Design of press tool for BLDC motor cover which was used in different missiles

1. A Review
on
Design of Progressive Draw Tool For Rear Flange of a Bi-cycle
By
D. PAVAN SINDHUR
(100515765207)
Under the guidance of
Mr. V. Nageswara Rao
UNIVERSITY COLLEGE OF ENGINEERING,
OSMANIA UNIVERSITY(CITD)
HYDERABAD.

2. ABSTRACT
Design and development of progressive tools for the sheet metal component is
one of the important phase in sheet metal manufacturing. Sheet metal press working process by as
variation in progressive tools geometry, strip layout, die shear, material properties, component and
press working equipment position error and process parameters related to its manufacturer. These
uncertainties in combination can induce heavy manufacturing losses through premature die failure,
final part geometric distortion and production risk. Identifications of these uncertainties and
qualifying them will facilitate a risk free manufacturing environment, which goes a long way to
minimize the overall cost of production.
The main theme of the project is to design and develop a progressive tool for
the “rear flange”. This flange is used in bicycle, through which spokes are connected. The
progressive die design is carried out at HMT, Hyderabad. The press tool designed for this
component is a progressive press tool in which drawing operation, simple blanking and piercing
operations are performed. By using design formulae tonnage is calculated and dimensions of the
individual component of progressive tool is determined.

3. INTRODUCTION
• The progressive die performs a series of fundamental sheet metal working at two or
more stages during the press running to produce a production part as the strip stock
moving through the die surface. Press working from the optimum die design and its
making has been the purpose of mass production in the manufacturing field.
• The design and manufacture of press tool or punches and dies, is branch of
production technology that has extended into lines of engineering manufacture over
the past seventy years. There is no doubt that the accuracy achieved by new ideas
in design and construction applied by the tool design engineer, coupled with
increased speed and rigidity of the press etc, used have all contributed towards
maintaining this form of metal tooling well to force as a means of obtaining, yet
strong, durable articles that can with stand severe day to day usage.

4. The four factors which are essential contributions to first class press work are
1. Good Operation Planning
2. Excellent Tool Design
3.Accurate Tool Making
4. Knowledgeable Press Setting
COMPONENT ANALYSIS :
Material : HROP
Thickness : 2.20 mm
Shear strength : 200 MPa
Supply condition : hand feed
Composition ( source : IS 1079 :2009 )
COMPONENT WEIGHT %
Carbon 0.08
Manganese 0.40
Sulphur 0.030
Phosphorus 0.035
COMPONENT

5. PROBLEM DEFINATION
• To design 6 stage progressive tool for the rear flange which is used in bicycle. The design is
drafted and modeled for assembly suing CAD software for the manufacturability of the
component
• Designing and drafting :
All the components from strip layout to the basic assembly have been designed and
drafted using AutoCAD.
• Modeling for assembly :
All tool elements were modeled by SOLIDWORKS software. This stage involves
making of various parts of the assembly, individual tool elements etc.
• Preparing 3D models:
The punch, die, stripper and punch plate need to be machined using the wire cut EDM
and CNC. For this, 3D models of the punch, die, stripper plate and punch plate were
made in solid works.

6. THEORY OF DRAWING OPERATION
Deep drawing process:
Cup drawing or deep drawing is one of the widely used sheet metal forming
operations. Cup shaped objects, utensils, pressure vessels, gas cylinders,
cans,shells,kitchen sinks etc are some of the products of deep drawing. In this
process, a sheet metal called blank is placed on a die cavity, held in position using a
holding plate or holding ring and pressed against the die cavity using a solid punch.
The sheet metal attains the shape of the die cavity with flat bottom. Both die and
punch should be provided with corner radius in order to avoid shearing of the sheet.

7. DEEP DRAWING

8. DESIGN CALCULATIONS

11. REMAINING WORK
• Design of strip layout.
• Determine the dimensions of elements of progressive tool.
• Selection of Materials for all elements of die set
• Modeling of component in solid works

12. References
• [1] ASM Metals Handbook 14b .
• [2] J. Duncan, S.J.Hu, Z.Marciniak “Mechanics of sheet metal forming”
Butterworth – Heinemann Publications, 2002.
• [3] Mark Colgan, John Monaghan, “Deep Drawing process: analysis and
experiment”, Journal of Materials Processing Technology, 132, 2003, 35-41.
• [4] P. Venkateswarlu, M. J. Davidson and G. R. N. Tagore, Influence of process
parameters on the cup drawing of aluminium 7075 sheet, International Journal of
Engineering, Science and Technology Vol. 2, No. 11, 2010, pp. 41-49.
• [5 ] Ghosh and Malik “Manufacturing science” East-West Press (P) Ltd., New
Delhi 1985

13. Thank you