VINAYAK V. SUSLADKAR{2009156}

By

INDO-GERMAN TOOL ROOM

AURANGABADPROJECT

PRESENTATIONON

PROGRESSIVE TOOL OF GASKET

PROGRESSIVE TOOL FOR GASKET

• WORK ORDER NO. - 1421620• CUSTOMER -

Elringklinger• COMPONENT - Gasket• MATERIAL - Stainless steel• SHEET THICKNESS - 1 mm

CONTENTS:-

1. INTRODUCTION TO PROGRESSIVE TOOL

2. STRIP LAYOUT3. CALCULATION4. SPECIAL FEATURES5. ASSEMBLY DETAILS

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.

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

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

SHEET LAYOUT

TOOL CALCULATIONS

CALCULATIONS1.ECONOMY FACTOR 

ECONOMY FACTOR = AREA x NO. OF ROWS x 100

PITCH

TOTAL TONNAGE REQUIRED:-1. PIERCING FORCE:-

PIERCING FORCE= L x S x t(max) Where,

l = length of strips = sheet thicknesst(max) = shear stress

3. BLANKING FORCE:-

BLANKING FORCE = Length x STRIP THICKNESS x T(max)/ 1000

 

PRESS FORCE = PIERCING FORCE + BLANKING FORCE

STRIPPING FORCE = UP TO 10 TO 20 % OF CUTTING FORCE

TOTAL FORCE REQUIRED = PRESS FORCE + STRIPPING FORCE

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.

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.

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.

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.