Optimization of International student expenses at Wayne state ppt
design n testing of tool used in press shop
1. project on:-
design and analysis of punch tool used in
press shop
By :-
Parag Kapile
Dinesh Panda
Ritesh Kumar
Kaustubh Patil
Guided by:-
Mr.Rajkumar Shinde
Sponsored by:-
SIDDHESHWR INDUSTRIES Pvt. Ltd.
2. Siddheshwar industries is one of the fastest growing companies in the field of precision component
for the Automotive and Engineering industries and are also suppliers to some of india’s largest
engineering companies .
Siddheshwar ind. Manufacturing capabilites include extensive Forging & Machining processes with
engineering resources for deveolping customer projects from prototype to production .
Siddheshwar industries are leading manufacturers of Gears , Crankshafts , Flanges , Albero shafts
for automotive & non-automotive industry.
The client list includes one of india’s giants in the two & three wheeler field – BAJAJ AUTO ltd.
It was established in 1994.The buisness has grown from a small machine shop to a multiscale
company with a turnover of Rs 170 Crore.
Mr.V.B.Takawane(CEO)
Mr.Raviraj
Takawane(director)
Mr.N.M.Chandeka
r (G.M.)
Mr.V.K.S.Nair
(G.M. purchase)
Mr.S.Shaha(vice
president)
Mr.N.Pathan
(maintenance)
3. PROBLEM DEFINITION:--
The cost of tooling in sheet metal industries contributes a considerable part to the overall cost
of manufacturing a component. It is therefore imperative to keep down this cost by ensuring
that the tool works for a long period in production without interruption. One way of
achieving this objective is to reduce the stress on the tool during punching/blanking.
To reduce the required shearing force and stresses on the punch.
To accommodate a Gear primary helical (GPH) plate on a smaller capacity punch press.
To distribute the cutting action over a period of time.
A 15 TON press machine operation is done on a 5 TON press machine.
To find best suitable punch among different cutting profiles
of punches using Finite Element method.
To increase life of punching tool.
View of a distorted punch
4. OVERVIEW OF PROJECT:-
Tool design and
analysis
Present scenario
(flat faced tool)
Design and
calculation of
stresses using
normal procedure
Proposal (tool
with rilef shear
angle)
Calculation of
stresses using
Finite element
method
6. Modelling of punch
To reduce the stress on the tool and thus enable thicker or more
resistant stock to be punched on the same press or to permit the use of
lower-rated presses, the employment of a punch or die with ground
relief on its face is a common practice.
It is reported that punching/blanking forces vary with various amounts
of shear relief on the tool face.
However, there is little information available to tool users as to how
the amount of shear relief has to be chosen in practice in relation to the
punching force required for a given product.
This project deals with the design analysis of various types of punches
with special attention to their cutting profiles, using the finite-element
technique. Results obtained helps for the selection of punches for
minimum distortion of the punch and reduced stress on the punch.
9. Metallurgical properties of D2 tool steel:--
MATERIAL PROPERTIES VALUES
Ultimate compressive strength 2150 N/mm2
Young’s modulus 210* 103 N/mm2
Poisson ratio 0.3
Modulus of rigidity 80*103 N/mm2
Density 7860 kg/m3
Length of tool 61.34 mm
MATERIAL PROPERTIES VALUES
Ultimate shear strength of workpiece (tm) 639 N/mm2
Diameter of hole in workpiece 12 mm
Thickness of workpiece 6 mm
Percentage of penetration required 60%
Ultimate tensile strength of workpiece 520 N/mm2
Metallurgical properties of workpiece:--(GPH stainless steel)
10. Calculation of stresses:-
CASE I: Without shear (Flat face)
1.) Maximum puching load : (initial)
Pi = L * t * tm
Pi = p * 12 * 6 * 639
Pi = 144.538 * 103 N
Pi = 144.538 kN
2.) Total work done in punching :
W = 144.538 * 6 * 0.6
W = 520.336 kJ
CASE II : With Shear angle assume Ø =22.5o
Total work done = Pf ( 0.6 * 6 + 12 )
520.366 = Pf ( 0.6 * 6 + 12 )
Pf = 33.354 KN cutting complete at 60% penetration = 0.6
(assuming for stainless steel material)
D=12mm
12. Calculation of forces for fem model
I] load Acting on punch:
where,
a) calculation of force components for different nodal points
m
..….(coefficient of friction m =0.10)
b) In case of punch 2 & 3:
c)whilst in case of punch 4:
13. Nodal loads on the cutting edge surface:
Here the cutting edge nodal points includes 1, 10, 26.
Fx, Fy, & Fz are the components of Fp at 1, 10 & 26.
Punch Profile No. Shear angle ∅ (degree) Node No. Force (N)
Fx Fy Fz
1 0 1
10
26
248
1003
3266
-248
-1003
-3266
2482
10027
32656
2 and 3 22.5 1
10
26
948
3837
12497
-948
-3837
-12497
2293
9264
30170
4 22.5 1
10
26
12497
3837
948
-1250
-384
-95
30170
9264
2293
15. Radial Deformation Vs Shear Angle
-500
-400
-300
-200
-100
0
100
200
0 6.5 7.5 15 22.5 30 37.5 45
R
a
d
i
a
l
d
e
f
o
r
m
a
t
i
o
n
∆
R
shear angle ∅(degree)
Radial deformation vs shear angle
concave shear
convex shear2
one way shear
16. puch load vs shear angle
0
10
20
30
40
50
60
70
80
90
100
0 7.5 15 22.5 30 37.5 45
F
o
r
c
e
(
k
N
)
Shear angle degree ∅
puch load vs shear angle
Fx and Fy
Fz
17. Radial stiffness Vs Punch type
0
5
10
15
20
25
30
35
40
45
50
flat face convex shear concave shear one way shear
R
a
d
i
a
l
s
t
i
f
f
n
e
s
s
punch type
Radial stiffness(*1000 kN/mm) vs punch type
Radial stiffness
18. Axial stiffness vs punch type
0
50
100
150
200
250
300
flat face convex concave one way shear
A
X
I
A
L
S
T
I
F
F
N
E
S
S
Axial stiffness(kN/mm) vs Punch type
axial stiffness
19. principal stress vs punch type
0
200
400
600
800
1000
1200
1400
1600
flat face convex concave one way shear
P
R
I
N
C
I
P
A
L
S
T
R
E
S
S
principal stress(N/mm2) vs punch type
principal stress
20. Steps in ansys:
Step 1. 3-d modelling Step 2. Importing in ansys
Step 3. Applying loads and boundary
condition
Step 4.Meshing the model
22. Results for shear tools
Result of Convex shear
Result of Concave shear Result of One side shear
23. Comparison of results:
Stress Calculated Results
(N/mm2)
Ansys Results
(axis symmetric loading)
(N/mm2)
Von mises Stress
(Maximum) Flat Face
1277.99 1465.6
Von mises Stress
(Maximum) One Way Shear
294.91 312.49
24. Conclusions
The present study on punch design has resulted in the development of 3-D finite-element
models of various types of punches and demonstrates the usefulness of these models in
solving practical problems involving a range of design parameters.
That the radial deformations of punches with balanced convex and concave shear have a
minimum value within the shear angle range of 17°-25° suggests that a shear angle of 22.5°
can be proposed safely for practical purposes.
That amongst the rigidity characteristics evaluated for all types of punches, the punch with
balanced convex shear, punch 2 & 3, shows the best performance suggests that this type of
punch can reasonably be recommended in practice in order to reduce the stress on the tool
and thus to enable thicker or more resistant stock to be punched on the same press or to
permit the use of a lower-rated press but punch 2 does not give good surface finish as
compared to punch 3.
Since the inclusion of eccentricity due to asymmetric load on the press is an important
factor in the punching/blanking process, the choice of punch 2, with balanced convex shear,
compared with sintered hard coating around circumferential edge of flat tool.
26. REFERENCES:-
Tools and Manufacturing Engineers Handbook, 3rd edn., McGraw-Hill, New
York, 1976.
Cyaril Donaldson , tool design, Tool Manuf. Eng.,
Fundamentals of tool manufacturing and die design by N.P.Mathur.
U.P. Singh, P,C. Veenstra and J.A. Ramaekers, Design study of the geometry of
a punching/ blanking tool, Ann. CIRP, (1977).
AISI D2 Tool steel facts by UDDHEOLM
Mini Review on Designing of Press Tools for Sheet Metal Parts in Journal of
Environmental Science, Computer Science and Engineering & Technology by
Kailash Kumar Lahadotiya, Abhay Dinkar Kakirde, and Asutosh Kumar Pandey
