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Design of punch and die for taper roller bearing cage for multi pocketing
 

Design of punch and die for taper roller bearing cage for multi pocketing

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    Design of punch and die for taper roller bearing cage for multi pocketing Design of punch and die for taper roller bearing cage for multi pocketing Document Transcript

    • International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 2, March - April (2013) © IAEME367DESIGN OF PUNCH AND DIE FOR TAPER ROLLER BEARINGCAGE FOR MULTI POCKETINGMr. M. V. ARDESHANA1, Mr. N. L. MEHTA21M.E.[CAD/CAM] Student, Department of Mechanical Engineering, B. H. Gardi College ofEngineering & Technology, Rajkot, Gujarat, India2Asst. Prof. Department of Mechanical Engineering, B. H. Gardi College of Engineering &Technology, Rajkot, Gujarat, IndiaABSTRACTTaper roller bearing is widely used in the different industries. So there is need todemand for the taper roller bearing. It has four components outer race, inner race cage androller. The main function of Cage is to maintain rolling element at a uniform pitch, so load isnever applied directly to the cage. Cage is manufactured by three ways pressed cage, machinecage, and molded cage. But mostly cage is manufactured by power press. In manufacturing ofcage pocketing operation is required as per the number of pockets. In existing situation singlepocket is produced in a single stroke of power press. So it has to go for the number of strokeas equal to number of pocket so production time is more for cage manufacturing. In proposedmethod of manufacturing for cage multi pocketing is performed in a single stroke of powerpress. Due to that production time for cage is reduced and productivity is increased.Keywords: Cage, Die, Multi Pocketing, Punch, Taper Roller Bearing1. INTRODUCTIONThe main function of the roller bearing cage is to avoid direct contact between therolling elements. At the roller bearings, the cage realizes also the guidance of rollers and atthe roller bearings with separable rings the cage retains the rolling elements. [1]Cages function to maintain rolling elements at a uniform pitch so load is never applieddirectly to the cage and to prevent the rolling elements from falling out when handling thebearing.INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERINGAND TECHNOLOGY (IJMET)ISSN 0976 – 6340 (Print)ISSN 0976 – 6359 (Online)Volume 4, Issue 2, March - April (2013), pp. 367-372© IAEME: www.iaeme.com/ijmet.aspJournal Impact Factor (2013): 5.7731 (Calculated by GISI)www.jifactor.comIJMET© I A E M E
    • International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 2, March - April (2013) © IAEME3682. EXISTING METHOD OF CAGE MANUFACTURINGPressed cages are usually made of steel, but sometimes of brass, too. They are lighterthan machined metal cages. [2] Prone type cage and taper roller bearing cage aremanufactured by power press operation.Machined cages of metal and textile laminated phenolic resin are made from tubes ofsteel, light metal or textile laminated phenolic resin, or cast brass rings. Machined cages arealso used where lip guidance of the cage is required. Riveted cage and Prong cage aremanufactured by Machine operation.Moulded cages of polyamide are produced by injection moulding and are used inmany large-series bearings. Injection moulding has made it possible to realize cage designswith an especially high load carrying capacity. Angular contact ball bearing cage aremanufactured by Moulding operation.Cage Drawing:Fig.1. TRB Cage 32211This is the Cage drawing as shown in Fig. In Existing Situation cage is manufacturedby Power press. In this cage total no. of pocket is 19. Right now single pocket required singlestroke of press so 19 pockets requires 19 stroke per a single cage manufacturing. Indexingmechanism is also required for maintaining proper distance between the two pockets.Production time for a single cage is more. So productivity is less. Production of cage is 6,00,000 piece per month in a company. To increase the productivity it has to increase theproduction. Therefore it is required to reduce the production time for a single cagemanufacturing. It has to improve the manufacturing process. [2]3. PROPOSED METHOD OF CAGE MANUFACTURINGIn propose method of cage manufacturing all 19 pockets produce in a single stroke ofa power press. So it can also reduce the production time for the cage. [2] And it can alsoincrease the productivity. Same way there is no need to go for the indexing in cage forproducing a pocket. For making all pocket in a single stroke multi pocketing assembly isrequired. Assembly contains the punch, die, punch retainer, centre pin, die plate, retainer ring.
    • International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 2, March - April (2013) © IAEME3693.1. Design of punch and dieHere, in this case Blanking Shape is shown in fig.Figure.2. Blanked shapeP= Perimeter of pocket=57.8 mm, S=Shear strength = 4000 psi= 275.79 N/mm2T= Thickness of strip = 1.8 mm Force = 28693.19 N (1)1 tonne =9806.65 N, So, 28693.19 N = 2.9 tone for 1 pocket.But we have to create 19 pockets in single punching operation. [3]For 19 pocket = 19 2.9 = 55.1 tone press capacity required.The clearance is a function of the kind, thickness and temper of the work material,harder materials requiring larger clearance than soft materials, the exception beingaluminium.Punch size A1 = 10.95 mm, Punch size A2 = 9.95 mm, Punch height = 18.40 mm3.2. Design of DieThe minimum thickness of the die block depends upon the strength required to resistthe cutting forces, and it will depend upon the type and thickness of the material being cut.Die thickness=19 mm for blanking perimeter 75 mmDie thickness=25 mm for blanking perimeter 75 to 250mmDie thickness=31 mm for blanking perimeter >250 mmOr die block thickness can be taken as T= cm, F is in tones.So, in this case blanking perimeter is 58 mm so die thickness should be 15 mm.Die size A1 = 11.25 mm, Die size A2 = 10.25 mm, Die Height = 18.70 mm3.3. Design of Punch Retainer/HolderThe main function of punch retainer is to hold the punch. Punch is rest in the slot ofpunch retainer. Punch holder – dimension of the punch holder should be at least 5 mm largerthan the punch. Punch holder thickness 25 to 75mm. Punch retainer thickness is 30 mm inthis die assembly. It has to rest 19 punches so 19 slots available in the punch retainer.3.4. Design of Retainer RingRetainer ring is mounted on the punch retainer. Retainer ring thickness is 25 mm.above the retainer ring it has to provide the constant pressure by bellow or spring. So allpunches are together with each other.3.5. Design of center pinCenter pin is fixed with the ram. Center pin is moving inside the punch.So as perconstrain center pin outside diameter is 84 mm and below portion diameter is 46 mm. Height
    • International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 2, March - April (2013) © IAEME370of center pin is 80 mm. It has outside taper for the proper mating between the outside ofcenter pin and inside of punch.Fig.3. Model of Punch Fig.4. Model of DieFig.5. Model of Punch Retainer Fig.6. Model of Die plateFig.7. Model of Centre Pin Fig.8. Model of Retainer ringFig.9. Multi pocketing Assembly Fig.10. Multi pocketing AssemblyPunch RetainerPunchDie PlateDieRetainerRingCenterPin
    • International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 2, March - April (2013) © IAEME3714. ANALYSIS OF PUNCHAllowable stress = yield strength/ factor of safety(2)Factor of safety = 1.5, σ = 2200/1.5 = 1466.66 N/mm2Static structural analysis of Punch:Fig.11. Displacement of punch is 0.05 mm Fig.12. Stress analysis of punchTable.4. Result and DiscussionSr. No. Allowable stress Von mises stress1 1466.66 N/ mm2205 N/mm2From the above analysis we can get the stress developed in the punch is less than the designallowable stress so the design is safe design.5. CONCLUSIONThe proposed manufacturing method for cage based on the multi pocketing process.The result for the analysis indicates the safe design for the punch. Multi pocketing assemblyinclude the design for punch, die, punch retainer, retainer ring and centre pin. The mainaspect of the multi pocketing is to reduce the production time for the cage but as a by productit can also increase the productivity.REFRENCES[1] Ripanu Marius-lonut,NagitGheroghe, Merticaru Vasile ,Husanu Valerica, Lacob StrugaruSorin Claudiu, Process Quality analysis and monitoring methodology for roller bearingscages stamping, Fascicle of Management and Technology Engineering, Volume XI(XXI)2012,NRI.[2] FAG Rolling Bearing Cages, Designation, Design, Material, TI Nr. WL 95-4 E August2000.
    • International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 2, March - April (2013) © IAEME372[3] Vyankatesh B. Emche and Rajesh R Kandalkar, Efficient Method of Producing OvalPunching holes on Sheet Metal, J Appl Mech Eng 2012, 1:2.[4] Wan Mohd Firdaus Bin Wan Sembak, Design and Fabricate Blanking Die for TensileTest Specimen, University Malaysia Pahang, November 2008.[5] Fuh-Kuo Chen, Bai-Hong Chiang, Analysis of die design for the stamping of a bathtub,Journal of Materials Processing Technology Vol.72 Year1997, Pg. No. 421–428.[6] Cmti Machine Tool Design Handbook (Tata McGraw hill, New Delhi-2007)[7] B. R. Manju, B. R. Manju and V. Sugumaran, “Wavelet Design for Fault Diagnosis ofRoller Bearings using Continuous Wavelet Transforms”, International Journal of MechanicalEngineering & Technology (IJMET), Volume 1, Issue 1, 2010, pp. 38 - 48, ISSN Print:0976 – 6340, ISSN Online: 0976 – 6359.[8] Vijay Gautam, Parveen Kumar and Aadityeshwar Singh Deo, “Effect of Punch ProfileRadius and Localised Compression on Springback in V-Bending of High Strength Steel andits Fea Simulation”, International Journal of Mechanical Engineering & Technology (IJMET),Volume 3, Issue 3, 2012, pp. 517 - 530, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359.[9] Manju B R, A.R. Rajan and V. Sugumaran, “A New Wavelet Feature for Fault Diagnosisof Roller Bearings using Decision Tree”, International Journal of Mechanical Engineering &Technology (IJMET), Volume 2, Issue 2, 2011, pp. 70 - 84, ISSN Print: 0976 – 6340,ISSN Online: 0976 – 6359.