This document describes the design and manufacturing of a compound press tool for making washers. It includes calculations of cutting force, economy factor, assembly and 3D views of the press tool. Key parameters are defined for the draw die such as blank diameter, punch diameter, thickness, draw ring radius, and clearance. Calculations are shown for blank holder pressure, blank holder force, draw force, and total ram force required. The final part meets quality tolerance limits.
This document describes the design and manufacturing of a compound press tool for making washers. It includes calculations of cutting force, economy factor, assembly and 3D views of the press tool. Key parameters are defined for the draw die such as blank diameter, punch diameter, thickness, draw ring radius, and clearance. Calculations are shown for blank holder pressure, blank holder force, draw force, and total ram force required. The final part meets quality tolerance limits.
This document describes the design and manufacturing of a compound press tool for making washers. It includes calculations of cutting force, economy factor, assembly and 3D views of the press tool. Key parameters are defined for the draw die such as blank diameter, punch diameter, thickness, draw ring radius, and clearance. Calculations are shown for blank holder pressure, blank holder force, draw force, and total ram force required. The final part meets quality tolerance limits.
This document describes the design and manufacturing of a compound press tool for making washers. It includes calculations of cutting force, economy factor, assembly and 3D views of the press tool. Key parameters are defined for the draw die such as blank diameter, punch diameter, thickness, draw ring radius, and clearance. Calculations are shown for blank holder pressure, blank holder force, draw force, and total ram force required. The final part meets quality tolerance limits.
From the above table Scrap Bridge thickness is 4.35mm taken
6.2.4 Cutting Force: CUTTING FORCE = 60X693X3 = 124740/1000 = 124.7 ~125 TONE SAFETY CONST x (125+25) = 1.2x150 = 180 TONE 7. Assembly and 3- D View of Press Tool 7. Assembly and 3-D View of Press Tool 7. Assembly and 3-D View of Press Tool DESIGN OF DRAW DIE FOR CYLINDRICAL CUP FORMATION PARAMETERS OF DRAW DIE
Where: D =Blank diameter, d1=Inside work piece diameter
after the first drawing operation, T = Material thickness, Rp=Draw ring, Ri=Punch radius, dp=Outside work piece diameter after the first drawing operation • Rp= 0.8[(D-d1) X T] 0.5…….(1)[5] • h0= (3/5) X T …………….(3)[5] • C = T + k (10T) 0.5 ……..... (4)[5] C = clearance, T = material thickness, k = coefficient Blank Holder Pressure (Pd1) - The value of blankholder pressure is decided on the basis of sheet metal material which is to be deformed. The blank holder force : Fd1= (π/4) [D2-d12] Pd1 .…………….. (5)[5] Draw force: Pdraw = A St nc ln(Ec)………………...(6)[6] A = π d1 T, A-area of cross section of a shell, T- Thickness of sheet metal, St- Ultimate tensile strength of material, E- Cupping strain factor, nc - Deformation efficiency of drawing process, The cupping strain factor E: E = [(D/d1) +1]/2 ………………(7)[6] A. Input parameters- Sheet metal (Input part) detail: Press data : Shut height 340mm Clamping slot dimension 50mm (thick) X 30mm(width) X45mm (depth) for M28 clamping bolt, pitch of clamp slots from center of press is 75 mm. Front to back maximum size 650mm Left to right maximum size 550mm Number of strokes per minute 20 Make-union Maximum capacity 160 ton No cushion pins for blank-holder Travel of blank-holder as per shape of output component. • Travel of blank-holder as per shape of output component As the depth of drawn component is 25mm, blank-holder travel is kept 26mm for proper holding 1mm before the start of operation. • Various parameters Blank Diameter (D)=110 mm Punch diameter (d1)=59 mm Thickness of sheet (T)=0.8 mm • Draw ring radius (Rp) Rp = 0.8 X [(D-d1) X T] 0.5=5.10 mm≈5 mm • Clearance value between punch and cavity (C) C = T + k √ (10 X T)= 0.99 mm≈ 1mm • Cavity diameter (d0) D0= 59+0.99= 59.99 mm≈ 60 mm • Blank-holder pressure (P) is decided based on the finite element analysis of metal flow. From method plan report and table 2 the value is selected as 1.17MPa • Blank-holder force (Pd1) –Pd1 = P X area of sheet metal holding=1.17 X [1102 - (π/4) X 592]=10.958 kN • Draw Force (F) –F= A X St X nc X ln(E) A= π X d1 X T=148.28 mm2, Cupping strain factor (E), E = [(D/d1) + 1]/2= 1.43 From fig.6, nc=2.3 F=148.28 X 260 X 2.3 X ln(1.43)= 39.035 kN • Total ram force required (T) = Draw force + Blankholder force = F + Pd1= 39.035 + 10.958= 49.993≈50 kN RESULTS AND DISCUSSION • The C.M.M. report indicates the part produced is within the tolerance limits which are decided by quality control department.
