MSME TOOL ROOM

INDO GERMAN TOOL ROOM AURANGABAD

(A Govt. of India society, Ministry of MSME)
An ISO 9001:2008 & ISO 14001:2004 Tool Room & Training Centre

PROJECT REPORT

DESIGN OF MOULD &

PRESS TOOL

FOR PARTIAL FULFILMENT OF

POST GRADUATE DIPLOMA IN TOOL DESIGN &

CAD/CAM
GADE SHASHANK L. ROLL NO. 1405657
JINDAM MANOJ M. ROLL NO. 1405664
MALALI VINAYAK L. ROLL NO. 1405669
 MSME TOOL ROOM
INDO GERMAN TOOL ROOM AURANGABAD
(A Govt. of India society, Ministry of MSME)
An ISO 9001:2008,ISO 29990 :2010 & ISO 14001:2004 & BS OSHAHS 18001:2007&
ISO/IEC 17025:2005 Certified Tool Room & Training Centre
www.site:http/www.igtr-aur.org,WWW.igtr.gov.in

CERTIFICATE OF APPROVAL OF PROJECT WORK

Certify that the project work in the Design Department was

successfully carried out by the following student
GADE SHASHANK L.
JINDAM MANOJ M.
MALALI VINAYAK L.
of PGDTD&CC JAN 2014 BATCH, in the partial fulfillment for the award
of Post Graduate Diploma In Tool design & CAD/CAM of the INDO GERMAN
TOOL ROOM, Aurangabad during the period of JAN 2014 TO JUN 2015.The
project has been approved as it satisfies the academic requirements in respect
of project work prescribed for the post graduate diploma.

Mr.Arnab Bhattacharjee Mr. G. D. Belurkar

(Project guide) (Sr. Engineer)

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 ACKNOWLEDGEMENT

I find this as a great opportunity at the completion of my course in tool design &
cad cam while submitting this report to express my sincere regards and a vote of thank
to our respected Mr. Gopal Awsekar and all members in M/S Indo German Tool
Room, Aurangabad, who directly or indirectly made their contribution for success of
my course.
I also find it as an opportunity to thanks to Mr. Gopal Belurkar Sir, Mr. Amit
Sir, Mr. Vishal Sir, and Mr. Pranav Sir for their valuable guidance and support from
time to time. I also take this opportunity to thank Mr. Arnab Bhattacharjee for their
able guidance and assistance in completing the final project.
At the end I would like to thank all the staff of IGTR for their hearty support.

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 PREFACE

This project reveals the effort taken during the implant

training in IGTR between the duration of JAN 2014 to JUN 2015.
The project gives a brief introduction about the work accomplished in
design including the explored applications in Unigraphics & other design
related information.
This project is basically upon the design and assembly of the
different tools such as Die casting die, Mold & Press tool. It also gives a
view of design consideration involved in press tool, mould & DCD. Also it
has the brief preview of the various works undertaken during the period.
Finally this project is an overview of the work in Design department.

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 INDEX
SR.NO DESCRIPTION PAGE NO.
MOULD
1 DESIGN CONSIDERATION 6
2 FLOW CHART OF MANUFACTURING 7
3 COMPONENT MODELS 8
4 CALCULATION 11
5 MATERIAL SELECTION 12
6 ASSEMBLY 13
7 COST ESTIMATION 14
8 BILL OF MATERIAL 15-16
9 CONCLUSION 17
10 NX 8.5 DRAWINGS 23
PRESS TOOL
13 INTRODUCTION 32
14 COMPONENT ANALYSIS 34
15 CALCULATION 36
16 ELEMENTS OF PRESS TOOL 38
17 BILL OF MATERIAL DETAILS 40
18 CONCLUSION 43
19 BIBLIOGRAPHY 53

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MOULD

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 DESIGN CONSIDERATION

 Material used for the component, its applications.

 Shrinkage of the material.
 Calculate the weight of the component.
 Study the detail of the component.
 Type of mould required for the component to be produced.
 Machine available for the component.
 Injection pressure required.
 Type of runner system & gate required.
 Type of ejection system weather blade, stripper etc.
 Split and side core consideration if the component is having any
groove or notch on its sides.
 Cycle time required for the component for complete fill.
 Effective cooling in a short duration is necessary.
 Cooling channels must be lick proof.
 Selection of the material for core & cavity.
 Adding of shrinkage to core & cavity dimensions.
 Parts in the assembly must not foul with each other in operation.
 The layout of the tool must not be oversized.

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FLOW CHART FOR MANUFACTURING
DESIGN

PART DRAWING RELEASE

RAW MATERIAL

MATERIAL PREPARATION

PRE-MACHINING

BENCH WORK

PRECISION MACHINING

HEAT TREATMENT

GRINDING

POLISHING

INSPECTION

ASSEMBLY

TRIAL OUT

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COMPONENT

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 CALCULATION

OBJECTIVE : TO DESIGN AN INJECTION MOULD FOR THE 3

PIN PLUG CASE AND PREPARE THE REQUIRED DETAIL
DRAWING

COMPONENT DETAILS
MATERIAL - POLYCARBONATE
DENSITY - 1.20g/cm3
SHRINKAGE - 0.020mm/mm
QUANTITY - 20,000
SURFACE AREA - 15192.44 mm2
MASS - 17.5 gms
VOLUME - 14601.283 mm3

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METHODICAL APPROACH TO PRACTICAL
INJECTION MOULD DESIGN

STEP : 1 STUDY THE 3 PIN PLUG CASE DRAWING

-Shape & Size
-Rate of Production
-Accuracy
-Type of Material

STEP : 2 DETERMINATION OF MOULDING WEIGHT

Molding weight = volume * density
= 14601.283 * 1.20 = 17.5 gms

Molding weight cavity with losses

= 17.5 * 1.20 = 19.25 gms

STEP : 3 STUDY THE INJECTION MOULDING MACHINE

SPECIFICATION
For the current exercise, we are going to use WINDSOR SP-80

STEP : 4 SELECTION OF TYPE OF MOULD

For the current exercise, we are going to use TWO PLATE COLD
CHAMBER MOULD.

STEP : 5 DETERMINATION OF NUMBER OF CAVITIES

a) Determined by shot capacity :
Ns = 0.85 * W / m

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 Ns = 0.85 * 156.24 / 19.25 = 6 cavities.

b) Determined by plasticizing capacity :

Np = 0.85 * P * Tc / 3600 * m
Np = 0.85 * 7600 * 45.59 /3600 * 19.25 = 4 cavities.

c) Determined by clamping capacity :

Nc = C / Pc Am
Nc= 800 / 63*106*15192.44*10-6 = 8 cavities.

For the current exercise, considering the quantity & rate of production, we
are going to design mould with single cavity.

Ns = No. of cavities based on shot capacity

W = Rated shot capacity for particular polymer (g)
m = Molding weight per cavity (g)
Np = No. of cavity based on plasticizing capacity
P = Rated plasticing capacity for particular polymer (g/hr)
Tc = Over all cycle time (sec.)
Nc = No. of cavity based on clamping capacity
C = Rated clamping capacity (Tons)
Pc = Clamping pressure (Tons / Sq. cm.)
Am = Projected area of molding including runners (Sq. cm.)

STEP: 6 SELECTION OF PARTING SURFACE (S)

For the current exercise, it is found that FLAT PARTING SURFACE is
best studied.

STEP: 7 PLACEMENT OF CAVITIES

For the current exercise, cavity is placed at the centre of the mould.

STEP : 8 DESIGN OF CAVITY AND CORE PLATE

Find out the minimum cavity wall thickness (t)
t = [ c *p * d4 / ( E * y ) ] 1/3
= [ 0.044 * 400 * 8 4 / ( 2.1 * 10 6 * 0.003 ) ] 1/3
= 15cm
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y = Max. deflection of side walls (cm.)
C = Constant
P = Max. cavity pressure (Kg / Sq. cm.)
E = Modulus of elasticity ( 2.1 * 10 6 kgf / sq. cm. )
t = Thickness of cavity wall (cm)
d = Cavity depth (cm)

Length, width and thickness of cavity plate

Cavity Plate Length = [( 1.25 * Ps + Dia of cooling hole + 6-10mm

cavity wall thickness) * 2+cavity size
= 246mm

Cavity Plate Width = [( 1.25 * Ps + Dia of cooling hole + 6-10mm cavity

wall thickness) * 2+cavity size
= 246mm

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STEP : 9 DETERMINATION OF CAVITY & CORE SIZES
a) For untoleranced dimensions :

Add shrinkage to all linear dimensions of the moulding to get the core and
cavity sizes.

b) For toleranced dimensions :

Cores, Projections and all other male plates :

[(max. DIM + 25% of component tolerance) + Shrinkage]-tp
Cavities depressions, Grooves and other female parts :
[(max. DIM + 25% of component tolerance) + Shrinkage]+tc

tp = Core making tolerance

tc = Cavity making tolerance

STEP : 10 DESIGN OF FEED SYSTEM

In this exercise, as the molding is having an undercut, SPRUE
GATE is selected. This gate is used for single impression rectangular
shaped moldings and two-plate moulds and for multi-impression tubular
shaped moldings on underfeed and runner less moulds.

Design of Gate

Gate length(L) = 0.75 – 1 mm

Gate depth(h) = 0.7 * n * t
=0.7 * 0.8 * 6 =3.3mm

Design of Sprue bush

The min. dia of the sprue = nozzle dia + 0.5 -1 mm

The sprue include angle = 3

The length of sprue depends on thickness of core plate, top plate and
design of locating ring.
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STEP : 11 DETERMINATION OF GUIDE PILLAR DIAMETER
Q = d * h * pf(kgs) for rectangular cores
= 3 * 8 * 400
= 9600 kgs

Working diameter (d) of guide pillar

d = [ 4Q / 3.14 N fs]1/2
= [ 4* 9600 / 3.14 *4 *16 ]
= 14 mm
As per table
d = 22 mm
Take-22mm

d = Max dia. Of core (cm)

h = Height of core (cm)
Pf = Cavity pressure (kg / sq.cm. )
Q = Side thrust (kgs.)
N = No. of pillars
fs = Pillar material shear stress (kg / sq. mm. )

STEP : 12 SELECTION OF EJECTOR SYSTEM

For the current tool, pin ejection is selected.

STEP : 13 TYPE OF VENTING

Ground recesses on the parting line of 0.05 deep by 8 mm wide, extending fully
from the cavity to the mould exterior.

STEP : 14 DRAFTS
Provide ½ degree side wall draft.

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FINGER CAM ACTUATION
In this system, hardened circular steel pins, termed finger cam are mounted at an
angle in a fixed mould plate.The splits, mounted on the guides on the moving mould
plate, have corresponding angled circular holes to accommodate these finger cam.
The distance traversed by each splits across the face to the mould plate is
determined by the length and angle of the finger cam. The moment can be computed by
the formula
M = ( L sin ø ) – ( c / cos ø )
Where, M = splits movement
Ø = angle of finger cam
L = working length of finger cam
C = clearance

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 MACHINE SELECTION

Machine selection for making any casting should be based principally on clamping
force and operating stroke, length of shot stroke, max. Shot pressure, maxi. die opening
and die size, max. & min. dies height, clearance between beams, over-all size and cost.

The rule of thumb for selection of die casting machine size is to use the smallest
machine that will do the job. This will ensure fundamental economy of operation, since
the larger the machine, the slower its cycle. For example 400-ton machine can cycle
about twice as fast as an 800-ton machine. Clamping force is not necessary the
deciding factor n the selection of a die a casting machine. Die dimensions must be
considered. The machine adequate tonnage for casting a part may have insufficient
platen area or tie-rod spacing for the die, or the opening stroke may not be sufficient for
removal of casting.

Another factor is the cost of the equipment, which must be amortized in the cost of
operation. The cost of auxiliary equipment for die casting machine is usually
proportionate with the size of the machine.

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ASSEMBLY

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FRONT VIEW

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FIXED HALF

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MOVING HALF

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EJECTION SYSTEM :

IN-LINE EJECTOR GRID

The ejector grid is that part of the mould which support the mould plate and
provide a space into which the ejector plate assembly can be fitted and operated.

This consist of two rectangular support blocks (risers) mounted on a back plate.

PGDTD & CC –III 22

 COST ESTIMATION

INVOLVES

 Designing cost of the tool.

 Material cost.
 Pre machining cost.
 Precision machining cost.
 Heat treatment cost.
 Fitting & assembly, bench work cost.
 Inspection & trail cost.

1) DESIGNING COST
 The amount and cost of time spent in designing a product are estimated either on the
basis of similar jobs previously manufactured or on the basis of good judgment of
designer. For new and complicated product the job estimator must consult the
designer.
 It is always preferable that standard rates per hour be used to calculate the cost of
designer’s time, and actual rates which are usually paid on a monthly or any other
basis.
2D DESIGNING COST = Rs 300 /-

3D DESIGNING COST = Rs 500 /-

2D DESIGNING COST = 30 x 300 = Rs 9,000 /-

3D DESIGNING COST = 15 x 500 = Rs 7,500 /-

TOTAL DESIGNING COST = Rs 16,500/-

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2) MATERIAL COSTS

 For estimating the material cost of the product, following steps are followed.
Find out the volume of the material.
Multiply it with density of the material.
 The drawings of the product to be manufactured are broken up into smaller simpler
parts and their volumes are calculated by applying the formulae.
 Volume of square or rectangular cube = L x B x H.
Where, L = length of piece,
B = breadth of piece,
H = height of piece.

 Volume of cylinder = π R² H.
Where, π = constant i.e. 3.14 or 22/7,
R = radius of piece,
H = height of piece.

 Volume of pyramid =( L x B x H)/3

Where, L = length of piece,
B = breadth of piece,

H = height of piece.

Density of steel = 7.86 gm/cm³

Sr. MATERIAL COST PER Kg.

No. (IN Rs.)
1. M.S. 60
2. EN-353 90
3. HDS 200
4. OHNS 180
5. H13 450

PGDTD & CC –III 24

3) PRE MACHINING COST

UNIT COSTS (IN HOURS)

LATHE 100/-
MILLING 100/-
SURFACE GRINDING 200/-
CYLINDRICAL 200/-
GRINDING

THE HOURS REQUIRES

LATHE = 20 Hrs
MILLING = 30 Hrs
SURFACE GRINDING = 10 Hrs
CYLINDRICAL GRINDING = 10 Hrs

HENCE,
LATHE OPERATION COST = 20 x 100 = 2,000/-
MILLING OPERATION COST = 30 x 100 = 3,000/-
SURFACE GRINDING OPERATION COST = 10 x 200 = 2,000/-
CYLINDRICAL GRINDING OPERATION COST = 10 x 200 = 2,000/-

TOTAL PRE MACHINING COST = Rs 9,000 /-

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4) PRECISION MACHINING COST

UNIT COSTS (IN HOURS)

CNC MILLING 600/-

CNC WIRE CUT 750/-
JIG BORING 600/-

THE HOURS REQUIRES:

CNC MILLING = 30 Hrs
JIG BORING = 20 Hrs
CNC WIRE CUT = 20 Hrs

HENCE,
CNC MILLING OPERATION COST = 30 x 600 = 18,000/-
JIG BORING OPERATION COST = 20 x 600 = 12,000/-
CNC WIRE CUT OPERATION COST = 20 x 750 = 15,000/-
--------------------
45,000/-

TOTAL PRECISION MACHINING COST = Rs 45,000 /-

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5) HEAT TREATMENT COST

UNIT COSTS (IN KG)

CONVENTIONAL 80/-

THE HOURS REQUIRES:

CONVENTIONAL HEAT TREATMENT COST = 5 x 80 = 400/-

TOTAL = 400/-

TOTAL HEAT TREATMENT COST = Rs 400/-

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6) FITTING / ASSEMBLY COST

UNIT COSTS (IN HOURS)

FITTING / ASSEMBLY COST = 150 /-

THE HOURS REQUIRES:

FITTING & ASSEMBLY TIME = 24 Hrs

HENCE,
FITTING & ASSEMBLY COST = 24 x 150 = 3,600
\

TOTAL FITTING & ASSEMBLY COST = Rs 3,600 /-

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 7) INSPECTION COST

UNIT COSTS (IN HOURS)

Sr. INSPECTION COST PER Hr

No. (IN Rs)
1 CONVENTIONAL 150/-
2 CMM 1000/-

THE HOURS REQUIRES:

CONVENTIONAL INSPECTION = 26 Hrs.

CMM INSPECTION = 24 Hrs.

HENCE,
CONVENTIONAL INSPECTION COST = 26 x 150 = 4000/-
CMM INSPECTION COST = 24 x 1000 = 24,000/-
-----------------------
Rs 28,000/-

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* TOTAL COST OF TOOL:

TOTAL DESIGNING COST = Rs 16,500/-

TOTAL MATERIAL COST = Rs 2,063 /-

TOTAL PRE MACHINING COST = Rs 9,000 /-

TOTAL PRECISION MACHINING COST = Rs 45,000 /-

TOTAL HEAT TREATMENT COST = Rs 400 /-

TOTAL FITTING / ASSEMBLY COST = Rs 3,600/-

TOTAL INSPECTION COST = Rs 28,000/-

--------------------------------
= Rs 1, 04,563 /-

TOTAL COST OF TOOL = Rs 1, 04,563 + 15% (PROFIT)

= Rs 1,04,563 + Rs 15,684

= Rs 1, 20,247

PGDTD & CC –III 30

 BILL OF MATERIAL

PART
DESCRIPTION QTY MATL
NO.
01 TOP PLATE 01 C14
02 REGISTER RING 01 40Cr1
03 CAVITY PLATE 01 EN30
04 CAVITY INSERT 01 H13
05 LOCKING HEEL 02 C14
06 SIDE CORE INSERTS 02 H13
07 CORE PLATE 01 C14
08 CORE INSERT 01 H13
09 CORE BACK PLATE 01 C14
10 EJECTOR PLATE 01 C14
11 EJECTOR RETAINER 01 C14
12 REST BUTTON 01 MS
13 EJECTOR GUIDE PILLAR 02 EN24
14 EJECTOR GUIDE BUSH 02 EN24
M6 (COUNTER SUNK SOCKET
15 06 STD
HEADED)
16 RETURN PIN DIA 12.0 04 STD
17 EJECTOR PIN DIA 8.0 04 STD
18 ANGULAR PIN 02 EN24
19 STOPPER 01 C14
20 GUIDE RAIL 02 EN30
21 WEAR PLATE 02 EN18
22 SHCS M12 08 STD
23 BOTTOM PLATE 01 C14
PGDTD & CC –III 31
 CONCLUSION
 The project was a medium for us to enhance our knowledge in the field of tool

& Die Designing & Manufacturing. It helped us a lot in better understanding of

the concepts of plastic mold manufacturing.

 During the project we had to communicate with various departments and

authorities to solve the problems and difficulties around in between. It has

helped to improve our abilities to work as a team.

PGDTD & CC –III 32

PRESS TOOL

PGDTD & CC –III 33

PGDTD & CC –III 34
 INDEX

 Introduction
 Component analysis
 Calculation
 Elements of press tool
 Bill of material details
 Conclusion
 Bibliography

PGDTD & CC –III 35

 FIGURE INDEX

 Component drawing
 Shearing theory
 Stresses in shearing
 Punch penetration into and fracture of metal
 Cutting clearance
 Optimum cutting clearance
 Land
 Angular clearance
 Stresses in bending
 Elements in bending
 Grain direction
 Spring back
 Types of strip layout
 Bottom plate
 Stripper plate
 Die plate
 Punch holder
 Back plate
 Guide plate
 Top plate
 Bending punch
 Notching punch
 Side cutting punch
 Piercing punches
 Piloting punches
 Parting off punches
 Guide bush
PGDTD & CC –III 36
 INTRODUCTION

Tool Design is the process of designing and developing the tools, methods and
techniques necessary to improve manufacturing efficiency and productivity. It
gives industry the machine and special tooling needed for today high speed, high
volume production. It does this at a level of quality and economy that will ensure
that the cost of the product is competitive. Since no single tool or process can serve
all the forms of manufacturing, tool designs an ever changing, growing process of
creative problem solving.
Press tool form a vital and an integral part of our modern production houses.
These tool act as the backbone for the production of stampings which range from
the most general items like your wrist watch parts to the most sophisticated and
complex items like the Skelton of automobiles, streamlined trains, aircraft, missiles
etc.
A great knowledge in the theory of design of press tools helps to have a better
scientific background instead of using thumb rule method. The designs should be
feasible for manufacturing with the available machinery and the equipment.
Standardization of tooling element reduces the time and the cost of manufacturing,
follow up the action of every stage of manufacturing and working of the tool helps
the tool designers considering to arrangement his knowledge and development of
skills.
The project involves the designing tools for the soap case made from sheet
metal. To produce the component in just one go is impossible and thus a gang of
press comes into frame.

PGDTD & CC –III 37

 COMPONENT ANALYSIS

COMPONENT DETAILS (BRASS ENCLOSURE)

Thickness of sheet = 2MM
Material = BRASS
Shear strength = 235N / mm2
Operation = Blanking, Piercing, & Bending.
Area = 16012.5 mm2
PGDTD & CC –III 38
TYPES OF PRESS OPERATIONS
 Cutting operations
 Non-Cutting operations
 Finishing operation

TYPES OF CUTTING OPERATIONS

 Piercing
 Blanking
 Notching
 Lancing
 Parting off
 Cutoff
 Perforating
 Trimming
 Shaving

TYPES OF NON CUTTING OPERATION

 Bending
 Drawing
 Embossing
 Coining
 Hemming
 Seaming

TYPES OF PRESS TOOLS

 Simple Tool
 Compound Tool
 Combination Tool
 Bending Tool
 Drawing Tool
PGDTD & CC –III 39
PRESSES AND TYPES OF PRESSES
A press is a sheet metal working tool with a stationary bed and a powered
ram can be driven towards the bed or away from the bed to apply force or
required pressure for various metal forming operations.
According to the Power Source
o Manually Operated or Power Driven
o Power Presses
According to the Type and Design of Frame
o Inclinable Frame Press
o Gap Frame Press
o Straight Side Press
o Adjustable Bed Type Press
o Open End Press Horning Press
According to the Position of Frame
o Inclinable Frame
o Vertical Frame
o Horizontal Frame
o Inclined Frame

According to Mechanism Used to Transmit Power to Ram

o Crank Press
o Cam Driven Press
o Eccentric Press
o Knuckle Press
o Toggle Press
o Screw Press
o Hydraulic Press
o Rack and Pinion Press

PGDTD & CC –III 40

According to Number of Drive Gears
Method of transmission of power from Motor to Crankshaft
o Direct Drive Press
o Flywheel Driven Presses
o Single Geared Drive Presses
o Double Geared Drive Presses
According to the Purpose of Use
o Shearing press
o Seaming press
o Straightening press
o Punching press
o Extruding press
o Coining press
o Forging press
o Rolling press
o Bending press.

According to Number of Crankshaft in a Press

PGDTD & CC –III 41

HYRAULIC PRESS

1. Press cylinders
2. Adjustable 8-way precision slide guiding
3. Hydraulic drawing cushion
4. Hydraulically actuated slide locking in upper end position as per UVV (safety
codes and regulations)
5. AC drive motors designed to suit application
6. High-performance axial piston pumps with electronic control
7. Torsion-resistant press frame
8. Slide-piston connection
9. Slide stroke limitation /impact shock dampening
10.Impact shock dampening cylinder

PGDTD & CC –III 42

Hydraulic Press Line with Blank holder & Crossbar Robot Automation

1 Blank loader 2 Unstacking robot

3 Loading robot 4 Head press
5 Press hydraulics 6 Crossbar robot
7 Transport belt for finished parts

PGDTD & CC –III 43

Blanking line with Servo Direct Technology

1. Decoiler
2. Coil in feed
3. Cropping shear
4. Coil washing machine
5. Levelling machine
6. Loop pit
7. Roll feed unit
8. Telescopic roller train with left-over coil feed
9. Blanking press with Servo Direct Technology
10.Blanking die
11.Telescopic conveyor
12.Vacuum blower for stacking aluminium blanks
13.Blank stacker
14.Stack cart
15.Hydraulic unit

PGDTD & CC –III 44

SHEARING THEORY

• Shearing is the method of cutting sheets or strips without forming chips.

• The material is stressed in a section which lies parallel to the forces applied.
• The forces are applied by means of shearing blades or punch and die.

• A corresponding depression is formed on the upper face.

• This stage imparts a radius on the upper edge of the opening in the strip and on
the lower edge of the punched out material. (which may be blank or slug)

PGDTD & CC –III 45

 As the load is further increased, the punch will penetrate the material
to a certain depth.
• An equally thick portion of the metal is forced
into the dies.
• This imparts a bright polished finish (cut band)
on both the strip and the blank or the slug. On
optimum cutting conditions the cut band will be
1/3rd the sheet thickness.

In this stage, fracture starts from both upper and lower cutting edges.
• As the punch travels further, these fractures will
extend towards each other and meet to cause
complete separation.
• This stage imparts a dull fractured edge.

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STRESSES IN SHEARING

PUNCH PENETRATION INTO AND FRACTURE OF METAL

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CUTTING CLEARANCE

 Cutting clearance is the gap between a side of the punch and the corresponding
side of the die opening when the punch is entered into the die opening.
 Cutting clearance should always be expressed as the amount of clearance per
side.
 Proper cutting clearance is necessary for the longer life of the tool.
 Quality of the piece part also depends on proper cutting clearance.
 A visual examination of the punched component will indicate the amount of
clearance and whether the punch and die have
o Optimum cutting clearance.
o Excessive clearance or
o In sufficient clearance or
o Misalignment

PGDTD & CC –III 48

OPTIMUM CUTTING CLEARANCE

 When optimum cutting clearance condition exists a small edge radius is formed.
 The edge radius is the result of the plastic deformation (first stage of shearing).
 A highly burnished cut band results from the second stage (penetration).
 The width of the cut band is approximately one third the thickness of the stock
material.
 The balance of the cut is the break resulting from fracture (third stage).

LAND
 The inner walls of the die opening are not usually made straight through.
 If they are straight, the blanks or slugs tend to get jammed inside the die opening.
 This may lead to the breakage of punch or die.
 To avoid this, the die walls are kept straight only to a certain dimension from the
cutting edge.
 The straight wall is called as land.

LAND = 3mm for sheet thickness up to 3mm

and for thicker material equal to the sheet thickness

PGDTD & CC –III 49

ANGULAR CLEARANCE

 The die walls below the land are relieved at an angle for the purpose of enabling
blanks or slugs to clear the die.
 Soft material requires greater angular clearance than hard materials.
 The normal value of angular clearance is 1.5° per side.
 Dies for materials like silicon steel and stainless steel are provided with angular
clearance from the cutting edge.
 These materials are abrasive in nature and tend to bell-mouth the die opening
rapidly if land is provided.

PGDTD & CC –III 50

PRINCIPLE OF BENDING
In bending operation, the material in the form of flat sheet is uniformly strained
around a linear axis which lies in the neutral plane & perpendicular to the lengthwise
direction of the sheet.
Bending of sheet metal has the distinct characteristic of stretching the metal at
localized areas only. The localized stress or pressure occurs only at bend radius. The
remaining flat metal is not stressed during bending. The metal on the outside of the
bend radius has been stretched indicating tensile stress has been applied. The metal on
the inside of the bend radius has been squeezed or placed under a compressive stress.

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STRESSES IN BENDING

TENSILE STRESS
(X).
NEUTRAL AXIS For a good bend design the
tensile stress at point "X" is
0 below the ultimate tensile
NEUTRAL AXIS strength
T COMPRESSIVE
C STRESS
At point "O" both
Shaded area
stresses are zero i.e. on
under stress.
neutral axis stress is
C- Compression No stress in zero.
T- Tension this area.
STRESS INDUCED
DURING BENDING

ELEMENTS OF BEND

 NEUTRAL AXIS:- The line of zero stress is called neutral axis.

 BEND ALLOWANCE:- Length of neutral axis in affected zone is called bend

allowance.
 BEND ANGLE:- It is the angle between two perpendicular lines drawn from
flange to center of radius.
 NEUTRAL PLANE:- The plane in the material in between the outer & inner
layers experiences no stress. This is called neutral plane.

Bend Axis &

Bend Radius

Outer Surface
Bend
Allowance Bend Angle Inner Surface
Bend Area
Bend Lines

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GRAIN DIRECTION

Direction of grains Direction of grains

Bending Across Grain Bending Along Grain
Direction Direction

SPRING BACK
In metal working process the total deformation imparted to a work piece
will be sum of elastic deformation & plastic deformation. The elastic deformation is
recoverable whereas plastic deformation is permanent. So that at the end of metal
working operation when the pressure on the metal is released there is an elastic
recovery by the material & the total deformation will get reduced to a little .

Metal zone plastically

deformed by tension.

SPRING BACK

SPRING BACK FORCES

Metal zone plastically ELASTIC METAL BAND

deformed by
compression.
NEUTRAL AXIS IN WIPING SPRING BACK
U BENDING

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VARIABLES & THEIR EFFECT ON SPRING BACK

 Harder sheet metal would have more degrees of spring back due
to a higher elastic limit & resulting a larger elastic band at the bend.
 A sharper or smaller bend radius would reduce spring back by
creating a larger plastic zone & could cause tearing due to higher stresses in
the outside surface.
 As metal is bent through more degrees of bend the plastic zone is
enlarged & spring back is reduced for each degree of bend.
 Thicker sheet metal has less spring back since more plastic
deformation occurs.

METHOD OFOVERCOMING SPRINGBACK

Following methods are used to reduce spring back effect.

1. Over bending
2. Corner setting or bottoming
3. Stretch bending

PGDTD & CC –III 54

INTRODUCTION TO PROGRESSIVE TOOL

Progressive dies provide an effective way to convert raw coil stock into a
finished product with minimal handling. As material feeds from station to station in the
die, it progressively works into a completed part.
Progressive dies usually run from right to left. The part material feeds one
progression for each press cycle. Early stations typically perforate holes that serve as
pilots to locate the stock strip in later stations.
There are many variations of progressive die designs. The design shown here
illustrates some common operations and terminology associated with progressive dies.

PGDTD & CC –III 55

DESIGN OF PRESS TOOL

Design of any press tool involves following steps:-

1. Determination of efficient strip layout.
2. Determination of force (press tonnage) required for the operation.
3. Computing all plates’ thickness, margins
and determination of shut height of the tool.
4. Punch and die shape and sizes.
5. Selection of press for required force, work piece size and shape.
6. Design of locating elements.
7. Draw the die plan and selection of pillar die set.
8. Calculate the punch lengths and select mounting methods.
9. Find the center of pressure and location of shank.

PGDTD & CC –III 56

NARROW RUN STRIP LAYOUT

Given data:
 Thickness of sheet= 2 mm
 Material=Brass
 Shear strength=235 N/mm2
 Area of the component = 16012.5 mm2
 Perimeter of the component=645.35 mm2

1. Read the drawing carefully.

2. Identify the operations.
Piercing .
Blanking.
Bending.
3. Identify type of tooling.
progressive tool.
PGDTD & CC –III 57
4. Draw the conceptual drawing.
5. Strip layout & economy factor

 Scrap bridge (b)=1.2*t=1.2*2=2.4 mm.

 Width of strip(w)=210+2*b=214.8mm.
 Pitch(p)=100+2*b=100+2*2.4=104.8mm.
 Area(a)=16012.5 mm2
Now, Economy factor,
E=(a*n*100)/(w*p).
=(16012.5*1*100)/(214.8*104.8).
=71.13%
6.Cutting clearance & size of punch & die.

= .01*2*(235/10)^.5
= 0.1 mm/side.
 piercing operation:
Punch size = 60*8
Die size = (60+2c)*(8+2c)=60.2*8.2 mm
 piloting operation:

 Blanking operation:
Die size=Blank size
punch size
6.Cutting Force:

= 604*2*235
= 283.8*10^3
= 28.3 tonne.

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7.Bending force;
 Bend Allowance ,A =[(2**θ)/360]*(R+kt)
where, A = Bend Allowance.
θ = Bend Angle.
R = Bend Radius.
t = Thickness
k = Distance of neutral fibre from inner fibre.
= 0.5 when, R > 2*t
= 0.33 when, R < 2*t
A= [(2**90)/360]/*(5+0.5*2)
= 9.42 mm
 Bending Force, Vb = (K*l*Ft*t^2)/(w)
Where, K =1.33 constant
l = Bend Length, mm
Ft = Tensile Strength of the blank ,N/mm2
w = Die opening or width of ‘V’ die.
Die opening (w) varies from 12 to 16 times of sheet thickness. It should not
be less than 6 times of sheet thickness.
Vb = (1.33*90*550*2^2)/(12*2)
= 10972.5 N
= 1.0972 tonne
 Bending occurs twice, so Total Bending Force required is 2.1944 tonne.
 8. Stripping force = (15%) Fsh
= (0.15)*28.3
= 4.24 tonne.
 9. Total Force = Cutting Force + Stripping Force+ Bending Force
= 28.3+4.24+ 2.1944
= 34.7344 tonne.

PGDTD & CC –III 59

 10. Press Tonnage = Total Force X Factor of safety
= 34.7344 * 1.2
= 41.6812 tonne.
 11. Selection of thread.
Strength of thread =42400/4
= 10600 N.
As per the Strength of thread=10600 N
Selecting M16 * 2.0 screw.
 11. Die plate thickness.
Dpt = (Fsh)^(1/3).
= (28.3 )^(1/3)
= 3.04 cm
= 30.4 mm.
 12. Top plate / Bottom plate thickness.
= 1.8*Dpt
= 1.8*30.4
= 54.72 mm.

 13. Stripper plate / punch plate thickness.

= 0.8*Dpt
= 0.8*30.4Th
= 24.32 mm.
 14. Thrust plate = 6 to 8 mm
Selecting = 8mm.
 15. Press shut height for Godrej heavy press GE25
Press shut height = 250 mm.
Tool shut height = 250-10
= 240 mm .

PGDTD & CC –III 60

  16. Punch length = Shut height-(2*Top/Bottom plate)-Die plate –Thrust plate+3.
= 240-(2* 54.72)-30.4+3
= 103.16 mm.

CALCULATIONS FOR PLATE THICKNESS

Thickness of die plate ( Dpt ) = 30.4 mm.

Thickness of punch holder plate = 24.32 mm.

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Thickness of stripper plate = 24.32 mm.

Thickness of bottom plate = 54.72 mm

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Thickness of top plate = 54.72 mm.

Progressive Tool 3-D model

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Progressive Tool 2-D model

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 BILL OF MATERIAL

PART
DESCRIPTION QTY. MATERIAL REMARK
NO.
1 BOTTOM PLATE 01 M.S. --
2 TOP PLATE 01 M.S. --
3 PUNCH HOLDER PLATE 01 M.S. --
4 PUNCH BACK PLATE 01 OHNS
5 DIE PLATE 01 HCHCr/ D3 HRC 60-62
6 STRIPPER PLATE 01 OHNS --
7 GUIDE PILLAR 04 EN-31 HRC 58~60
8 GUIDE BUSH 04 EN-31 HRC 58~60
9 BENDING PUNCH 02 HCHCr/ D3 HRC 60-62
10 DOWEL 02 STD
11 TRIMMING PUNCH 01 HCHCr/ D3 HRC 60-62
12 PIERCING PUNCH-1 03 HCHCr/ D3 HRC 60-62
13 PIERCING PUNCH-2 02 HCHCr/ D3 HRC 60-62
14 PIERCING PUNCH-3 02 HCHCr/ D3 HRC 60-62
15 ALLEN BOLT-LOWER HALF 08 STD -
16 ALLEN BOLT-UPPER HALF 08 STD -
17 ALLEN BOLT-GUIDE PILLAR 04 STD -

PGDTD & CC –III 65

 CONCLUSION

The tools were all designed by carefully studying the component details and
its needs. The sequence of operations as well as its designs was done solely by
theoretical knowledge. Meanwhile it is a foregone conclusion that a design can
never be fully done from a purely theoretical expertise; it requires the knowledge of
so many other key functional departments like the production, precision , process
planning and importantly the experience in the shop floor practices .The design
may not be foolproof or infallible but standing over many uncertainties it was an
honest attempt to make a set of truly workable designs.

PGDTD & CC –III 66

 BIBLIOGRAPHY

1. BASIC DIE MAKING - D. EUGENE

2. TOOL DESIGN - CRYLL DONALDSON

3. DIE DESIGN FUNDAMENTALS - J.B. PAQUIN

4. PROGRESSIVE DIES - SME

5. TOOL DESIGN THEORY – NTTF

6. TOOL DESIGN - IGTR

PGDTD & CC –III 67