load of = 5.194 *1000/ 5
= 1038.8 kg.
 Using the catalogue provided by the industry, “Pawan High Quality Springs”,
Aurangabad.
 For the above load and diameter of 40 mm ,
 It is being found that the type of springs that are to be used for both the top and the
bottom strippers is an extra heavy load spring with a free length of 51mm.
 Color coding for extra heavy load spring is “YELLOW”.

5.6. Selection of springs for the Forming tool:

For this tool, based on the available area using the idea sketches drawn, it has been found that
we can use 5 springs of 32 mm dia.
Stripper force that was obtained = 3.635 tonnes.
Number of springs used = 5
Each spring will carry a load of = 3.635 *1000/ 5
= 727 kg.
For the above load and diameter of 32 mm,
 It is being found that the type of springs that are to be used is heavy load spring with a
free length of 64mm.
 Color coding for heavy load spring is “RED”.

Refer to fig 5.3 to view the spring as per the above specification

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6. MODELING OF BLANKING AND PIERCING DIE:

Piercing is a shearing process where a punch and die are used to create a hole in sheet metal or
a plate. The process and machinery are usually the same as that used in blanking, except that the
piece being punched out is scrap in the piercing process.[1] There are many specialized types of
piercing: lancing, perforating, notching, nibbling, shaving, cutoff, and dinking.

The amount of clearance between a punch and die for piercing is governed by the thickness and
strength of the work-piece material being pierced. The punch-die clearance determines the load
or pressure experienced at the cutting edge of the tool, commonly known as point pressure.
Excessive point pressure can lead to accelerated wear and ultimately failure. Burr height is
typically used as an index to measure tool wear, because it is easy to measure during production.

Blanking is a shearing process where a punch and die are used to create a "blank" from sheet
metal or a plate. The process and machinery are usually the same as that used in piercing, except
that the piece being punched out in the piercing process is scrap.

From the structure of the component, we analyzed that we need to design a compound blanking
and piercing die for getting the specified contour of the component. Therefore the blank open
calculations were being done and the strip layout was being designed. Now based on the thumb
rules generally followed by the industry for the design of these tools, blanking and piercing tool
is designed, modeled in 2-D and 3-D.

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6.1. 2- Dimensional models of the Blanking and Piercing die :

2- Dimensional Assembled views and other views of the Blanking and piercing die.

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Figure 6.1.: 2-Dimensional Front, Top& Side views of Assembled, Top, Bottom - Blanking and Piercing tool

6.2. 3-Dimensional models of the Blanking and Piercing Die :

Different views of the bottom die – Blanking and Piercing

Bottom view indicating the through punch holes for easy slug removal.
Page | 31
Different views of the top die – Blanking and Piercing.

Assembled views of the Blanking and Piercing tool :

Figure 6.2: 3-Dimensional Front, Top& Side views of Assembled, Top, Bottom - Blanking and Piercing tool

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6.3. Detailed part drawings – Blanking and Piercing die :
Detailed explanation of the individual parts of the Blanking and Piercing die with their part
diagrams

Lower plate:

Figure 6.3-A: Lower Plate

Dimensions: 440X270X4
Material used: MILD STEEL
Description: It is named to indicate the lower part of the tool and this is called so for its support
to the portion of the tool to which all the parts of the bottom tool will be fixed. Material used for
it will be mild steel due to its ductile nature, low-cost and availability. This part is placed over

Page | 33
the stationary table of press. The above diagram indicates the location of drilled hole for guide
pillar and few more holes for easy handling of tool.

Top plate:

Figure 6.3-B: Top Plate

Dimensions: 440X270X40
Material used: MILD STEEL
Description: This is the part of the tool that basically supports the top parts of the tool; it is
normally called as shoe (Basically Punch Shoe – holds punch and Die Shoe – holds die). This
part of tool carries all the assembly of punch or die depending on convenience we assemble it

Page | 34
parts on this plate. Top plate is fixed to movable ram of press. The axes and the holes drilled
show the guide bush position and centre of tool.

Support Plate:

Figure 6.3-C: Support Plate

Dimensions: 150X80X8

Page | 35
Material used: MILD STEEL

Description: Support plate indicates it is the part by which we can increase the speed and
comfort in operating the stock into the tool i.e. feeding the tool. It is part that cannot be
normally seen in all tools only it depends on the volume of production or on another
reason of blanks of bigger area to be produced. It is fixed towards the operator side. As
there is no special application material, Mild-Steel can be used for its availability. This
diagram indicates the location of all the small parts from the centre of the tool.

Locating Pin:

Figure 6.3-D: Locating Pin

Dimensions: 10X20

Material used: STD

Description: Locating pins main purpose is to direct and locate the stock material into the
correct position. This is an abundantly available part in a varied range of specifications; such
standard parts used reduce the investment in developing such tools. Locating pins improve the
feeding into the tool; reduce the effort in feeding the tool

Shoulder Bolts:

Page | 36
Figure 6.3-E: Shoulder Bolts.

Dimensions: 1.) 18X73, 2.) 22x69

Material used: EN8D
Description: Shoulder bolts are normally called Socket bolts. It is used for main purpose of
restoring the position of parts like pad and stripper before and after loading the tool. It maintains
the energy in the springs.

Shank:

Figure 6.3-F: Shank

Dimensions: 40X50
Material used: MILDSTEEL

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Description: Shank is the part that can be fixed into the moving ram of press tool machines,
which can be very economic in reducing materials. It replaces the use of hang rods, hooks in
handling the tools. It is normally placed on the top plate of the press tool arrangement.

Pad:

Figure 6.3-G: Pad

Dimensions: 290X260X25
Material used: MILDSTEEL
Description: Pad is used to fix the stock material in a firm grip and perform the operations like
blanking, piercing and such cutting operations. Also eject or strip out the material around the
punch or inside from the die.

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Springs (YELLOW):

Figure 6.3-H: Spring

Dimensions: 32X51
Material used: STD
Description: Springs are used for the purpose of restoring the energy in the tool which is the
main source of application of stripping and ejection action. They are variedly selected from the
specifications of load, diameter, free-length and travel which also can be chosen in a constraint
of life cycle of spring. Springs used have minimum loading conditions for which we choose
them from load per millimeter deflection.
Setting Ring:

Figure 6.3-I: Setting Ring

Dimensions: 58X45
Material used: MILD STEEL
Description: It is the ring that is used mainly to support the sliding parts to move easily, they
are used when we require large travel of tool. Setting ring aligns the sliding parts in proper

Page | 39
position and also avoids load on guide pillars due to the longer length of the pillar. This just
supports the guide pillar for easy travel into the guide bush.

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Guide Bush:

Page | 41
Figure 6.3-J: Guide Bush

Dimensions: 58X80
Material used: EN353
Description: It is the part which allows guide pillar to slide, perform better and reduce the difficulty in
alignment in every stroke the press actuates. Such sliding parts reduce friction in every stroke; it is
fixed to top plate and allows very easy motion over the guide pillar. EN353 is used due to the sliding
parts must have good hardness to overcome shearing action by friction on continuous sliding over each-
other.

Guide Pillar:

Figure 6.3-K: Guide Pillar

Dimensions: 40X160
Material used: EN353

Page | 42
Description: Guide Pillar is fixed over the bottom shoe to easily guide the top tool over it, easy
motion of both the punch and the die and perform balanced operation over the stock material.

Good hardness is preferred for such sliding parts to operate in better efficiencies. EN353 is
selected for this guide pillar material. Case hardening is done for the guide pillar as full
hardening is not required.

Piercing Punch:

Figure 6.3-L: Piercing Punch

Dimensions: 1.) 19X45; 2.) 58X45

Material used: HCHCr
Description: Piercing punch is the tool used in cutting operations that require a part to be
removed from the stock material, piercing terms as removing a profile inside the stock material
which is different from other cutting operations. Removed material is called as slug and the
obtained stock material is the component. In piercing operation the required clearance is given

Page | 43
to the piercing die and piercing punch has the lower limit of tolerance of the profile to be
pierced.

Punch Holder:

Figure 6.3-M: Punch Holder

Dimensions: 205X164X21
Material used: MILDSTEEL
Description: Normally punches used will have direct attachment into the any of the shoe/ plate,
but few piercing operations require very small perimeter to be pierced. Such profiles have

Page | 44
difficulty in assembly into the tool; such punches can be retained to the shoe using a punch
holder/ retainer. Mild steel is used to optimize the cost in tooling.

Stripper:

Figure 6.3-N: Stripper

Dimensions: 207X166X20
Material used: MILDSTEEL
Description: This supports the blank in the blanking die and provides a firm grip of stock
against the punch during the blanking operation. It is used for the ejection purpose of blank
from the tool. It acts as a clipper for performing piercing operation, only purpose is to grip the
material when it is loaded, and eject the component at the time when load is removed from it.
Thus material used needs to have good availability and good property of ductility with suitable
heat treatment can be used for good optimization of economy in investment in development of
tool.

Page | 45
Blanking Punch:

Figure 6.3-O: Blanking Punch

Dimensions: 208X167X44
Material used: HCHCr
Description: Blank punch is the part that mates with the blanking die and performs blanking
operation by shear action over material. HCHCr is chosen for cutting operations for its
availability, its ability to with stand the operating conditions. Clearances are given on this part
for maintaining the lower limit of blank dimensions. Blanking punch also acts as Piercing die,
performs piercing operations on the blank or stock material.

Page | 46
Die Block Insert:

Figure 6.3-P: Die Block Insert

Dimensions: 1.) 250X100X45 2.) 125X25X45 (1+1) 3.) 250X80X45

Material used: HCHCr
Description : This is the main part that acts as die which has the outer profile of the blank
machined, here in a blanking operation die is the outer dimension and higher limit of the blank
tolerance so clearance will be given on the punch that performs blanking operation. Material
used is very expensive, optimizing the use of material can be implemented; depending on
volume of production die block thickness can be layered with easily available material with
suitable heat treatment of layered material.

Page | 47
Standard Parts Used for this compound Blanking and Piercing tool:

Figure 6.3-Q: Standard Parts

Cap Screw:
Dimensions: M12X50 (6+5)
Material used: STD

Cylindrical pins:
Dimensions: 12X50(4)
Material used: STD

Counter-Sunk Screw:
Dimensions: M8X20
Material used: STD
Cap Screw:
Dimensions: M10X30
Material used: STD

Page | 48
Cylindrical pins:

Dimensions: 10X30
Material used: STD
Description: These are parts used in assembly of the tool, they are manufactured in high
volumes, and thus the cost of development of tool in their purchase will be less
compared to the other products which have to be specifically produced for the specific
purpose of performing the specific work. These standard parts have importance in all the
tools and equipment, for assemblies, sub-assemblies. They are used for correct location
of the parts

Page | 49
7. MODELING OF FORMING DIE

The shaping of thin sheets of metal (usually less than ¼ in. or 6 mm) by applying pressure
through male or female dies or both. Parts formed of sheet metal have such diverse geometries
that it is difficult to classify them. Sheet forming is accomplished basically by processes such as
stretching, bending, deep drawing, embossing bulging, flanging, roll forming, and spinning. In
most of these operations there are no intentional major changes in the thickness of the sheet
metal.
Here we basically deal with the forming process called Flanging.
Flanging is a forming process in which the edge of a metal part is bent over to make a flange at
a sharp angle to the body of the part. Flange is a protruding rim, edge, rib, or collar, as on a
wheel or a pipe shaft, used to strengthen an object, hold it in place, or attach it to another object.

Figure 7.1: Flanging Operation.

7.1. 2 Dimensional models of the forming die

2- Dimensional Assembled views and other views of the Forming Tool.

Page | 50
Page | 51
Figure 7.2: 2-Dimensional Front, Top& Side views of Assembled, Top, and Bottom – Forming Tool.

7.2. 3-Dimensional models of Forming Die:

Different views of the bottom die – Forming

Different views of the top die – Forming

Page | 52
Different views of the assembled Forming Die :

Figure 7.3: 3-Dimensional Front, Top& Side views of Assembled, Top, Bottom – Forming Tool

7.3. Detailed part drawings – Forming Die :

Detailed explanation of the individual parts of the Blanking and Piercing die with their part
diagrams
Lower Plate:

Page | 53
Figure 7.4-A: Lower Plate

Dimensions: 465X310X40
Material used: MILD STEEL
Description: This is important part of the tool on which other parts are placed. All are rigidly
fixed to this plate with the help of screws and dowel pins. The various parts which are fixed to
this plate are blank holder, risers, guide pillars, bottoming blocks and also the springs are placed
on this plate. From the raw material this plate finished into a rectangular shape so that it can be
easily fit on to the bed of press. The material used for this is MILD STEEL as it is used only for
the holding the parts of die

Top Plate:

Page | 54
Figure 7.4-B: Top Plate

Dimensions: 465X190X40
Material used: MILD STEEL
Description: The lower plate and the top plate of the die tool are the important parts and the
body of the tool. The top punch is fixed to the top plate with the help of screws and pins.

Page | 55
Guide Pillar:

Figure 7.4-C: Guide Pillar

Dimensions: 40X185
Material used: EN353
Description: The Guide Pillar is mainly used for the correct alignment of the top and bottom
dies during the forming operation. There are two pillars fixed to the lower plate using a
press fit. The material EN353 is selected, which is hardened and tempered to 55-58
HRC. As it is a sliding part it should have more wear resistance.

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 Guide Bush:

Figure 7.4-D: Guide Bush

Dimensions: 58X85
Material used: EN353
Description: This is fixed to the top plate. The guide bush is so designed that during the
forming operation, the guide pillar and guide bush ensures the correct alignment of the
top and bottom dies. They engage the guide pillars with a close sliding fit. This is also
made of EN353 as guide pillar as these two are sliding parts.

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Raiser:

Figure 7.4-E: Raiser

Dimensions: 295X295X50
Material used: MILD STEEL
Description: This is rigidly fixed on the lower plate. The height of the raiser is based on the
shape of the component that is to be formed. On this riser the bottom steel [insert] is
fixed. This also ensures the support to the bottom steel. Raiser is made of MILD STEEL
as it is just used to hold the bottom steel rigidly.

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Form Punch:

Figure 7.4-F: Form Punch.

Dimensions: 207X144X60
Material used: EN31
Description: The punch which is called as the form punch is fixed to the top plate and it is
made corresponding to the shape and profile of the component that is to be formed. This is
made of EN31 which is hard material as the punch directly comes into contact with the sheet
metal which is formed to the required shape under it.

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Springs:

Figure 7.4-G: Spring

Dimensions:  32X64
Material used: STD
Description: These are mainly used for supporting the blank holder for the distribution of the
press load. The important function of the springs is that they are used for the ejection of
the component after the forming operation. These are available in market of standard
sizes and are selected based on the press load that is acting on the die.

Shoulder Bolts:

Figure 7.4-H: Shoulder Bolts

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Dimensions: 18X75
Material used: MILD STEEL
Description: These are also of standard size. These bolts are used for holding the blank holder
(pad). After the forming operation the compressed springs will push away the blank
holder
when the top die is removed. In order to hold that, these bolts are fixed to the blank holder
through lower plate. Shoulder bolts are made of C45 which are toughened to 90kg/mm2,
because during the disengagement of the two dies, the springs eject the blank holder
with a greater force. So, in order to withstand the stripper force these are toughened.

Bottoming Block:

Figure 7.4-I: Bottoming Block

Dimensions: 1.) 85X40X20; 2.) 109X40X20; 3.) 55X40X20

Material used: EN8D

Description: This is rigidly fixed to the lower plate. This is used for restricting the motion
of blank holder (pad) during forming operation. Its height is fixed based on the shape of the
component to be formed. The bottoming block is made of EN8D, case hardened and grinded
to 40-45HRC. As the load applied on the dies during the operation, it restricts the travel of
the blank holder to certain a limit based on the length of the flange to be produced in the
component.

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Blank Holder:

Figure 7.4-J: Blank Holder

Dimensions: 214X149X37
Material used: EN31
Description: The blank holder is also finished corresponding to the shape of the component to
be formed.This is made of EN31, which is also a hard material. As this comes in contact
with the sheet metal during the forming operation, it is made of hard material. The
forming is done in between the top punch and the blank holder (pad).

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Block:

Figure 7.4-K: Block

Dimensions: 214X149X37
Material used: MILD STEEL
Description: This is fixed to the raiser along with a plate of some dimension. They both
together acts as stripper.

Plate:

Figure 7.4-L: Plate

Dimensions: 440X270X40
Material used: MILD STEEL

Page | 63
Description: The plate is rigidly fixed to the raiser along with the block. The main use of this
is, after the forming operation, in case when the component is fixed to the top punch,
during the disengagement of top and bottom dies, it just strips the component from the
top punch.As the block this is also made of MILD STEEL as these are just used for
stripping of the component and there will be no load acting on them.

Bottom Steel:

Figure 7.4-M: Bottom Steel

Dimensions: 1.) 110X110X35 (1+1); 2.) 145X61X35(1+1)

Material used: EN31
Description: This is placed on the raiser and is rigidly fixed on to it with screws and dowels.
The contour of this bottom steel is made corresponding to that of the component to be
formed.This is made of EN31 which is hard, as there will be contact with the sheet metal
during the forming operation.

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Locating Pin:

Figure 7.4-N: Locating Pin

Dimensions: 214X149X37
Material used: EN31
Description: This is used mainly for the exact positioning of the blank that is to be formed.
These are the projections made on the blank holder (pad). This ensures the restriction of the
motion of the blank during forming operation.

Standard Parts Used for this compound Blanking and Piercing tool:

Figure 7.4-O: Standard Parts

Cap Screw:
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 Dimensions: M12X60
Material used: STD

Cyp Pin:
Dimensions: 12X60
Material used: STD

Cap Screw:
Dimensions: M12X45
Material used: STD

Cyp Pin:
Dimensions: 12X45
Material used: STD

Cap Screw:
Dimensions: M8X30
Material used: STD

Cap Screw:
Dimensions: M8X25
Material used: STD

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Cyp Pin:

Dimensions: M12X50

Material used: STD

Cap Screw:

Dimensions: 12X50

Material used: STD

Description: These are parts used in assembly of the tool, they are manufactured in high
volumes, and thus the cost of development of tool in their purchase will be less
compared to the other products which have to be specifically produced for the specific
purpose of performing the specific work. These standard parts have importance in all the
tools and equipment, for assemblies, sub-assemblies. They are used for correct location
of the parts

Page | 67
 8. BILL OF MATERIALS
8.1. Bill of material list – Blanking and Piercing tool
Sl.no Description Material Finish Size Quantity Remarks
1 Lower Plate Mild Steel 440X270X40 1
2 Top Plate Mild Steel 440X270X40 1
3 Support Plate Mild Steel 150X80X8 1
4 Support Plate Mild Steel 150X80X8 1
HARDENED & TEMPERED
5 Locating Pins STD 10X25 4 55 TO 58 HRC
6 Shoulder Bolt EN8D 18X73 3 TOUGHENED TO 90 Kg/mm2
7 Shank Mild Steel 40X50 1
HARDENED & TEMPERED
8 Pad Mild Steel 290X260X25 1 40 TO 45 HRC
9 Spring(YELLOW) STD 32X51 6
10 Setting Ring Mild Steel 58X45 2
CASE HARDENED 50 TO 55
11 Guide Bush EN353 58X80 2 HRC
CASE HARDENED 50 TO 55
12 Guide Pillar EN353 40X160 2 HRC
13 Shoulder Bolt EN8D 22X89 4 TOUGHENED TO 90 Kg/mm2
HARDENED & TEMPERED
14 Piercing Punch HCHCr 58X45 1 58 TO 60 HRC
HARDENED & TEMPERED
15 Piercing Punch HCHCr 19X45 1 58 TO 60 HRC
HARDENED & TEMPERED
16 Punch holder Mild Steel 205X164X21 1 40 TO 45 HRC
HARDENED & TEMPERED
17 Stripper Mild Steel 207X166X20 1 40 TO 45 HRC
18 Blank Punch HCHCr 208X167X44 1
HARDENED & TEMPERED
19 Die Block Insert HCHCr 250X80X45 1 58 TO 60 HRC
HARDENED & TEMPERED
20 Die Block Insert HCHCr 125X75X45 2 58 TO 60 HRC
HARDENED & TEMPERED
21 Die Block Insert HCHCr 250X100X45 1 58 TO 60 HRC
22 Cap Screw STD M12X50 13
23 Cyp Pin STD 12X50 4
24 Counter Sunk Screw STD M8X20 4
25 Cyp Pin STD 8X20 4
26 Cap Screw STD M10X30 6
27 Cyp Pin STD 10X30 2

Page | 68
 8.2. Bill of material list – Forming tool
Sl.no Description Material Finish Size Quantity Remarks
1 Lower Plate Mild Steel 465X310X40 1
2 Top Plate Mild Steel 465X190X40 1
CASE HARDENED & GROUND TO 55
3 Guide Pillar EN353 40X185 2 TO 58 HRC
CASE HARDENED & GROUND TO 55
4 Guide Bush EN353 58X80 2 TO 58 HRC
5 Raiser Mild Steel 295X295X50 1
HARDENED & TEMPERED TO 55 TO
6 Top Punch EN31 207X144X60 1 58 HRC
7 Spring (RED) STD 32X64 5
8 Shoulder Bolt C45 18X75 2 TOUGHENED TO 90 Kg/mm2
Bottoming
9 Block EN8D 85X40X20 1 TOUGHENED TO 90 Kg/mm2
Bottoming
10 Block EN8D 109X40X20 1 TOUGHENED TO 90 Kg/mm2
Bottoming
11 Block EN8D 55X40X20 1 TOUGHENED TO 90 Kg/mm2
HARDENED & TEMPERED TO 40 TO
12 Blank Holder EN31 214X149X37 1 45 HRC
13 Block Mild Steel 35X25X20 2
14 Plate Mild Steel 37X35X5 2
HARDENED & TEMPERED TO 55 TO
15 Bottom Steel EN31 110X110X35 1 58 HRC
HARDENED & TEMPERED TO 55 TO
16 Bottom Steel EN31 145X61X35 1 58 HRC
HARDENED & TEMPERED TO 55 TO
17 Bottom Steel EN31 145X61X35 1 58 HRC
HARDENED & TEMPERED TO 55 TO
18 Bottom Steel EN31 110X110X35 1 58 HRC
HARDENED & TEMPERED TO 50 TO
19 Locating Pin EN31 50X20 1 55 HRC
HARDENED & TEMPERED TO 50 TO
20 Locating Pin EN31 13X17 1 55 HRC
21 Cap Screw STD M12X60 7
22 Cyp Pin STD 12X60 2
23 Cap Screw STD M12X45 10
24 Cyp Pin STD 12X45 8
25 Cap Screw STD M08X30 4
26 Cap Screw STD M08X25 6
27 Cap Screw STD M12X50 5
28 Cyp Pin STD 12X50 2

Page | 69
9. CONCLUSION

Requirement of the industry for designing sheet metal dies for the component “REAR
SUSPENSION MOUNTING BRACKET” is fulfilled. It is the new component that they have
designed for their new project “TEJA SUPER” which is yet to be released. Process of
manufacturing these kind of components using the fabrication techniques has been eliminated
with the design of sheet metal dies for it , thus increasing the rate of production of these
components eliminating the assembly problems with the rear suspension and improving the
accuracy and quality of the component. Based on the component drawing provided by the
industry, analysis of the component material characteristics, dimensions and contour, conclusion
on the type of dies to be designed for manufacturing this component has been made. In order to
minimize the costs that occur for the die tools and making the processes easier, it has been
decided to make a compound die which can perform both Blanking and Piercing operations at a
time along with a Forming Die for getting the flanged structure.

Since it is one of the important components for which the dies are to be designed, care
has been taken about the contour of the component and its finish in the final stage i.e. forming.
The component to be produced from the dies should not undergo any kind of further machining,
so the dies designed are to be good enough in giving the near net shape as given by the R & D
department in the component drawing. Opening up of the component for obtaining the blank
dimensions with exact shape and size was not an easy task for us as it required good enough
level of imagination for obtaining the exact contour of the component in the opened state. By
dividing the component into different kinds of sections, we have overcome the problem and
finally obtained the Test Blank dimensions and contour. Then, the design of Blanking and
Piercing die and Forming die has been done using some of the thumb rules followed by the
industry. Manuals and charts provided by the industry were helpful in understanding some of
the unknown terms involved in the die making. Spring catalogue was being used for the
selection of springs for both the tools. The required standards of springs which have maximum
life were not available for the load calculations that were obtained. In order to overcome this
problem, we opted for the springs having medium life, but compensated it by increasing the
number of springs that can be used in the area available.

Page | 70
Material saving has been done in all possible cases and tried to adjust the dimensions accurately
by choosing the standards available in the market.

Dimensions of the top die in forming tool were initially same as that of the bottom die.
When the necessity of that dimension was being questioned by ourselves, we have reduced the
breadth of the rectangular shaped top die of the Forming Die to the extent that it is safe to use
thus saving the material cost to the maximum extent. Though calculations lead to the results
which are to be implemented in design of the dies, taking the material costs into consideration,
we have opted alternatives for reducing the material to the maximum extent. Thus a complete
set of sheet metal dies were being designed for the component which is to be manufactured to
the near net shape as given by them without any further machining.
Future scope for this project lies in the deformation analysis of the dies and simulating
the processes so that there can be further reduction in the material being used thus saving the
material costs to the maximum extent. Thickness of the plates need not to be very high as
obtained in the theoretical calculations, they can be reduced to some extent based on the results
that can be obtained by the simulation process.

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10. REFERENCES

1) BASICS OF DIE MAKING by D.Eugene Ostergaard.

2) ADVANCED DIE MAKING by D.Eugene Ostergaard.
3) TOOL DESIGN by Cyril Donaldson, George H LeCain and V C Goold.
4) SHEET METAL FORMING PROCESSES AND DIE DESIGN by Vukota Boljanovic.
5) TOOL AND DIE MAKING TROUBLE SHOOTER by Richard .M. Leed.
6) Manuals and charts provided by MLR Motors Ltd., Balanagar.
7) Spring Catalogues provided by Pawan Springs, Aurangabad.
8) www.sheetmetaldesign.com
9) www.diedesigner.com

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11. APPENDIX

A) Charts

Lead Radius for forming tool

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Guide Pillar standard - 1

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Guide Pillar Standard - 2

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Guide Pillar Standard (Graphical range)

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B) Tables

MATERIAL COMPOSITIONS OF THE STANDARD MATERIALS USED:

ROUGHNESS TABLE

ROUGHNESS REPRESENTATION TABLE

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