Design and Analysis of Blanking and Piercing die punch – Mechanical Project
Abstract – The sheet metal working processes are widely used in almost all industries like automotive, defense, medical and mechanical industries. The major advantage for using metal working process is to improve production rate and to reduce the cost per piece. Nowadays many people are working for developing die punches with innovative ideas. This project is also based on new design for die punch. The project mainly focuses on different operations done on single setup of die punch in a single stroke, presently these operations are done
on three separate setups which leading to reduce the production rate and increasing cycle time with cost as well.
The theoretical calculations were done for calculating cutting force, tonnage required, Von-Mises stresses, fatigue life, buckling load and total deformation. The 3D parts are modeled in CATIA-v5 and saved in .stp file format so that it can be imported from any of the analysis software. As per the companies requirement cad drawings are drawn in AUTOCAD software. The various analyses like Von-Mises stress analysis, fatigue life, are carried out on Ansys 14.0 workbench analysis software and results are compared with theoretical results. The results are within 5% of allowable limit.
Forming processes like Piercing, Blanking, stamping and bending are very widely used in the making of sheet metal parts and it assembles different processes to manufacture sheet metal parts. Piercing and Blanking are metal shearing processes in which the input sheet material is sheared to a destination shape. In blanking, the blanked piece of material is the product and while in piercing, the material that is blanked is scrap while the remaining part of the strip is the product, as shown in the Figure. In this project, blanking and piercing are used to produce component. Blanking is one of the processes in which the sheet undergoes brutal deformation since the sheet metal is separated to have the
slug and part.
The aim of this project is to reduce cycle time of existing process of milling, blanking and drilling operation for component. These all operations need be combined in a single setup of die punch with a proper tool design. The monthly volume of component is 4000 to 6000 nos. Hence company needs cycle time reduction and cost reduction as well on these hinges to meet global competition. The existing
cycle time of operations is approximately 4 minutes. After the implementation of this project we can expect this to 30 secs.
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