Compound tooling

2. Presentation Flow
▶ Abstract
▶ Introduction
▶ Literature Review
▶ Problem Statement
▶ Objectives
▶ Methodology and flow chart
▶ Progress
▶ Reference

3. ABSTRACT
▶ The design & fabrication are the most important elements in
translating the idea to a product. Before converting raw material to a
finished product it should have an accurate design of the product &
also tool for manufacturing such product. If the tool design is not
accurate then defects will occur in the manufactured product, small
mistakes in tool designing can make the manufactured product
useless & it consumed more amount time to manufacturing than
allotted. This project is about design & manufacturing of a
Compound tool for a speedometer component. This project starts
from study of component, initial conceptual design, design
verification & its validation, manufacturing aspects, process
planning. The theoretical study has done and modelling is carried
out withAutoCAD.

4. INTRODUCTION
▶ Sheet Metal industry is large and growing industry. There are many special
purposes machines used in this industry to-day.
▶ Characteristic of the press working process is the application of large
forces by press tools for a short time interval, which result in the cutting
(shearing) or deformation of the work material.
▶ Compound tool is an inverted tool where blanking and piercing takes place
in a single stage.
▶ A strip of metal is fed through the compound die, but unlike progressive or
transfer die stamping, compound stamping tooling performs multiple cuts,
punches, and bends in one stroke rather than multiple strokes.
▶ Speed is a key component to compound die stamping; however, the speed
also depends on the size of the part. Large components require more time
to exit the die, whereas small components can exit more quickly.

5. LITERATURE SURVEY
▶ Mr. Bhaskar F. Satpute (2016), has designed compound die for an automobile body part. The part is consisting of
four different operations which are blanking, notching, piercing, and bending. The main objective was to improve
quality of finish product (scrap & rework minimization), reduced tooling and tool maintenance cost, per unit cost
minimization. The methodology opted from this survey was analysis of spring back effect. Further he concludes that
compound press tooling has a vital press tooling method due to its some advantages like high rate of production, per
unit cost minimization etc. There is opportunity for designer to use the tool for quality improvement along with best
utilization of various resources. By adopting the techniques of compound die the industrialist can gets more
advantage belongs to different variables (resources) by comparing with other techniques of press tooling, this type of
tooling proves its ability over others.
▶ A.A. Kamarul adnan (2022), the main purpose was to analyse the influence of blanking clearance size on the burr
development for mild steel sheet, brass and aluminium. The main reason for this research is estimating the burr size
on blank parts. It is still significant since the quality of the products is determined by evaluating the amount of
allowable burr in the parts. This study focuses on burr height rather than the wear of the punch and die cutting edge;
burr height can affect punch and die sharpness. It also can guide practitioners in estimating blanking clearance and the
burr height of mild steel, brass and aluminium. Finding of this research is to determine the influence of blanking
clearance on the development of burr height at the edge of part on mild steel, brass, and aluminium sheets. The
models of the relationship between blanking clearance and burr height have resulted in the blanking process. The
material strength will also produce different burr heights, and the high tensile strength will result in a higher burr.

6. LITERATURE SURVEY
▶ Akshay P. Gajare (2020), the problem he identified was at present some industries are
performing all three operations blanking, piercing and forming on separate machines.
Hence there is a scope to develop a combination tool for performing two operations at one
stroke on single machine such as the combination of piercing and forming operation. The
main objective was to study sheet metal operations, design press tool for combined
operation. So he concludes that press tool components industry manufacturing plate level,
determined that, at present the firm is using separate tool for piercing and forming
operations on two different machines. It was decided to use combined tool for piercing and
forming operations to manufacture plate level. Literature review on design & analysis of
combination tool the is done. It was found, there is scope for developing.

7. Problem statement
▶ At present some industries are performing all three operations blanking, piercing and forming on separate
machines. Hence, there is a scope to develop a combination tool for performing two operations at one stroke.
Today customers are more and more quality & cost conscious. To satisfy the need of the customer any
industry needs to adopt an effective approach towards the better process, which involves less cost to the
company and also maintain or improve the level of quality. By applying compound tool approach, they will
be able to control the quality and cost.

8. OBJECTIVES
▶ A die design is to simultaneously perform more than one operation with each stroke of the
press. To avoid multiple strokes this method is used.
• This can be cost effective for medium to high volume production runs.
• Suitable for fast and efficient production of simple parts.
• Helpful for single-die cases to ensure high repeatability.
• Compound tooling is less costly and faster to build than progressive tooling.

9. METHODOLOGY
• Compound tooling is a process where a part is manufactured by a press tool in just one motion by
using both a blanking tool and a piercing tool at once.
• Compound tooling, like every press tool, is utilized for manufacturing parts from sheet metal for high
quantity production.
• The process involved here is
1. Press selection
2. Die design
3. Tool design
4. Machining of tool
5. Assembly

10. FLOW CHART

11. CALCULATIONS
▶ Clearence per side
c/s=0.01×t√fₛₕ
=0.01 ×0.8 × 21
=0.036mm/side
▶ Shear length
l=N₁+N₂
= (π ×36)+(π ×4)
=1421.21mm
▶ Number of components
= 1000
𝑝𝑖𝑡𝑐ℎ
=1000
47
=21 Components

12. ▶ Shear force
sf=k×t×l×fₛₕ
1000
=
1.33×0.8×1421.22×21
1000
=31.755 Tons
Where,
sf=shear force
k=constant
t=thickness
l=shear length
fₛₕ=shear strength in kg/𝑚𝑚2
▶ Die thickness
Dₜ=3
31700 + 𝐹𝑂𝑆
=31.64+20×31.64
100
=31.64+6.3
=37.9
Dₜ≅ 38𝑚𝑚

13. DESIGN
STRIPPER PLATE
Stripes off or remove the strip from punch
subsequent to the operation

14. BOTT
OM PLAT
E
▶ Hold and supports are part of the
press tool.
T
OP PLAT
E
 It is used to hold the top half of
the press tool with press slide.
 It is also called as Bolster Plate.

15. ▶PUNCH BACK PLATE
This plate prevents the hardened punches
penetrating into top plate. It is also called backup
plate.

16. DRAW PUNCH
▶ The draw punch is used in compound tooling to
pull the metal sheet into the die cavity.
▶ This enables the creation of complex shapes and
forms in a single stamping operation, making it a
cost-effective and efficient
manufacturing process.

17. DIE PLATE
▶ The die plate plays a critical role in
compound tooling by providing a
stable and reliable foundation for
the other components of the tooling.
▶ And also ensures accurate and
consistent positioning of these
components to achieve high-quality
and precise parts.

18. FORMING PUNCH
▶ The forming punch is used to shape and deform
materials into a desired form or geometry.
▶ The forming punch is designed to provide precision
and accuracy in shaping and deforming materials.
▶ The forming punch is an essential tool in the
manufacturing industry, particularly in sheet metal
forming operations.

19. GUIDE BUSH
▶ The guide bush helps to maintain the precise
alignment of the workpiece with the cutting tool.
▶ The guide bush helps to reduce vibration during
the machining operation, which can improve
surface finish and reduce tool wear.

20. PINS
▶ The pin is an important component in
compound tooling, providing accurate
positioning.
▶ Improved precision.
▶ Increased efficiency.
▶ Enhanced safety.
▶ Greater flexibility.

21. ADVANTAGES
▶ Reduced cycle time
▶ Improved accuracy
▶ Increased efficiency
▶ Cost savings
▶ Reduced tooling costs

22. APPLICATIONS
▶ Precision machining
▶ Automotive industry
▶ Aerospace industry
▶ Medical device industry
▶ Electronics industry

23. PROJECT PROGRESS
▶ The tool manufacturing process is currently
progressing smoothly under the 'Machining process'.
The team is utilizing advanced machinery and
techniques to ensure precision and accuracy in the
production of tools. The Machining step is a critical
phase in the manufacturing process, and the team is
dedicated to upholding the highest standards of quality
and efficiency. We are confident that the final product
will meet and exceed our customers' expectations.

24. References
• Pawan Kumar Rai, Dr.Aas Mohammad, Hasan Zakir Jafri” Causes &
Preventation of Defects (Burr) In Sheet Metal Component”
• ‘Gaurav C. Rathod, Dr. D. N. Raut & SamadhanAdlinge’,“Study and
Analysis of Press Tool Design”,International Journal of Engineering
Research & Technology (IJERT)- Vol. 6 Issue 07, July - 2017 .
• Optimum selection of variable punch-die clearance to improve tool life in
blanking non-symmetric shapes by Soumya Subramonian a, Taylan Altan
an, Bogdan Ciocirlan b, CraigCampbell