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ABSTRACT
KEYWORDS: Failure Modes, Punching, Risk Priority Number, FMEA Table, Chipping.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
1. INTRODUCTION
In today’s market, the expectancy of the customer towards high quality, reliable and
cost effective products is really high. So this expectancy proves a burden for the
manufactures as they strive to satisfy the customers with defect free, reliable product. So the
manufacturers switch to a newer technique which helps them to achieve the expected
standards. The challenge is to design a quality and reliability product early in the
development cycle. Such challenges are met with latest techniques and strategies
implemented in both the design and product manufacturing. One such technique is Failure
Mode and Effect Analysis (FMEA). Failure Mode and Effect Analysis (FMEA) is used to
identify potential failure modes, determine their effect on the operation of the product, and
identify actions to mitigate the failures [1-2].
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
reliability of the product. When these components are defective, this leads to the failure of the
product. Some of the failures in the punching process are like Punch chipping, Slug jamming,
Galling etc. [7]. These result in unfavorable consequences like failure of the system or
production of inaccurate products. Hence it is essential to conduct a FMEA in this process so
that the failure is avoided totally or reduced. Prior notification of these failures can prevent
them by following control measures.
2. IMPLEMENTATION OF FMEA
Capacity : 60 Ton
Maximum stroke : 6"
Bed Area : 42" X 32"
Speed : 40 Strokes per minute
Floor to Bed : 33"
Dimensions : 10'10" High, 8'6" RL, 6' FB
Weight : 15,000 Lbs
Tool used : Tungsten steel
Work piece material : Silicon steel
Several trials are to be conducted with the above mentioned parameters.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
Fig 1: High Speed Press Fig 2: Defective product from punching process
Burr formation
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
knowledge of the process. There could be other factors to consider (contributors to the overall
severity of the event being analyzed) [4]. Calculating the severity levels provides for a
classification ranking that encompasses safety, production continuity, scrap loss, etc. user.
Each effect is given a severity number (S) from 1 (no danger) to 10 (critical). A failure mode
with severity number of 10 results in severe dissatisfaction of the customer and may even
result in the physical injury due to the failure. Severity ratings in the range of 4-6 result in
mild dissatisfaction of the customer whereas those in the range of 1-3 are not so severe and
may even be not detected [2-6]. Table 1gives the guidelines based on which severity ratings
were given.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
The total risk priority number should be calculated by adding all of the risk priority
numbers. This number alone is meaningless because each FMEA has a different number of
failure modes and effects. The small RPN is always better than the high RPN. The RPN can
be computed for the entire process and/or for the design process only. Once it is calculated, it
is easy to determine the areas of greatest concern. There could be less severe failures, but
which occur more often and are less detectable. These actions can include specific inspection,
testing or quality procedures, redesign (such as selection of new components), adding more
redundancy and limiting environmental stresses or operating range. Once the actions have
been implemented in the design/process, the new RPN should be checked, to confirm the
improvements [1,2,6].
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
5 1 Review die, 35
Poor material press, &
control feeder setup
3 6 Excessive Reduce 126
stripping punch-to-die
force entry
Increase
punch-to-die
button
clearance
Consider
coatings to
add lubricity
2 2 Punch point 28
hardness too Verify
low hardness
1 1 Improper 7
punch Change
material punch
selected material
8 2 Sharpening Use Coolant, 112
damage correct speeds
and feeds for
grinding
7 1 Remove 49
Regrind burr regrind burr
1 1 Increase 7
clearance
Change
Tight die material
clearance Use Coatings
and surface
treatments
6 2 Increase 84
Sharp corners clearance in
on shaped the corners of
punches die button
6 4 Use shear 168
Flat punch angles and
face use edge
breakers
3 4 Improper Triple 84
heat tempered for
treatment high-speed
and follow
the guided
speeds
4 3 Cut-off 84
Improper operation &
punch large point
stagger first to enter
7 2 Improper 98
finish on
punch point Ensure there
and/or punch are no harsh
face grinding
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
Decreases 5 1 35
Sharpen or
resistance to Worn tools
replace tools
fracture
Shortens 4 1 Misalign Check 28
fatigue life components alignment
3 Slug 8 1 1 8
Jamming Punch Tight die Increase die
breakage clearance clearance
6 1 Excessive Change relief 48
Punch point land length from counter
deformation bore to taper
Land length
should not
exceed four
times material
thickness
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
5 2 Lack of 70
lubrication
on part
and/or
incorrect Check
lubrication lubrication
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
From the table 4, which shows FMEA table for punching process, it is observed that
the punch chipping and point breakage due to the high impact or compressive force has the
highest risk priority number. This can be minimized by the proper selection of punch-die
materials and by maintaining the correct clearance between punch and die. The burr and slug
formations also have detrimental effect on the overall quality of the final product. These
undesirable developments can be curtailed by varying the feed rates and speed of the
machine. To reduce the breakage of tool and burr formation due to excessive feed rate and
high cutting speeds, we have to perform the process in rated speed and acceptable feed rates.
In order to produce the punched products without any deformations or distortions, better tool
and work holding devices are to be used. To reduce metal chipping, initial speed has to be
minimum and proper cutting speeds should be employed. The tool life can be increased by
proper lubrication, minimizing the wear and other parameter perfection has to be achieved.
4. CONCLUSION
Thus the high speed punching process in motor manufacturing section has been
analyzed and the expected failure modes have been noted. From the results of the critical
analysis made on the punching process, the failure modes with greater risk priority number
has been selected. The causes, effects and possible alternate solutions are given along with
the ratings and priorities of action that decrease risk failure. The risk priority numbers are
specified which indicates the necessity of care for producing defect-free punching process
and its products. Thus this process analysis will serve as a helpful tool to detect the failure
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 4, Issue 3, September - December (2013), © IAEME
modes occurring in the punching process and also assures in the effective functioning of the
process.
This study provides a documented method for selecting a design with a high
probability of successful operation and safety. As a result of this approach, the system
development cost and time, the possibility of occurrence of same kind of failure in future are
reduced along with improved quality, reliability and safety of process/product. Consequently,
the productivity of the product is also increased. This approach can be well suitably applied
to consumer products like automotives, home appliances, etc., and other fields such as
manufacturing, aerospace, instrumentation, medical, chemical processing, etc.
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