complete minor project report on manual punching die in doc

MANUAL SHEET METAL PUNCHING DIE . TE ME
Chapter 1
INTRODUCTION
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless
everyday objects are constructed of the material. Thicknesses can vary significantly, although
extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.
In sheet metal working there is different parameters like Sheet metal processing, Sheet metal
forming processes, Shearing processes, Forming processes, Finishing processes, Shearing Process
and the shearing process involves such types of process i.e. (Punching, Blanking, Perforating,
Parting, Notching, Lancing) and our project is totally depends upon the punching process the
punching process is defined as a “shearing process using a die and punch where the interior portion
of the sheared sheet is to be discarded.” And we made a manually operated sheet metal punching die
with the help of this die we can punch the metal plat till 6 mm smoothly.
DEFINITIONS OF VARIOUS PROCESSING
Sheet metal processing
The raw material for sheet metal manufacturing processes is the output of the rolling process.
Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin
and very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is
to cut the correct shape and sized ‘blank’ from larger sheet.
Sheet metal forming processes
Sheet metal processes can be broken down into two major classifications and one minor
classification
• Shearing processes -- process which apply shearing forces to cut, fracture, or separate
the material.
• Forming processes -- process which cause the metal to undergo desired shape changes
without failure, excessive thinning, or cracking. This includes bending and stretching.
JIEMS, Akkalkuwa 1

• Finishing processes -- process which are used to improve the final surface
characteristics.
Shearing Process
1. Punching: shearing process using a die and punch where the interior portion of the sheared
sheet is to be discarded.
2. Blanking: shearing process using a die and punch where the exterior portion of the
shearing operation is to be discarded.
3. Perforating: punching a number of holes in a sheet
4. Parting: shearing the sheet into two or more pieces
5. Notching: removing pieces from the edges
6. Lancing: leaving a tab without removing any material
For
ming
Processes
• Bending: forming process causes the sheet metal to undergo the desired shape change by
bending without failure.
• Stretching: forming process causes the sheet metal to undergo the desired shape change
by stretching without failure.
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• Drawing: forming process causes the sheet metal to undergo the desired shape change by
drawing without failure.
• Roll forming: Roll forming is a process by which a metal strip is progressively bent as it
passes through a series of forming rolls.
Common Die-Bending Operations
Various Bending Operations
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Schematic illustration of a stretch-forming process.
Schematic of the Drawing process.
Eight-roll
sequence for
the roll
forming of a
box channel
Presses
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• Mechanical Press - The ram is actuated using a flywheel. Stroke motion is not uniform.
• Hydraulic
Press - Longer strokes
than mechanical presses, and develop full force throughout the stroke. Stroke motion is of
uniform speed, especially adapted to deep drawing operations.
Hydraulic Press
Dies and Punches
• Simple-- Single operation with a single stroke
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• Compound-- Two operations with a single stroke
• Combination-- Two operations at two stations
• Progressive-- Two or more operations at two or more stations with each press stroke,
creates what is called a strip development
Progressive dies Punches
Tools and Accessories
The various operations such as cutting, shearing, bending, folding etc. are performed
by these tools.
Marking and measuring tools
• Steel Rule - It is used to set out dimensions.
• Try Square - Try square is used for making and testing angles of 90degree
• Scriber – It used to scribe or mark lines on metal work pieces.
• Divider - This is used for marking circles, arcs, laying out perpendicular lines, bisecting
lines, etc.
Striking Tools
• Mallet - It is wooden-headed hammer of round or rectangular cross section. The
striking face is made flat to the work. A mallet is used to give light blows to the Sheet
metal in bending and finishing.
Merits
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• High strength
• Good dimensional accuracy and surface finish
• Relatively low cost
Demerits
• Wrinkling and tearing are typical limits to drawing operations
• Different techniques can be used to overcome these limitations
o Draw beads
o Vertical projections and matching grooves in the die and blank holder
• Trimming may be used to reach final dimensions
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Chapter 2
LITERATURE SURVEY
We have survey following literature or books for selection of project.
• Manufacturing Engineering
• Production Engineering
• Sheet Metalworking
• Market Survey
Before you launch the product you need to check your self-market product for the
product selected by you A comprehension market study in must be specific advantages of such
study are as under.
• It makes it possible for you to estimate scale & utilization of installed capacity with reference
to proposed enterprise.
• You can judge weather the proposed capacity is one the higher or lower size.
• It enables you to evaluate the viability of an enterprise by arcing at a years estimate of seals.
• It provides a preliminary input for the marketing strategy & process formulation or the
enterprise (A market program is set of decision required in respect of various markets related to
issues it influences the market).
Market survey is usually focused on gross market demand present & future. It typically
highlights the gap between expected market demand & supply in respect offer given product.
Such a gap could be positive & therefore favorably. The gap could also negative
JIEMS, Akkalkuwa 8

Chapter 3
SELECTION OF PROJECT
Before selecting a project, survey has to be done regarding demand & market value of the
product feasibility of the available resources & facilities.
RESOURCES OF PROJECT
Resources of project, which are very useful for doing project work are given below:
• Tool room
• Machine shop
• Fabrication Industries
• Discussion with project guide
• Market survey
• Industrial support
SELECTION OF PROJECTION
• Entrepreneurship
• Liberty
• Discuss with student group
• Market survey
• Resource utilized
• Discuss with project in charge
• Magazine.
JIEMS, Akkalkuwa 9

Chapter 4
BASIC ELEMENTS OF PROJECT
Base
The strong base for hold the total elements stable is made up by mild steel this controls
the total assembly and it is situated on foundation.
Bed
The bed is lower part of press frame that serves as a table on which a bolster plate is
mounted.
Handle
The handle is used for giving guide to tool and we apply force on handle & this press the
tool.
Guide Pillar
These are cylindrical pins known as guide pins or guide pillars. These provide accurate
alignment to the die set. One end of the pillar is given press fit in the base plate with
H7/p6 tolerance. The other portion, which is sufficiently long, provides guide for top plate
for easy sliding.
Ram
Ram is the guide of punch it guides the punch in proper way it is situated between punch
and handle.
Punch
This is most important element of the tool. It is the cutting element of the tool. Punch
gives the whole size and the shape on the component. This is made out of high carbon
high chromium steel material. The tool is fixed in punch and punching is shearing process
using a die and punch where the interior portion of the sheared sheet is to be discarded.
JIEMS, Akkalkuwa 10

Die
The female member of the tool in which openings are made for the punch to enter in
them is termed as die. It includes well supporting and actuating part of the tool. It also
includes cutting profiles, bending die insert, pushers, stoppers, strip guides etc.
Die Plate
In this plate all die inserts held accurately. This plate thickness as same as die inserts
thickness .This plate made out of HCHCr (D2).
JIEMS, Akkalkuwa 11

JIEMS, Akkalkuwa 12

Chapter 5
WORKING PRINCIPLE OF SHEET METAL PUNCHING DIE
The figure shows the working principle of Manual Sheet Metal Punching Die in figure
the ram is pressed by handle this strikes on punching plate the punch is mounted on this
punching plate and guide post gives to punch in a proper direction now the punch stricken on the
job and job is get cut the job is foxed on die and the die is hold on die holder and bellow that
base is mounted. The simple working principle shown below in figure.
JIEMS, Akkalkuwa 13

Chapter 6
TARGET SPECIFICATIONS
In order to determine the technical specifications the team first considered the revised
customer needs statement. From this “Needs Statement” the team established several target
specifications; which are listed below. OSHA regulations – Design must meet or exceed safety
levels required by OSHA • Disk dimensions – Punch to cut 2.5 inch diameter circles. The customer
has provided us with a “go no-go” cap to check the tolerances of the cut discs. • Production rate –
Minimal rate of four disks per minute, a higher rate would be a delighter. • Ease of Operation –
Currently mid to high functioning level customers cut the screens; these consumers have moderate to
mild physical and/or mental disabilities. Our targeted operator is a low functioning consumer; or one
with severe mental disabilities. • Footprint – Smaller than 3’x5’ to fit on a table. • Weight- The
device and the combined applied force cannot exceed the maximum allowable weight for the table of
300 pounds. • Durability – Design should require minimal maintenance for four hundred thousand
cut discs, or a ten year production life. The maintenance on the device should not require any special
tooling, lubrication, or expensive parts.
DESIGN PARAMETERS
The design criteria developed by the team for the screen cutter, are listed below:
• Reliable
• Cut disks to minimize splinters
• Required force on defined thickness
• Reasonably comfortable for user
• Aesthetically acceptable
• Proper Safety Signage
• Easily maintainable
JIEMS, Akkalkuwa 14

Chapter 7
PUNCH DESIGN
The team is currently considering two types of round punches for cutting the screen. As
shown in Figure the two possibilities being evaluated are a solid flat punch and punch which has had
some of the center stock milled out. Currently the team has performed a test using a ¾” solid punch
and die to cut a sample of screen. These tests revealed that this type of die is capable of providing
clean circular cuts when the appropriate amount of force is provided. However, if insufficient force
is supplied to the punch then the screen is not cut cleanly and the shape becomes distorted and the
edges of the cut screen fray. The exact amount of force required has not been quantified yet this will
be done when the 2-31/2” solid punch is tested. The team has also conducted test using a 1-3/4”
milled out punch. These tests were performed on standard notebook paper cutting though in excess
of 20 sheets. These tests revealed that this design of punch and die required little input force to cut
through large amounts of material. Further testing will be done on the screen material using this
punch and die.
During these test the team will be looking to see if the edges of the screen are cut cleanly,
what effect if any the screen material has on the punch tool life. After it was decided that the screen
cutting process should not require the use of individual screen squares, the remaining concept ideas
were evaluated using the decision matrix. The scores for each of the concepts being compared were
relatively close with the exception of the Scotch Yoke mechanism, which is shown in Figure. The
resulting decision matrix scores were close because, each of the 3 highest scoring concepts shared
JIEMS, Akkalkuwa 15

multiple commonalties. These common features included: Lever style input operation and a punch
and die style cutting mechanism. For this reason the team has chosen to purse an integrated design
concept that will include: a manual screen feeding system; and a die and punch cutting mechanism
with some type of a force multiplier to provide the operator with a mechanical advantage while
cutting the screen. The final design concept may resemble the stapler concept shown in Figure if
only one punch is utilized. The team designed a machine that was similar to the Punch/Press Stamp
machine. The type of punch that will be utilized will be determined based on further testing of the
two styles being considered, solid, milled with a bevel.
PUNCHING FORCE
As the name indicates it is the force of the punch needed to cut the blank or pierce a sheet
F(p) = L . t . Τ
F(p)= punching force, N
τ =Shear strength MPa
For holes with diameter d<t
F(p)=D.t. s/3√D/t
Where, D= diameter of punch, mm
s = tensile strength in Mpa.
JIEMS, Akkalkuwa 16

Chapter 8
CUTTER ANALYSIS (TOOL ANALYSIS)
In order to understand the function of the cutters, two experiments were conducted. One
analysis used to calculate the force exerted on the lever was an experiment to find the actual weight
need to pierce one cutter through the screen material. In this experiment weight was added to the
cutter until it broke through the screen creating a 2.5’’ diameter circular screen cutout.
The cutters themselves consist of four springs in which are located on each corner to allow the cutter
to bounce back to its original position. It can be seen that less force is needed when the springs are
totally eliminated. This experiment is an application of Hooke’s Law, where the force is equal to the
spring constant multiplied by the length. The springs used on the cutters will create an additive
spring force, thus requiring a higher input force. The analysis revealed that the weight needed to cut
one screen using the maximum of four springs would be approximately 60lbs. Another experiment
JIEMS, Akkalkuwa 17

was conducted to analyze the fatigue of the cutters based on a continuous punching operation.
During the experiment five-hundred x 2.5’’ diameter circular screens were cut using a single
experimental cutter. The cutter was examined both visually and tactilely before and after the
experiment; and it was found that there were no changes to the shape, sharpness, or cutter itself. This
experiment was implemented to see if fatigue, dullness, or fracture would occur. All circles punched
during this experiment passed the customer’s quality check.
Chapter 9
REQUIRED MACHINE TOOLS & EQUIPMENTS
The tools & equipment, which are needed for project Induced draft cooling tower. We must
required different machines for different operations like.
• Lath machine
• Sheet cutting machine (Hand shearing machine)
• Sheet banding machine
• Welding machine
• Drilling machine
• Hand grinder
And also some equipments like
• Measuring tape (500 mm)
• Vernier caliper (200 mm)
• Marker (Standard quality)
• Hand hacksaw (300 mm)
• Drill bit (3 mm to 15 mm)
• Right (single) point cutting tool.
JIEMS, Akkalkuwa 18

Chapter 10
COSTING
There are three elements of any products are:
• Material
• Labor
• Expenses
1. MATERIAL:
Direct material:
Material which is processed for final product but it is a part of the product is direct
material cost is this material is called direct from market.
In – direct material:
Material which does not forms part of the final product but it is a must be for processing
direct material is called in-direct material e.g. – Cotton waste, oil, etc.
2. LABOR:
Direct labor:
The worked who actually performed the work on the directly material rather
mechanically of by machine is called direct labor.
In-direct labor:
It supervised the activity of the direct labor.
3. EXPENSES:
Direct Expenses:
JIEMS, Akkalkuwa 19

The expenses, which can be directly changed on the particular product, are called
expenses.
In – Direct Expenses:
The expenses that can not be directly or confidently changed on particular products are
called in-direct expenses.
CALCULATIONS
Prime cost
• Direct material = 3500 Rs.
• Overhead cost:
20% Prime Cost = 700 Rs.
• Production cost :(Nil)
Using collage workshop
• Net Desired Profit
Nil
JIEMS, Akkalkuwa 20

Chapter 11
CONCLUSION
In course of this project I have gained a great deal of confidence and knowledge in the way of tool
manufacturing.
The work has gone in detail in all the analysis methodically. The tool can also be designed and
manufactured without any these analyses, but the success and the economics of the tool is not assured.
I have executed my very best to achieve the required results, as far as the tool is concerned. This
project has paved a new way for me to tap the knowledge that lies in the waste field of Press tools.
I learned many aspects such as co-operating and adjusting myself with other fellow crew working on
this tool. And the strong positive guidance given by our guides during solving of problems is really
commendable; hence the success of the design analysis of the tool is assured.
JIEMS, Akkalkuwa 21

REFERENCES
• Anderson, D.C., Chang, T.C.: Geometric Reasoning in Feature-based Design and Process
Planning. Computer & Graphics, Vol.14, No. 2, pp. 225-235, 1990.
• Bourne, D.A.: Intelligent Manufacturing Workstations. In Knowledge-Based Automation
of Processes, ASME Winter Annual Meeting, Anaheim, CA, pp. 77-84, 1992.
• Cutkosky, M.R., Brown, D.R., Tenenbaum, J.M.: Extending Concurrent Product and
Process Design Toward Earlier Design Stages. Concurrent Product and Process Design,
Chao and Lu(eds.). ASME DE-Vol. 21, PED-Vol 36, 1989, pp. 65-72.
• De Vin, L.J. et. al: PART-S, a CAPP System for Small Batch Manufacturing of Sheet
Metal Components. In Proceedings of the 24th CIRP International Seminar on
Manufacturing Systems, Copenhagen, pp. 171-182, 1992
• Dixon, J.R.: Designing with Features: Building Manufacturing Knowledge into More
Intelligent CAD Systems. In Proceedings of ASME Manufacturing international-88,
Atlanta, GA, April.
• Floriani, L.De: Feature Extraction from Boundary Models of Three-Dimensional Objects.
IEEE Transactions on Pattern Analysis and Machine Intelligence, Vol. 11, No. 8, August,
1989.
• Gupta, S.K., Nau, D.S.: Systematic Approach to Analyzing the Manufacturability of
Machined Parts. Computer-Aided Design, Vol. 27, No. 5, pp. 323-342, 1995.
• Hayes, C.: Using Goal Interactions to Guide Planning. In Proceedings of AAAI-87; the
Sixth National Conference on Artiﬁcial Intelligence, pp. 224-228, 1987.
• Inui, M., Kimura, F.: Design of Machining Processes with Dynamics Manipulation of
Product Models. In Artiﬁcial Intelligence in Design, Pham, D.T. (ed.). Springer-Verlag,
New York, pp. 195-227, 1991
• Kurochi, N. et al.: CAD/CAM System for Sheet Metal Structural Parts: Development and
Implementation. Bull. Japan Soc. of Prec. Eng., Vol. 13, No. 3, Sep. 1979.
• Nau, D.S. et al.: Solid Modeling and Geometric Reasoning for Design and Process
Planning. Tech. Report CS-TR-2056, University of Maryland, July, 1988.
JIEMS, Akkalkuwa 22

• Nau, D.S., Karinthi, R.R.: An Algebraic Approach to Feature Interactions. Technical
Report
JIEMS, Akkalkuwa 23

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