PROJECT GUIDES:

Mr. M K KHANMANAGER(TRG)

Mr. N. S. PETERSENIOR TRAINING OFFICER

Mr. ALBERT F. D.

SHIVSHANKAR K

UBED M B.

SAJID T

AMARESH J

CHETAN P

SHANKAR. TELI

We are submitting this project as a part of fulfillment of the course i.e. diploma in tool and die making at Nettur technical training foundation, Dharwad Karnataka in the year 2006-2007

We are very much thankful to the honorable persons who have guided us properly during our project. we acknowledge their valuable guidance by which we were able to complete the project successfully

We express our sincere thanks to MR.R.VENKATES

MR.M.K.KHAN

MR.ALBERT.F.D

MR.N.S.PETER

We express our thanks to Mr. K.Venugopal (director training) who has given an opportunity to carry out and complete project successfully & all others who have helped &co-operated with us in completing this project.

• INTRODUCTION

• TOOL MANUFACTURING PROCEDURE

• OPERATION INVOLVED IN THE TOOL

• ELEMENTS OF THE TOOL

• WORKING OF THE TOOL

• HEAT TREATMENT

• QUALITY ANALYSIS

• ESTIMATION

• ASSEMBLY &COMPONENT DRAWING

• INSPECTION REPORT

• PROCESS PLANNING

• BIBILOGRAPHY

• CONCLUSION

NTTF started in the year 1964,with the heks Swiss contact society of Swiss in the press tool moulds &jigs &fixtures

Where the trainees are trained systematically in the both practical &theoretical knowledge with the advanced AutoCAD, PRO-E, UG, CNC &other latest technology .

We the trainees of diploma in tool &die making of NTTF Dharwad are presenting this project on the actuator clip tool.

Progressive tools are the press tools in which two or more stations are incorporated under each stations one or more operations will take place. in this the trip must move from first to the last stages to produce complete component.

In progressive tools, in between the working station idle stations may also be incorporated on the die to simplify the die construction or to provide sufficient strength to the die.

ADVANTAGES: 1.The biggest advantages of the progressive tools lies in the fact that the components remains as an integral part of the strip till the last stations, this facilitates easy feeding of the strip from one stations to another2.Greater accuracy than using a number of single stage tools.

DISADVANTAGES:1.Since progressive tools have more working stations the skilled involved in maintaining the accuracy between the station is greater.2.Higher tool maintenance cost.3.Higher material wastage due to certain restriction in strip layout.

DIFFERENT TYPES OF OPERATIONS CARRIED IN PRESS TOOLS:

In addition to piercing & blanking various other shearing &non shearing operations can be carried out in press tools. they are:SHEARING OPERATION:

* NOTCHING* PARTING OFF* LANCING* SHAVING* TRIMMING

NON SHEARING OPERATIONS:

* BENDING* FLANGING* COINING * EMBOSSING* DRAWING* CURLING

THE FOLLOWING OPERATIONS ARE USED IN THE PRESS TOOLS:

1.BLANKING

The operation of cutting or shearing the piece of stock to predetermining counters is blanking. in blanking a flat stampings are produced and entire periphery cutout pieces is called blank .

2.PIERCING

The operation of cutting or shearing a piece out of stock predetermining counters is called piercing. is done to inside counter of the components.

3.PILOTING

It is the operation a pin or projection will be provided for location work in subsequent operation from a previous counters for higher accuracy.

4.NOTCHING

It is a operation where various shapes made to cut from edge of the strip, blank or part.

5.CUT-OFF

It is usually used in finely stage of the tool, to separate component from the strip where no scrap or waste is obtained.

6.BENDING

Bending is the operation of causing deformation to sheet metal in a straight line along, across or in angle to its side to obtain a new configuration in bending. the deformation is a single plane only.

7.FORMING

Forming in general , refers to all operation that impart a change of shape to blank or component without causing change in thickness .

ELEMENTS OF THE PRESS TOOL:

PUNCH & DIE PUNCH HOLDER

THRUST PLATESTRIPPER

TOP PLATE &BOTTOM PLATESHANK

STOPPERSGUIDE PILLAR

SCREWS & DOWELSGUIDE BUSH

DIE PLATE:

Die plate is one of the main object of the tool. it is having cavity opening for producing component shapes die plate is made of superior non shrinking tool steel and hardened up to 60-62HRC

PUNCHESPUNCHESCUTTING PUNCHES:CUTTING PUNCHES:

They do the operations like blanking , They do the operations like blanking , piercing, notching, trimming, etcpiercing, notching, trimming, etc..

NONNON--CUTTING PUNCHES:CUTTING PUNCHES:They do the operations like bending They do the operations like bending ,forming, drawing etc,forming, drawing etc..

DIE DIE ––PLATEPLATEIt is the most important element of It is the most important element of the tool. this is mounted on the the tool. this is mounted on the bottom plate. die punch plate is the bottom plate. die punch plate is the cutting element of the tool which gives cutting element of the tool which gives the blank size & shape. this is made the blank size & shape. this is made out of high carbon high chromium out of high carbon high chromium material . It is hardened & tempered material . It is hardened & tempered to 60to 60--62 HRC. Die plate thickness is 62 HRC. Die plate thickness is decided on the basis of stock material decided on the basis of stock material being cut.being cut.

CARBIDE DIESCARBIDE DIESTungsten carbide is used as a die Tungsten carbide is used as a die material for blanking piercing, material for blanking piercing, trimming, forming, drawing, & trimming, forming, drawing, & swaging operations. They are used swaging operations. They are used where the production rates are high & where the production rates are high & the parts have closer tolerances. the parts have closer tolerances. Carbide dies are widely used to Carbide dies are widely used to produce electrical laminations at lower produce electrical laminations at lower costs per piece compared with steel costs per piece compared with steel dies. dies.

TOOL MANUFACTURING PROCEDURE:

THE METHOD OF MANUFACTURE DEPENDS UPON THE SIZE AND SHAPE OF PUNCH &DIE. CYLINDRICAL PUNCHES AND CORRESPONDING DIES/ INSERTS CAN BE MANUFACTURED EASILY ON LATHE AND CYLINDRICAL GRINDER,AND ASSEMBLED IN PUNCH PLATE AND BOTTOM PLATE. THE CENTERED DISTANCE BETWEEN PUNCHES AND CORRESPONDING HOLES MUST BE EXACTLY EQUAL OTHER WISE THE PUNCHES WILL NOT ENTER IN THE STRIPPER AND DIE HOLES ALTHOUGH A LITTLE VARIATIONS (0.01-0.02). IN CENTER DISTANCE WILL NOT PREVENT ASSEMBLY IT WILL MAKE THE DIE CLEARANCEAROUND THE PUNCH UNEQUAL LEADING TO UNEVEAN BURR IN WORKPIECE. OFFCOURSE, ALL THE CONSTITUENTS, I.E. PUNCH PLATE &STRIPPER PLATE AND DIE CAN BE JIG BORED SEPERATELY VERY ACCURATELY,BUT THIS CAN INCREASE TOOL COST IN IMMENSELY.

MANUFACTURING PROCESS

Manufacturing may be divided into two parts

1.Part manufacturing

2.Aseembly

PART MANUFACTURING;

we machined all the parts as per the drawing, grounded and kept allowances for all the plates requiring hardening. Then we did the required finishing operations.

2.DIE SET ASSEMBLYA two pillar die set was selected as in

progressive tool the force exerted on the punch is more.

We machined top plate and bottom plate our self.

According to the drawing the holes were bored by CNC milling machine.

After boring the plates were taken to inspection and bored dimensions were noted down. The bushes were turned and sent for hardening .Back of hardening the pillars and bushes were sent for cylindrical grinding

After hardening the sub assembly of the die set was completed by fitting them in there positions

3.Sub assembly

The alignment of the punch and die was checked by keeping the shim equal to the sheet thickness that is 0.4mm.

the punches were kept over the die inserts and checked for the clearance, when found correct the hole from the punch transferred to punch holder and assembled later.

SUBCONTRACT REPORT:

After making references by the grinding, the punches and tool elements were sent for wire cutting.

WIRE CUTTING DETAILS

First we did the all the primary operations for the plates and punches. Next these elements were sent for hardening and tempering. For wire cutting the tool elements were taken to BUSHAN Tooling private limited, Bangalore.

The wire cutting was done based on the data provided by the designers in CADD.

SURFACE GRINDING DETAILS

As the size of the most of the plates of the tool was vary large and it could not be accommodated on our machines. So the plates were sent for surface grinding to a near by industry.

ELEMENTS OF THE TOOL

1.TOP PLATE

Top plate is the made up of mild steel. It is the top most portion

2.BOTTOM PLATE

This plate gives cushioning effect as well as provides enough surface for the tool to be clamped on the press bed.

Progressive die is mounted on this plate .The parallel blocks are clamped under this plate.

3.PUNCH HOLDER

This plate is also called punch plate. All the punches are accurately held in this plate. This plate should be thick enough to accommodate punches perpendicular. This made out of MS

4.PUNCHThis is the cutting element of

the tool. Punch gives the hole size &component shape. This made out of HCHCr material. Punches are hardened & tempered to 58-60 HCR.The punch of the length in normal position is kept up to 60mm.

5.DIE PLATEThis is most important tool

element. This is mounted on bottom plate Die plate is the cutting element of the tool which gives the blank size and shape. This is made out of HCHCr material. Dies are hardened & tempered to 60-60 HRC.Die plate thickness is bases of stock material being cut.

6.BACK PLATEThis plate is known as thrust

plate. This plate is mounted on top of punch holder. It is made out of medium carbon steel. It is hardened &tempered to 45-48HRC. Punch heads have direct contact with this plate, which will prevent the penetration to the top plate during punching operation.

7. PILOT

The pilot positions stock strip in relation with die openings. Usually the strip is over fed then the actual pitch length. When the press moves down the pilot comes down and engages the pre pierced hole, thus dragging the strip back into theregestry position.

8.BENDING PUNCH

Bending punch deforms portions of flat blanks to some positions, the line of bend straight along its length.

9.SHAVING PUNCH

It is the operation of removing small amount of material from around the edges of the blanks or hole.

10.STRIPPER PLATE

The main function of the stripper is to strip the stock material from the punches after each stroke. In addition the stripper may act as guide the punches

11.STOPPER

After each and every stroke of the press the strip has to fed forward for one pitch length. This can done by means of stopper. It is made up of EN31 material, hardened tempered up to 45-48 HRC.

12.SETTING BLOCK

These are provided to arrest the further downward movement of the top half of the tool. The function setting block is to prevent further damage of tool.

14.STRIP LIFTER

It is used to lift the strip parallel to the die surface to accommodate easy feeding due to the cam bending operation. It is made up of D2 material and tempered 52-56HRC

15.CAMASSEMBLY

It is due to force by means of its profile. Here the cam was used for bending operations eight stage. A a sliding fit is maintained between cam and cam holder. In the bottom plate the movement of cam through the cam holder channel is the restricted by using dowel at one end. It contains bending punch along with cam retainer. the other end of the cam lies of the cam retainer. a knocking punch is threaded to the top plate and its length can be adjusted by using cam nuts. material of the cam is En31 hardened up to 54-56 HRC

as soon as the tool is closed that cam actuator comes and it hits the cam which the results in the upper movements of the bending punch. When the actuator looses its contact the cam during the rivers stroke of the press cam comes back to the original position with help of spring.

16. GUIDE PILLAR:GUIDE PILLARS PRECISION GROUND

WHICH ARE press fitted accurately bored holes in the stripper plate. They engages the die bushing to align punch and die components with a high degree of closeness and accuracy

17.GUIDE BUSHguide bush are accurately ground sleeves

which are use to align the guide pillars.

18.STANDERD ELEMENTSStandard elements like screws,dowels,grub

screws supplied by the customer.

•Even though the plastic is replacing the sheet metal, the sheet metal is also playing very important role in the industries . The demand for the tools occupy a major field of sheet metal toolings which gives components at economic rates.

•The under taken project work involves manufacture of 18 Stage Progressive Tool for Actuator Clip component for ABB. This manufacturing process involves the designing, manufacturing, inspection, assembly & trial. It gives insight to various difficulties faced by us & the solutions which we have adopted

• The ACTUATOR CLIP is the component which is used in the

PRODUCT DETAILS•Component Name:- ACTUATOR CLIP

•Is There Any Sample Reference :- No

•Material Of The Component :- Brass

•Shear Strength :-

•Thickness Of The Component :-0.4mm

PRESS TECHNICAL DATA

The first and foremost consideration for choosing a press is the tonnage required for the operation of press Tool, similarly the tablesize, throat, stroke and shut height of the press should suit the press tool. We can mount and operate a Press Tool if the above requisites are met.

Always a Tool is manufactured only after considering the type of press.

A standard specification of the press is:

1)Type of constructions: Cast steel or welded steel.

2)Power source: Manual, mechanical, or pneumatic

3) Operating speed: Low, medium or high speed.

4)Type of frame: Gap frame, straight sided or“C”frame.

5)Capacity of frame :10tons, 20 tons, 40 tons, 80 tons,100 tons etc.

6)Size of the bed : 450x710, 560x710, 560x900.7)Facilities available :Strip straighter, feeding

equipment, safety switches etc.

DESIGN CALCULATION

1) CUTTING FORCECutting force is that force which has to

act on the stock material in order to blank or slug.This determines the capacity of the press to be used for the particular tool.

Cutting force = L x S x Tmax.

L-length of periphery to be cut in mm. = S-stock thickness in mm.

= 0.4 mmTmax – shear strength in N/mm2

=

Cutting force ==

Press force =Cutting force+Stripping force

(20%of cutting force)=

2) CUTTING CLEARANCE:

Cutting clearance is the gap between a side of a punch and the corresponding side of a die opening on one side of the edge, when the punch is entered into the die opening. Therefore the cutting clearance should always be thought of and expressed as the amount of clearance per side.

Cutting Clearance =C X S X (T max/10)

= 0.005x0.4x()

= mm/side

3) SCRAP BRIDGE:

Side bridge = 1.2 x sheet thickness

= 1.2 x 0.4mm= .48mm

4) ECONOMY FACTOR:Stock material conservation being a

decisive factor in press working, the tool designer should try out every possible means to attain this, without sacrificing the accuracy requirement of the piece part. Economy of any layout in percentage of the are of the strip is found out by the following formula.

Economy Factor =Area of blank x100xNo. of rows

Pitch x width

SHEARINGTHEORY:

The name shearing stands for the method of cutting sheets or stocks

without forming chips. The material is stressed in section which lies parallel to the forces applied. The forces are applied either by means of shearing blades or punch and die. The force necessary to bring rupture of the

material depends primarily upon the shearing strength and stressed section or the stressed area and secondly upon

the shape, condition and position of the shear blades.

Critical stages of shearing

STAGE 1:

The pressure applied by the punch on the stock material tends to deform into the die opening when the elastic limit is exceeded by further loading, a portion of material will be forced into the die opening in the form of an embossed pad on the lower face of the material and will result in corresponding depression on its upper face. This stage imparts a radius on the upper edge of the opening in the strip and on the lower edge of the punched out material, this is called the stage of

plastic deformation.

STAGE 2:

As the load further increased, the punch will penetrate the material to certain depth and fotce an equality thick portion of metal into the die. This satge imparts a bright polished finish (cut band) on both, the strip and blank or slug. This is the

penetration stage .

STAGE 3

In this stage fracture will start from both upper and lower cutting edges. As the punch travels further, these fractures will extend towards each other and eventually meet, causing complete separation. This stage imparts a dull fractured edge. This is the fractured stage.

HEAT TREATMENT

Heat treatment is a process of heating and cooling the metals under definite condition to change their properties according to the process used, steel can be hardened to resist cutting action, scratching, indentation or penetration by other materials. In some cases steel are softened to permit further machining.

In this process internal stresses can be removed from the metals and grain structure may be altered.The metals are made more resistant to wear, heat and corrosion.

The process involved in heating treatment:

Heating: Steel is heat treated to temperature called austenising

temperature i.e. above 723c.Soaking: The steel is held at this temperature for a period of time. This period is called as soaking period. This results in formation of

homogeneous austenite.Cooling: Then steel is cooled back to a lower temperature at a particular cooling rate to obtain desired properties.

HARDENING:

PURPOSES:i.To increase the

hardness.ii.To increase cutting

ability.iii.To increase wear

resistance.

PROCEDURE:After reaching the required temperature

the steels are soaked. After soaking, the steels are cooled rapidly to room temperature exceeding the critical cooling rate. Due to fast cooling the austenite is converted into martensite which is a very hard phase. Therefore hardened steels will possess high hardness and brittleness. Steels are quenched usually in water,oil or salt solutions. Complicated shapes of steels should be quenched in oil to avoid cracking and distortion. Low alloy steels are quenched in oil and high alloy steels are quenched in forced air.

Successful hardening requires following two conditions.

Formation of homogeneous austenite.

Rapid cooling of steels in suitable media.

TEMPERING :

The structure of the steels after hardening is not suitable for engineering applications. Therefore structure of steels should be improved.It is done by the means of tempering.

It may be defined as heating the steels to a temperature below the lower critical temperature slowly to get a desired combination of hardness and toughness. All hardened steels must be tempered after hardening immediately.

PURPOSES:

i.To avoid failure of steel by cracking.

ii.To remove the internal stresses produced during quenching.

iii.To avoid change in dimensions and properties of steel.

NORMALISING:

• PROCEDURE

It is similar to annealing process. But there is a slight change with respect to cooling. The usual normalizing temperature is between 800ºC-930ºC. The holding time at this temp is ½ hr to 2hrs. After this steels are cooled to room temperature. Since air cooling is faster than the furnace cooling this process is quicker than annealing Therefore normalised steels will have finer pearlite, more hardness, more strength and toughness than annealed steels.

• PURPOSES:

To improve the machinability of low carbon steels.

To obtain the desired microstructure and mechanical

properties.To refine the grain size.To homogenize the

microstructure.

TEMPERATURES:

For hypoeutectoid steels 820-870ºC.

For hypereutectoid steels - 790º -- 840ºC.

• PURPOSES:

i. To make the steels soft and reduce hardness.

ii. To relieve internal stresses.iii. To improve machinability.iv. To restore ductility.

• TYPES

i. Box annealing.ii. Bright annealing.

iii. Stress relief annealing.iv. Spheridise annealing.v. Isothermal annealing.vi. Process annealing.

The first step in the design procedure is to define the problem in a clear and simple statement of the functional needs. The Tool Designer will receive the part print, information, why the tool is needed? What capabilities the Tool must be of? What type of machine tool must be used? The number of parts to be produced and other pertinent information concerning the part.

1)TOOL DESIGN PROCEDURESTUDY OF THE COMPONENT

The research and sketches should be combined into one or two tentative design solutions, which may consist of rough working, showing the side and top view and perhaps one end view if needed. An isomeric or perspective sketch may be made if desired although the Tool designer is not as concerned with visual aspects of the design decided upon

2)CONCEPT DESIGN.

Before staring any design some major considerations are required to be made which can solve majority of the problems while designing the Press Tool, Mould, Jigs and Fixtures. Considerations are as follows.

3) DESIGN CONSIDERATIONS.

In any design, manufacturing process should be easy, simplified and majority of the operation should be carried out in-house.

Last but never the least it is very much necessary to think about the maintenance of tool. If due to any reason some parts break then it should be easily manufactured in short times, idle time is reduced.

4) MANUFACTURING CONSIDERATIONS.

PARALLEL BLOCK 02BOTTOM PLATE 01STIPPER RET.PLATE 01TOP PLATE 01TOP PARALLEL 01PUNCH HOLDER 04CAM HOLDER 01EXT.TABLE 01EX.TABLE HOLDER 01SHANK 01

15

TRANSFER GUIDE 01TRANSFER PIN 01DIE BACK PLATE 04 PH.BACK PLATE 04 PUNCH BLOCK 01 STRIPPER INSERT 04 SETTING PLATE 03 KNOCKING PUNCH 01 CAM 01EXT.GUIDE 02 STRIP GUIDE 06

25

DIE INSERT 04 GUIDE PILLAR 04GUIDE BUSH 04

BALL CAGE 04SETTING BLOCK 02

WASHER 50DIE BUSH 05STRIP GUIDE BUSH 05PIERCING PUNCH 06PITCH CUTTER 01

35

PROFILE PUNCH 11LIFTER 10COININGPUNCH 02

THRUST PIECE 02INDENTOR 01PILOT 15ANG.FORM DIE 02

PRE-FORM DIE 01

ANG.FORM PUNCH 02

PRE-FORM PUNCH 01

45

55

BENDING DIE 06CARRIER 01BACK PLATE 14BENDING PUNCH 06DOWEL BUSH 24SPRING WASHER 04PILLAR HOLDER 04CONECTING HOLDER 01LOCATING PIECE 01STANDARDS

QUANTITY : 01No.MATERIAL : Mild steel.SIZE : 30X180X240mmMACHINING : Premachining, Grinding,OPERATION CNC spotting boring,

bench workHARDENING : Not requiredFUNCTION : The punch and the

punch assembly is

clamped to the top plate

and also the shank

is fixed to the top plate CRITICAL DIM : Guide bush holes

(H7/g6fit and pitch)

TOP PLATE:

QUANTITY : 01NoMATERIAL : Mild steel SIZE : 36x180x240mmMACHINING : Premachining,

Grinding,OPERATION CNC spotting

boring, bench work

HARDENING : Not requiredFUNCTION : It is the base plate

on which whole bottom

assembly ismounted and it

should havesufficient

thickness to with standthe load.

CRITICAL DIM : Guide pillar holes and

pitch (H7/p6 fit)

BOTTOM PLATE

PUNCH HOLDER:

QUANTITY : 04No.MATERIAL : Mild steel.

MACHINING : Premachining,Grinding,

OPERATION cavity milling, bench workHARDENING : Not requiredFUNCTION : It holds the

punch in exact

position CRITICAL DIM :Cavity

dimension,(H7/k6 fit)

PUNCH:

MATERIAL :D2MACHINING :Premachining,

Grinding, profile OPERATIONmilling & grinding, bench work HARDENING :58-60 HRCFUNCTION :Main element of

the tool which bends the

required length of

component

GUIDE PILLAR:

MATERIAL : EN30 MACHINING : Premachining, Cylindrical OPERATIONGrinding, bench workHARDENING : CH52-55 RCFUNCTION : To align the top assembly

with bottom assembly

GUIDE BUSH:

MATERIAL :EN30 MACHINING :Premachining, Cylindrical

OPERATION Grinding, internal

Cylindrical Grinding HARDENING :CH52-55 RC FUNCTION :To align the top assembly

with bottom assembly

DIE PLATE :

MATERIAL : D2MACHINING :Premachining, Grinding, OPERATION cavity milling, 3-d . profile

milling, bench work HARDENING :60-62 HRCFUNCTION :It’s also a main element

of the tool which does

the cutting operationCRITICAL DIM :Cavity dimension

•Increasing the stock material thickness, increases the severity.

•Increasing the bend angle increases the severity.

•Decreasing the bend radius increases the severity.

•The bend angle is the angle included between the two extreme positions of the bend radius. It originates at the bend axis.

90°

90°

BEND AREABEND ANGLE

R

BEND ALLOWANCE

OUTER SURFACE

T

0.33T - 0

.5T

INNER SURFACE

BEND LINES

BEND AXIS

The Principle of Bending involves:

• Selection of material of length equal to neutral fiber.• Stressing it beyond elastic limit,

PLASTIC DEFORMATION DUE TO BENDING

4 METHODS to OVERCOME SPRING BACK

in ‘V’ BENDING DIES

•Over Bending

•Corner Setting

•Offset Punch Method

•Angular Punch Relief

Estimation or estimating is an art of the cost, which is likely to be in cured on the manufacture of an article, before it is actually manufactured.

Thus it is the calculation of the probable cost of an article before the manufacturing status.

In estimation, the profit or loss of an article can be determined before the article is manufactured. It is also involves predetermination of the quantity machine time, labour required etc.

Ø Estimation helps in deciding the manufacturing and

selling policies.Ø Estimation also helps in

filling up the tenders.Ø A particular material

should be purchased from the market or to be manufactured can be decided in estimation.

Ø Estimation helps in modification of design.

Ø Estimation helps in modification of design amount of overheads.

RAW MATERIALThe cost of the raw materials used

in manufacturing of a tool is called as the material cost. The material cost is divided as direct and indirect material. The material cost is that which becomes part of the Tool. It is the material which can be measured and charged directly to coat of the tool like bottom plate, top plate, die and punch etc, the in direct material cost is the one which can not be traced has part of the tool, like cotton waste, coolant etc.

MACHINING COST

The machining cost is calculated by estimating the machine time taken during each manufacturing process for each part of the Tool and each machining operation has its own cost and is calculated in rate/hour.

OVERHEADS

Some expenses such as factory render, insurance, depreciation, salaries of staffs, maintenance of plant, repair charges are indirectly involved in the manufacturing of a Tool. These are called overheads and they will vary according to the volume of output.

BEFORE TAKING THE TOOL FOR THE TRYOUT

Following points need to be followed in order:

� Never mount the Tool in press, which is not suitable for testing particular tape of i.e., the Tool size should be with in press specification � Prior to mounting the Tool make sure that the press is in good working order and has necessary safety guards and accessories, its safety devices are in order, and the clearance in slide guides are properly adjusted.� Clean the press‘s bed and mount the Tool � Always use mechanical handling devices to mount heavy weight Tools � Don’t mount the press Tool on the press unless the distance between the two bolster plate (fixed half and movable half) of the press is more that the shut height of the Tool.

� Secure the Tool in the press reliably using, T-nuts, clamps, bolts &

washers.� Adjust the stoke and daylight of the Tool as necessary for the operation.Carry out the tryout and collect the samples inspection of the samples will be done and if all of them of under the dimensional requirements then the Tool is ready for production purpose and if there is some deviation then re-work has to be done and again tryout operation to be repeated.

Inspection is a means of measurement of quality by using some prescribed standards such hardness tensile strength, dimensional accuracy; wear resistance, surface finish, chemical composition and functional requirement.

The philosophy of inspection in only “Preventive” and not “remedial”. The short inspection is the method of measuring and checking the quality of teams of specified standards.

Master file - NTTF

Tool Design - Cyril.Donaldson

Basic Die Making - EugenEOstergards

Die design Handbook - F.W.Wilson

*CONCLUSION*In the project work , the designing

and manufacturing is done for only one stage press Tool for. PRAB ENGINEERS HUBLI.

Economical manufacturing process are suggested by keeping in view with the in house facilities, and the Tool is designed to meet the specification OF the press.

The Tool can also be designed and manufactured without any of the above analysis but success and economy of Tool is not assured.

Completion of this project report has gained us a great confidence and knowledge and great experience in Tool designing, Tool manufacturing estimation and costing etc this project report highlight some of the main subjects which are very important for a Tool making in this day today life last but not least, this project will be a future reference to us.

WORKING OF THE WORKING OF THE TOOLTOOL

The working procedure of the tool is as The working procedure of the tool is as given below:given below:--

STAGE# 1STAGE# 1Pitch cutting & also piercing (dia.3) for the piloting hole Pitch cutting & also piercing (dia.3) for the piloting hole takes place.takes place.

STAGE # 2STAGE # 2Piloting, coining & piercing (dia.2 x 4nos.) is done in this Piloting, coining & piercing (dia.2 x 4nos.) is done in this stage.stage.

STAGE # 3STAGE # 3Piloting & profile piercing is done in this stage.Piloting & profile piercing is done in this stage.

STAGE # 4STAGE # 4Piloting, piercing & profile piercing takes place when the Piloting, piercing & profile piercing takes place when the strip is stopped at this stage.strip is stopped at this stage.

STAGE # 5STAGE # 5In this stage only piloting is done.In this stage only piloting is done.

STAGE # 6STAGE # 6Piloting & profile piercing is done here.Piloting & profile piercing is done here.

STAGE # 7STAGE # 7This stage is same as the previous one where piloting & This stage is same as the previous one where piloting & profile piercing happens.profile piercing happens.

STAGE # 8STAGE # 8In this stage FORMING takes place along with piloting. In this stage FORMING takes place along with piloting. This is the stage from where the component starts getting This is the stage from where the component starts getting its shape.its shape.

STAGE # 9STAGE # 9Only piloting is done here.Only piloting is done here.

STAGE # 10STAGE # 10The tenth stage is for the piloting & PREThe tenth stage is for the piloting & PRE--FORMING up FORMING up to a depth of 0.4mm to take place. The shape is got by to a depth of 0.4mm to take place. The shape is got by the mating punch & die.the mating punch & die.

STAGE # 11STAGE # 11Only piloting takes place here.Only piloting takes place here.

STAGE # 12STAGE # 12In this stage, UPWARD BENDING is done with the help In this stage, UPWARD BENDING is done with the help of the bending dies acting from bottom mounted on of the bending dies acting from bottom mounted on the carrier actuated by a spring loaded CAM. Piloting is the carrier actuated by a spring loaded CAM. Piloting is also done. also done.

STAGE # 13STAGE # 13Only piloting takes place here.Only piloting takes place here.

STAGE # 14STAGE # 14PROFILE PIERCING is done to give the outer shape to PROFILE PIERCING is done to give the outer shape to the 2 consecutive components.the 2 consecutive components.

STAGE # 15STAGE # 15Here ,the PREHere ,the PRE--BENDING of the 45 degrees bend is BENDING of the 45 degrees bend is done against a punch & die.done against a punch & die.

STAGE # 16STAGE # 16Here ,the FINAL BENDING of the 45 degrees bend Here ,the FINAL BENDING of the 45 degrees bend takes place.takes place.

STAGE # 17STAGE # 17This is an IDLE stage.This is an IDLE stage.

STAGE # 18STAGE # 18The final stage of the tool where PARTINGThe final stage of the tool where PARTING--OFF is done OFF is done to produce 2 components , which were earlier joined to produce 2 components , which were earlier joined by the scrap bridge.by the scrap bridge.

WORKING OF THE WORKING OF THE TOOLTOOL

The working procedure of the tool is as The working procedure of the tool is as given below:given below:--

STAGE# 1STAGE# 1Pitch cutting & also piercing (dia.3) for the piloting hole Pitch cutting & also piercing (dia.3) for the piloting hole takes place.takes place.

STAGE # 2STAGE # 2Piloting,coining & piercing (dia.2 x 4nos.) is done in this Piloting,coining & piercing (dia.2 x 4nos.) is done in this stage.stage.

STAGE # 3STAGE # 3Piloting & profile piercing is done in this stage.Piloting & profile piercing is done in this stage.

STAGE # 4STAGE # 4Piloting, piercing & profile piercing takes place when the Piloting, piercing & profile piercing takes place when the strip is stopped at this stage.strip is stopped at this stage.

STAGE # 5STAGE # 5In this stage only piloting is done.In this stage only piloting is done.

STAGE # 6STAGE # 6Piloting & profile piercing is done here.Piloting & profile piercing is done here.

STAGE # 7STAGE # 7This stage is same as the previous one where piloting & This stage is same as the previous one where piloting & profile piercing happens.profile piercing happens.

STAGE # 8STAGE # 8In this stage FORMING takes place along with piloting. In this stage FORMING takes place along with piloting. This is the stage from where the component starts getting This is the stage from where the component starts getting its shape.its shape.

STAGE # 9STAGE # 9Only piloting is done here.Only piloting is done here.