This document provides details about the design of a progressive tool for manufacturing a stainless steel gasket. It includes the work order information, material specifications, sheet layout, and calculations for tool forces. Key aspects of the tool's design are roller lifters to smoothly feed the strip and miss-feed sensors to prevent defects if the strip is misfed. The tool is designed to manufacture the gasket through multiple progressive stages of shaping.

1. VINAYAK V. SUSLADKAR
{2009156}
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2. PROGRESSIVE TOOL FOR
GASKET
• WORK ORDER NO. - 1421620
• CUSTOMER - Elringklinger
• COMPONENT - Gasket
• MATERIAL - Stainless steel
• SHEET THICKNESS - 1 mm

3. CONTENTS:-
1. INTRODUCTION TO PROGRESSIVE TOOL
2. STRIP LAYOUT
3. CALCULATION
4. SPECIAL FEATURES
5. ASSEMBLY DETAILS

4. INTRODUCTION TO PROGRESSIVE
TOOL
Press tool is chip less tooling operation in which sheet metal is subjected to
both cutting and non cutting operations. In some cases the strip is
subjected to a combination of cutting/non cutting or both. Such type of
tools are called Progressive tools.
The final component is obtained by progressing the sheet metal or strip in
more than one stage. At each stage the tool will progressively shape the
component towards its final shape, with the final stage normally being
cutting-off.
Bulging:
Bulging is a drawing process. Drawing operation subjects the material to severe
plastic deformation.
Bulging is a secondary process usually after drawing operations in which
material is displaced to create a larger, or smaller, diameter ring of same
material beyond the original body diameter of a part.

5. COMPONENT DETAILS
• COMPONENT - Gasket
• MATERIAL - Stainless steel
• DENSITY - 1.14g/cm3
• SHEET THICKNESS - 1 mm
• PROJECTED AREA - 1142cm2
• MASS - 0.13kg
• PERIMETER - 1018.5mm
• *All given data is approximate or considered

6. o A gasket is a mechanical seal which fills the space between two
or more mating surfaces, generally to prevent leakage from the
joined objects while under compression.
o Gaskets come in many different designs based on industrial usage,
budget, chemical contact and physical parameters:
 Sheet gaskets.
 Solid material gaskets.
 Spiral-wound gaskets.
 Constant seating stress gaskets.
 Double-jacketed gaskets.
 Flange gasket.
GASKET

7. SHEET LAYOUT

8. TOOL CALCULATIONS
 CALCULATIONS
1.ECONOMY FACTOR
ECONOMY FACTOR = AREA x NO. OF ROWS x 100
PITCH

9.  TOTAL TONNAGE REQUIRED:-
1. PIERCING FORCE:-
PIERCING FORCE= L x S x t(max)
Where,
l = length of strip
s = sheet thickness
t(max) = shear stress

10. 3. BLANKING FORCE:-
BLANKING FORCE = Length x STRIP
THICKNESS x T(max)/ 1000

11. PRESS FORCE = PIERCING FORCE + BLANKING FORCE
STRIPPING FORCE = UP TO 10 TO 20 % OF CUTTING
FORCE
TOTAL FORCE REQUIRED = PRESS FORCE + STRIPPING
FORCE

12. SOME DESIGN FEATURES:-
i. ROLLER LIFTERS:-
The die is designed with roller
lifters at various stations.
Roller lifters have a roller at the
top so that the strip can be
fed smoothly
It also incorporates a spring in
lower body which ensures
that roller goes below the die
surface during the stroke and
retain its position as stroke is
over.

13. ii. MISS-FEED SENSOR:
Many a times to sustain high-speed production, sensors
are on all of its dies to prevent collisions or miss-
feed and the production of defective parts that would
bring its process to a halt.
A pin laser type sensor is used to
guide the strip in this tool
If the strip is being misfed or any
slug strike the strip the sensor
automatically stops the stroke.
Overfeed sensor, slug sensor,
stripper sensors are also
used in press tools.

14. ACHIEVEMENTS
• I got an opportunity to study on the design of progressive
press tool.
• I got a general idea on estimating the cost and time
required in designing, procuring, manufacturing &
assembling of this tool.
• I had to interact with various departments and authorities
to receive their share of expertise. It has helped to
improve my ability to follow up on progress.

15. PROBLEMS DURING TOOLING'S
• Punch break due to improper alignment of punch
and die.
• Die wear due to friction between punch and die
or between strip and die due to absence of roller
lifters.
• Chip formation due to differences in punch and
die fitment.