Our sincere thanks to ,

 Mr. M.VISWANATHAN (PRINCIPAL)

 Mr.J.MURALI (MANAGER TRG)

 Mr.A.SARAVANAN(SECTION INCHARGE)

 Mr.V.RANGARAJAN(SECTION INCHARGE)

OTHER STAFF MEMBERS

 INTRODUCTION
•As a part of our curriculum project is vital subject, as we have to design a live tool.

•Project work plays a vital role in technical education.

•During course of the project, the student will be able to acquire adequate knowledge and
gain experience in the relative field.

•As project work exposure the students to various problems, they get the confidence to
overcome such problems in future.

•It helps them to achieve the goal with will.

•Project work helps to learn how to evolve specifications under given constraints by
systematic approach and construct a Tool.

• The primary object of this project report is to give the detailed concept of forming
&dimpling tool.

•Report also provides the detail study of sequence in designing a tool, properties of
material and so on.
COMPONENT DRAWING

FUNCTIONING DIMENSION:
•Ǿ13 hole with respect to the tooling hole 26.8, 71.2.
•PCD of the locating hole
OUR CUSTOMER :

Turbo Energy Limited (Sholingur).

This component plays a vital role in the pneumatics assembly of the

ford engine.

It includes a drum which is being butt welded along with a washers

and an actuating rod.
 DESIGN PROCESS
The following process has to be considered while designing a press tool.
•Selection of economic strip layout.

•Grain direction of strip must be taken under consideration.

•Selection of suitable standard die set.

•Calculate all design factors like pitch, cutting force, stripping force, buckling
force etc.

•Read the component drawing thoroughly, gather all data and fill the information
sheet.
•Make the component drawing according to the specification .

•Shank point location must be found out to avoid wear in the pillar and bush.
•Selection of presses

•Make assembled drawings of tools and prepare for heat treatment details.
THE ABOVE MENTIONED PARAMETERS WILL MAKE DESIGN AN
EASY AND EFFICIENT PROCESS.
ANALYSIS OF PART

The part designed has to be examined for its stress

concentration and other deformation factors, since the part
involves forming operation.

This analysis will help us to predict the chances of

failure (fracture) during forming, and so alternatives can be
planned in design and development
of the press tools. Various methods can be adopted for the
analysis.
OUR APPROACH TOWARDS THE PROJECT:

Methodology

Methodology adapted here will explain us the step by

step method of systematic approach that is going to be executed
to complete the project successfully.

Preparation of Part drawing

The part drawing has been developed out of sample

given by the customer. Two dimensional drawing is done by
AutoCAD 2000 and 3D drawing is made in Pro-E (wild fire 2.0And
part details are specified as per the customer requirement like
tolerance, critical dimensions, coating details etc.
 Selecting the type and stages for
designing and manufacturing

As per the production capability, production requirement

and part geometry it is decided to go with stage tools for part, like
Blanking tool
Forming tool and
Dimpling tool
instead of a single progressive tool.
Blank development

In order to develop the blanking tool (progressive type), we

need to determine the blank size of the part i.e. size of the blank
before forming.
The blank size can be determined by any of analytical
methods or by using modeling software's like
FASTFORM,FASTBLANK etc.

Design & Development of forming tool

After determining the blank size (approx), forming tool has
to be designed and manufactured before the blanking. Forming
punch and die can be extruded out of the 3D model of the part
drawn in Pro-E (wild fire 2.0) software.
 Finalizing the Blank size

After manufacturing the forming tool, tool has to be tried

with approximately developed blank, these approximately
developed blank around 10 nos. can be made by wire EDM
process.

These blank has to be tried in forming tool and inspected

for the correctness as per specification, if variation is found then
developed size can be altered and tryout process is repeated until
correct dimensions are achieved in forming.
Design and Manufacturing of Progressive &
Dimpling tool

Once forming stage is free zed out then design and

manufacturing of blanking in progressive condition and dimpling
operation is carried out to the achieved dimension that resulted
after the trial and error method in forming stage.

Tryout and Product Validation

After manufacturing the tools, the tools are tried in

house and inspection is carried and validation report is submitted
to the customer along with samples.
 Product drawing modification

The product drawing is revised by the customer i.e. the

part number and the impression number need to be stamped in the
product that is going to be manufactured refer fig.1 for the stamping
letter details of part number “5701” and impression no. “1”.

Fig.1 Product drawing with stamping details

 GENERAL NOTES

TOOL TO BE LOAD ON - 63 TON PRESS -

SHUT HEIGHT - 240mm
COMPONENT NAME - ACTUATOR HOLDER
COMP.DRG.NO - 6000 641 032
ORDER NO - 12557
TOOL DRG. NO - 15109
SHEET THICKNESS - 3.16 / 2.84 mm
MATERIAL - RR St 1403 - EQUIVALENT
MATERIAL NO - 1.0338
TENSILE STRENGTH - 270 to 350 MPa
ELONGATION - 32% Min
YIELD STRENGTH - 220 MPa Min
Important of the functioning dimension.
• The dimpled projection should be even and it should vary
from 0.7-0.8 for effective seating of butt welding of the dump
with the holder.

• The flatness in the dimpled area and in the flat area should be
with in 0.1.

• The height of the variable angle should be 5

• The angle should be 4.5

• The locating holes should not be damaged due to the

dragging action.

• The dimpling PCD should be exact with the center of ǿ13 hole
with the tolerance of 28.5-29.5.
Our project includes the manufacturing of,

• Ford actuator bending tool. (12557).

• Ford actuator dimpling tool (12558).
• Checking fixture (or) gauge for ford
actuator. (12559).
 RAW MATERIAL RECEIVING

Soon after getting blueprints, process planning has been done in

chorus the raw material has also been indented.

The raw material size was also given in bill of material.

The same size has been indented.

We have collected some of material from the stores of NTTF-IL

vellore.

The top plate and bottom plate are casted. So it has been out so
selam engineering works.

We have inspected the raw material in the presence of store

below holes.
OUFIRST STEP TOWARDS THE PROJECT
To start with the projects at first we have blank developed
and study the various characteristics.
The changes in dimension such as ǿ13 hole were
observed. Then based on the blank development the second
model of the component is prepared.
Then the wire cut samples were taken. This is to done to
study the practically varying characteristics such as,
 MATERIAL.
 SPRING BACK OF THE MATERIAL.
 IT’S BENDING CHARACTERISTICS ETC.,
The final size of the blank will be decided only using the trail
and error method using the wire cut samples.
BENDING TOOL
PROCESS
PLANNING
PROGRESS
CHART
BENDING TOOL:

At first the forming tool was designed with full

boxing, trail over the wire cut samples were taken and it
is later observed the following problem occurred.

• Shift in bending line.

• Dragging action over the locating hole.
 FMEA-1
(Failure Mode Effective Analysis)
SOLUTION ANALYSIS
Incorporating the spring with pressure pad.
ADVANTAGES:-
•Shift in bend line can be avoided.
•Dragging action due to improper action of load can be prevented.
DISADVANTAGES:-
•The existing punch & die has to be modified.
•It further increases the complication of the tool.
Then the coiled spring incorporated with the traveling pressure pad
trail over the wire cut samples was taken and later it is observed the
following problems have been occurred.
i.Unbalanced spring force will act over the component leads to
thinning action and poor flatness over that area.
ii.Less spring force results in the dragging action on the holes.
iii.Bowing action on the flat area due to the non availability of proper
boxing.
 FMEA-2
After FMEA
The following modifications are being done in our project
to avoid the above problem.

• To avoid unbalance stripping load which acts over the

component and to prevent the thinning action the rest button is
incorporated.

• To prevent the dragging action over the hole the spring force
further increased by the incorporation of the spur spring.

• To prevent the bowing action over the flat area a bottoming

block is incorporated beneath the pressure pad this gives good
boxing and ensures the good flatness in the particular area.
Forming punch and Die Design

The forming punch and die surface is extracted out of the

part drawing which is made out of Pro-E , which has considerably
saved the design time ref Fig. 7 and Fig.8

Fig.7 Formi ng Die design Fig.8 Forming Punch design

DEVELOPMENT OF FORMING TOOL
The forming tool is manufactured first in order to confirm the
blank size. The forming tool is manufactured with in house
facilities. The materials are processed under different machining
centers, for example the forming punch and die is a solid one
which is processed in the CNC machine where in the shape is
directly transferred from the Pro-E model.
The forming tool is assembled and made ready for trial on
2008 02 15
The assembled view of the tool can be clearly seen in Fig.9 and Fig.10

Fig.9 Tool Bottom assembly

Fig.10 Tool Top Assembly