PROGRESSIVE TOOL FOR

REINFORCEMENT REAR PANEL.(WO. NO. - 1521291)

Prepared By :-

SUSLADKAR VINAYAK VIVEK (2009156)

ACKNOWLEDGEMENT I am very thankful to Mr. H. D. KAPSE (Managing Director, Indo-German Tool Room) Mr. J. D. BAGUL (Manager Training) for assigning me the live project in the PRODUCTION DEPARTMENT.

I would like to express my sincere thanks to Mr. V. M. Jadhav (Sr. Manager Production), Mr. Naresh Raparti, Mr. Ravi Asore, Mr. Pranav Shrivastava, for their expert guidance and valuable time from their busy schedule while manufacturing the tool.

I express my deepest gratitude to my parents without whom I would not have been what I am today. Their care and encouragement have been most effective behind my success.

Last but not the least I would like to thank all the members of I.G.T.R. and my colleagues for their support and cooperation.

CONTENTS:-

1. Introduction to Prototype

2. Acknowledgement

3. Component drawing and strip layout

4. Operation sequence

5. Operation details

6. Press tool data

7. Achievements

8. Conclusion

WHAT IS PROTOTYPE ?

A Prototype is an early sample, model, or release of a product built to test a concept or process or to act as a thing to be replicated.

Prototype was firstly designed and manufactured in small size for trial and to diagnose errors in that tool.

In progressive press tool a number of various cutting operations are performed at different stages in order to obtain the required component.

COMPONENT DRAWING

SAMPLE COMPONANTS

STRIP LAYOUT :-

CALCULATION THEORY :-

Economy Factor :- Area = 15000 mm2

No. of rows = 1 Pitch = 1.2(S.B.) + 50(width) = 52.2 mm Width = 2.4(S. B.) + 300 = 302.4 mm

ECONOMY FACTOR = 95.02%

TOTAL TONNAGE REQUIRED:-

1. PIERCING FORCE:-

PERIMETER (L) = 37.68

SHEET THICKNESS (T) = 1mm

STRESS (S) = 60kg/mm square

Piercing force= 37.68 x 1 x 60

PIERCING FORCE = 2.260TON

2.BLANKING FORCE:-BLANKING PERIMETER (L) = 700mm

STRIP THICKNESS (T)= 1mm

S.s = 60N/sq. m.

Blank force = perimeter x t x s / 1000

  = 700 x 1 x 60/1000

BLANKING FORCE = 42.00TON

OPERATION SEQUENCE

i. Piercing ii. Profile Piercingiii. Bendingiv. Restrikingv. Blanking

Profile Piercing

Blanking

Bending

OPERATIONS :-

1) BENDING :- Bending is a manufacturing process that produces V-shape ,or channel shape along a straight axis in ductile materials, most commonly sheet metal.

2) PIERCING :- Piercing is a press working process in which sheet metal is cut where a cutout portion is scrap and remaining portion is required part.

3) BLANKING :- Blanking is a press working process in which sheet metal is cut where cutout portion is a blank and is a required portion while remaining is scrap.

PRESS TOOL DATA :-

WORK ORDER NO. - 1521291

COMPONENT - REINFORCEMENT REAR PANNEL

MATERIAL - LOW CARBON STEEL

SHEET THICKNESS - 1 mm

CUSTOMER NAME - RUCHA TECH. , AURANGABAD.

I. DESIGN

II. PART DRAWING RELEASE

III. RAW MATERIAL

IV. MATERIAL PREPARATION

V. PRE-MACHINING

VI. BENCH WORK

VII. PRECISION MACHINING

VIII.HEAT TREATMENT

IX. GRINDING

X. POLISHING

XI. INSPECTION

XII. ASSEMBLY

XIII. TRIAL OUT

FLOW CHART FOR MANUFACTURING :-

ACHEIVEMENTS :-

1. We got an opportunity to work on an advanced design press tool.

2. The project was a medium for us to enhance our knowledge in the field of tool & Die Designing & Manufacturing. It helped us a lot in better understanding of the concepts of blanking tool manufacturing.

3. During the project We had to communicate with various departments and authorities to solve the problems and difficulties around in between. It has helped to improve our abilities to work as a team

4. The tool was required to be completed in a specific period of time for which we had to work to the best of our abilities to complete the tool.

5.  In the project work We were given an opportunity to study the Progressive tool from designing to trial out .

6. It was a nice opportunity for us to learn about such a tool, thus enhancing my knowledge

•CONCLUSION

In 6 months training I have studied following things-

•Introduction to Precision Department.

•Gone through the working process in wire cut section from the stage of CAM designing till dispatch of various work orders.

•Introduction to the ISO procedure followed in Precision department.

•Studied 6 wire cut m/c and also a robo drill m/c, 4 type of lathe m/c.

•Involved in precise parts manufacturing of press tool, moulds& die-casting dies parts.

•Maintained 5S, TPM principles.

•Designed CAM program for the parts using MasterCAM, DEL-CAM.

•Studied various parameters, design and mfg considerations & calculations involved in the mfg. of parts.

•Known about the various loading, unloading, dialing methods of parts.

•Setting of jaw of lathe chuck.

Known about the various types of water filters, wires, electrodes, cutting tools, inserts, turning tools etc.

Thank You