Design and Development of a Tool for Combined Depression and Piercing Operation, rim manufacturing, piercing operation, the operation is done for seating the Valve stem which protrudes out of the wheel for inflating tubes &Tyres

1. topic: Design and Development of a Tool
for Combined Depression and Piercing
Operation

2. content
01
02
03
04
Introduction
Problem Formulation
Experimentation
Results and discussion
06
05 Conclusions
References

3. Abstract
Pressing operation
1. work deals with combining two pressing operations done separately.
2. This operation is done for seating the Valve stem which protrudes out of the wheel for inflating
tubes &Tyres.
3. In the first pressing a depression flat is observed in the component.
4. And in the second operation a hole is pierced in the same flat
Hole depression
Hole piercing
Developing
a single tool

4. abstract (CONTD.)
The objective is to develop a tool and process for using a single press for performing dual operation
reduce down time
reduce operator Fatigue
increases production
01
02
03
. Economically optimization
04

5. Metalworking parameters
Metalworking comprises of deformation methods in which a
metal billet or blank is formed by tools or dies.
01
The design and mechanism of such methods depend on an understanding of the
features of the raw material, the parameters at the tool/work piece interact, the
mechanics of plastic deformation, the machine used, and the requirement of finished-
product..
02
Influencing parameters for selection of tool geometry and
material. These are the as well also processing conditions like
work piece and die temperatures and lubrication
03
.
01 Introduction

6. Introduction (contd.)
In the process, the surfaces of the deforming metal
and the tools are in contact, and friction between them
may have a major influence on material flow
In sheet forming, a piece of sheet metal is plastically
deformed by tensile loads into a three-dimensional
shape, often without significant changes in sheet
thickness or surface characteristic.
Example of sheet drawing operations:
Drawing, explosive, incremental, peen, roll
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In the process, the surfaces of the deforming metal and
the tools are in contact, and friction between them may
have a major influence on material flow.
In bulk forming, the input material is in billet, rod, or slab form,
and the surface-to-volume ratio in the formed part increases
considerably under the action of largely compressive loading
The deforming material, or work piece, undergoes large
plastic (permanent) deformation, resulting in an
appreciable change in shape or cross section.
Examples of generic bulk forming processes
are extrusion, forging, rolling, and drawing.
Metal
working
processes
Bulk or massive,
forming operations
Classification of metalworking
processes
Sheet forming
operations

7. Piercing operationIntroduction (contd.)
1. Piercing is the cutting of holes in sheet metal, generally by removing a slug of metal, with
a punch and die.
2. In piercing the work metal that surrounds the piercing punch is the work piece and the
punched-out slug is scrap
3. Piercing is ordinarily the fastest method of making holes in steel sheet or strip and is
generally the most economical method for medium-to-high production.
4. Pierced holes can be almost any size and shape; elongated holes are usually called slots
5. The accuracy of conventional tool steel or carbide dies provides pierced holes with a
degree of quality and accuracy that is satisfactory for a wide variety of applications

8. Scrap data report
02 Problem Formulation
 Rejection data of 3 months for tractor wheel assembly are collected from the Quality department of
organization.
 1% of rims are getting rejected due to only Tool Clamp Marks, Wrong depression and wrong piercing.
From the data it is clear that there is strong requirement for the process control along with necessary chan
ges in the Process and Tool Design

9. Rim manufacturing
03 Experimentation
Assembly line of rim manufacturing

10. Flow process
Experiment (contd.)

11. Rim manufacturing stages
Experiment (contd.)
Feeding, rim bank rolling (process 1-4)
1. A coiler machine is an essential machine that is used before
the rim welding.
2. It provides the forms for coiled hoops from flat rim bands.
3. It can be used in the preparation of wheels for light weight cars
trucks, construction vehicles, farm vehicles and more.
4. After the feeding, deburring, stamping and auto colling, the
rim band will become a coiled hoop.
01
02 Flattening, butt welding (process 5-6)
1. It is necessary to use the flattening machine to flatten
the joint of the coiled rim bands that are over 4mm
thick before proceeding to the flash butt welding
process.

12. Experiment (contd.)
03
04
Trimming, planishing, end cutting (process 7-9)
1. The welding slag will be produced on both the inside and
outside surface of the weld joint after the welding process.
2. A special machine unit comprised of the trimmer planisher
and end cutting machine can be used to remove the slag and
make the surface of the weld joint flat and smooth.
Flaring (process 10-12)
1. After the weld joint processing. cooling, and re rounding
processes, a horizontal flaring machine will be used to
flare two edges of the rim to make the following roll for
ming processes easier.

13. Experiment (contd.)
05
06
Roll forming (process 13-16)
1. The roll forming machine is used for the symmetrical or
asymmetrical roll forming of wheel rims for passenger cars,
tractors, and construction vehicles.
2. This machine is used for the 1st through the 4th roll
forming.
3. The 4throll forming process is optional and is used to press
non-skid patterns onto the rim of tractors and construction
vehicles.
Edge flanging, expanding (process 17-19)
1. A horizontal expanding machine is used for the expanding
size process after the roll forming of the wheel rims.
2. Precise expanding and sizing using a special tooling allows
the formed rims to meet the design requirements for
diameter

14. Experiment (contd.)
07
08
Gas tightness, testing, valve hole punching (process 19)
1. Gas tightness detection tests are conducted to ensure the
welding quality and reduce air leakage.
2. The valve hole punching is done after profiling and is an
important step in steel wheel rim manufacturing.
3. With a corresponding mold, it can punch the right valve
hole on the effective part of the rim
4. The valve hole punching press is used for the flat
pressing and hole punching on tubeless wheel rims.
Press disc into rim, welding (process 20-22)
1. A steel wheel is made of the wheel rim and the wheel disc
2. The wheel rim and tire form an airtight unit for bearing the
vehicle's weight and transmitting power.
3. The wheel disc is connected to a hub and transmits the pow
er from the engine.
4. Usually, the wheel rim and disc of passenger cars and truck
s are connected by welding whereas large wheel rims and
discs for farm vehicles are bolted to each other

15. Concept development
Experiment (contd.)
1524
1415
420
415
• Including clearance gap of 20 mm
• All dimensions are in mm
200
800
1. Taking normal man’s average height as 5 feet (1524 mm)
2. Holding 20 Kilograms on average and working is also difficult as because of height

16. Tool design
Experiment (contd.)
1. The tool design phase is required to be started with the concept of having the depression male punch on the top and to have the punch and
die in between the depression block.
2. There will be two strokes from the same press, in the first the depression flat would be made in the component.
3. In the next stroke the piercing would be done.
4. The existing process of valve hole depression is done in a Hydraulic Press of 200T and piercing in a Mechanical Press of 100T.
5. The concept that is to be developed should be such that both the operations are done in a single stage

17. Experiment (contd.)
1. In the first operation the tool to be designed for
making a depression with a male depression flat on
the top and the female die on the bottom
2. In the next operation punch should protrude out of
male depression flat by some mechanical
arrangement.
3. This mechanical arrangement makes sure that
always for the first operation the punch space is not
locked.
4. And in the second operation the mechanical arrang
ement makes the punch to protrude out to the
required height for piercing

18. Experiment (contd.)
1. Only press found which is working on the multiple tool selection concept is CNC Turret Punching Press located at Chassis Shop.
2. The Press is a Mechanical Press of 200 Ton capacity and controlled by CNC.
3. Press is having a Turret which can hold 14 numbers of various tool varieties. Based on the material thickness it can punch hole diameter
ranging from 9mm to 44mm as per requirement

19. 04 Results and discussion
Automation and modification done by maintenance department for the following:
1. Two stroke of the ram after in a single press of push button.
2. At the first stroke of the ram Pneumatic Cylinder remains in retracted condition
3. After completion of first stroke cylinder extends and hence wedge piece which locks the punch before second stroke proceeds.
4. After completion of the second stroke Pneumatic cylinder comes to retracted condition.
After completion of the assembly of the tools and automation of the machine, first trial taken for only depression operation, once
depressed portion confirmed as per the quality then punch installed and combined trial taken. It was planned to take the volume of 500
rims for confirming and repeatability and reproducibility for quality of the combined operation.

20. 05 Conclusions
Trials confirmed on a lot of 500 pieces for confirming the repeatability and reproducibility. Modified design
has been successfully implemented and following benefits are noted and observed by the organization.
1) Elimination of one operation.
2) Improved product quality.
3) Reduction in Cost per Rim.
4) Reduction in processing time.
5) Reduction in operator Fatigue.
6) Reduction in skill level of the operator.
7) Reduction in Rejection Percentage.
8) Reduction in Tool down time.
9) Reduction in Machine down time.

21. 06
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