INTERNATIONAL JOURNAL OF PURE AND APPLIED RESEARCH IN ENGINEERING AND TECHNOLOGY
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1 INTERNATIONAL JOURNAL OF PURE AND APPLIED RESEARCH IN ENGINEERING AND TECHNOLOGY A PATH FOR HORIZING YOUR INNOVATIVE WORK DESIGN, MANUFACTURING AND ANALYSIS OF SIMPLE PRESS TOOL MR. G. C. MEKALKE 1, MR. S. B. YESUGADE 2, MR. S. R. PATIL 2, MR. D. A. KAMBLE 2, MR. P.A.KHANDALE 2 1. Assistant Professor, Department of Mechanical Engineering, DKTE s Textile and Engineering Institute, Ichalkaranji, India; 2. Graduate student, Department of Mechanical Engineering, DKTE s Textile and Engineering Institute, Ichalkaranji, India;. Accepted Date: 15/05/2015; Published Date: 01/06/2015 Abstract: This project deals with the stress analysis using FEA for hydraulic simple press tool. Metal forming processes are almost chip less. These operations are mainly carried out by the help of presses and press tools. In this presses deformation and cutting of sheet metal parts is carried out by applying pressure or force. Press machine always works under impact load condition. Because of continuous impact load, the hydraulic press machine always experience continuous stress. Some parts of the machine experience compressive stresses and some experience tensile stresses. Different components of the machine are subjected to different types of loading conditions and are analysed using FEA tool. ANSYS is one of the FEM tools, which is used for analysis. Keywords: Hydraulic press, design, ANSYS, FEA, etc. \ Corresponding Author: MR. G. C. MEKALKE Access Online On: How to Cite This Article: PAPER-QR CODE G. C. Mekalke, IJPRET, 2015; Volume 3 (10):
2 INTRODUCTION Press tool is defined as a device used for producing sheet metal components in large volume by applying an external force with the help of a machine tool called PRESS. Press Tools Tools are mainly manufactured for high rate of production of components. Iif the requirement of sheet metal components is less (less than 1000 numbers) then these devices are not economical. hence, press tools are categorized according to the requirement such as simple press tools, speed press tools, precision press tools, Horological press tools (watch components), special purpose press tools(cantilever press tools, side cam/straight cam/angular cam press tools and in type of operations such as cutting press tools, non cutting press tools, and hybrid press tools(cutting and non-cutting operations). DIE BLOCK and ITS CONSTRUCTION A die block is defined as the block or plate in which the die profile is cut. Many factors will influence the design of these die blocks. Whether the die block is conventional or vertical, shape and complexity of the profile, size and thickness of the component, production requirement, quality and hardness of the component, machining facility available. Therefore the die block construction is very important in a tool. Further, die block construction also depends on the variety of operations such as forming, drawing, embossing etc. Die construction: Here the blank punch cum piercing die is mounted on the bottom of the bottom plate which is bolted with machine bed. Blank die and piercing punch are mounted on the top plate which is mounted on the cylinder head. A striper plate is placed between blank, die and piercing punch which is used for to eject the component from the die. A stripper plate is held with blank punch. There are rules and regulations that are often followed when creating tools to ensure that the products are of the quality that is needed. If a maker disregards the rules, chances are that products made will not be suitable. With poor quality tools, the manufacturing industry will not give out its best and this can affect a whole economy. In olden days when tools were handmade, several machines had to be used to polish them up. The purpose of this was to give the tools a finer finish and increase the quality. However, the 136
3 process of producing quality tools has been made easier and faster due to the introduction of more efficient machines. There are numerically controlled machines that are used to make tools more easily. Tool making machines can grind, mill and polish up the tools within a very short time. This is a very positive development from the time consuming hand making process. For any maker of tools to be able to come up with good products, he should be able to have the image of the required end product in mind. Only when you understand what is needed can you develop it accordingly. Therefore, additional knowledge such as computer literacy and the ability to use computer technology to come up with better tools is required. It is an easier way of ensuring quality and conformity to modern standards. With the ever changing technology, tools can only get better. Methods Used in Creating New Tools Tool making requires utmost precision for the creation of new equipment and parts. Standards are set to ensure that all the steps for the task are handled with the highest quality possible. Efficient and more effective machineries exist today to aid in the process. While these machines are used, it is still best to adhere to the rules and guidelines required in creating these tools. Designing the tool is often the first essential step to creating new parts for the machines. This is crucial, as the design becomes this holographic representation of how the machine should perform. Precise measurements are needed to make sure that the entire diagram will work according to the requirements of the machines. Otherwise, the results would not end with useful products for the end-user. III. DESIGN AND CALCULATIONS We have consider the idea of using a Simple press tool Cutting Clearance :- ( Clearance Calculations) The ideal clearance can be calculated by the following formula Clearance = C S (Tmax/10) Where, c is a constant = for very accurate component = 0.01 for normal components S = sheet thickness in mm =
4 Tmax = shear strength of the stock material in N/mm 2 = 350N/mm 2 Clearance = mm Clearance = mm (2 times) FOR PIERCING OPERATION Punch is exact = 5.5 mm Die size = Punch + Clearance = = mm. FOR BLANKING OPERATION Die is exact = mm CALCULATION OF CUTTING FORCE:- Punch size = Die size Clearance = = mm. Cutting force is the force which has to act on the stock material in order to cut out the blank or slug. Tsh = Cutting force = L S Tmax = KN = = N Where, L=length of periphery to be cut in mm. S = sheet thickness in mm. 138
5 T max = shear strength of the stock material in N/mm 2. Die thickness Td = 3 Tsh = mm Bottom plate thickness = 1.75 Td = mm Top plate thickness = 1.5 Td = mm Punch holder = 0.75 Td = mm Stripper plate = 0.5 Td = mm Impact plate = 20 tone < 5 mm. Scrap bridge = 1.2 thickness = = mm Length = 92 mm width = 20 mm WORK AREA Work area length = Td 2 + actual area = = = mm Work area width =
6 Strip Layout: Economy Factor Calculations: = mm STD Work area selected = mm E =(Area of the blank x 100% x No of Rows)/ (Pitch x Strip Width) ECONOMY OF MATERIAL: Fig.1.Strip Layout of Compound Die Fig.2. Strip Layout of Progressive Die Fig.3. Strip Layout of Simple Cutting Die 140
7 In figure, the different ways of arranging to blanks the given work piece are shown. The arrangement in figure can be worked at single pass with a single punch. Nesting considerably reduces the scrap. However, the strip layout with maximum material saving may not be the best strip layout, as the die construction may become more complex which would offset the savings due to material economy unless a large number of parts are to be produced. Table No. 1. Comparison of Strip Layouts Strip Layouts For Parameters Compound Die Progressive Die Simple Cutting Die Force required More ( 3.5 Ton) More (6.1 Ton) Less (2 Ton) Economical Less More Average Die Cost More More Less Handling of produced component Complicated Easy Easy From the comparison of these three dies we selected the simple cutting die because force required for cutting is less and it is economical as the scrap generated is less. Also cost for die manufacturing is less and handling of produced components is easy. 141
8 Finite Element Analysis 1. DISPLACEMENT PLOT 2. STRESS PLOT Image1: Displacement plot of Die 3. DISPLACEMENT PLOT Image 2: Stress plot of Die Image 3: Displacement plot of Punch 142
9 4. STRESS PLOT 5. DISPLACEMENT PLOT Image 4: Stress plot of Punch 6. STRESS PLOT Image 5: Displacement Plot of Base Plate Image 6: Stress Plot of Base plate 143
10 CONCLUSIONS:- The following conclusions are drawn from the present study: 1. An attempt was made to analyse 2 tonne hydraulic press machine using ANSYS software. 2. Analysis shows that the stresses are well below the yield stress and hence it is safe. 3. Press machine always works under impact load condition. 4. The design calculations of hydraulic power press system are playing important role as we come to know the value of total force develops in the system. 5. Selection of good shape provides strength to the system as the system is only undergoing through bending according to the FEA Analysis the best solution is obtained by changing the shape and design of the top and bottom structure. ACKNOWLEDGEMENTS We are heartily thankful to my guide Asst. Prof. G. C. Mekalke who encourages me and provided me necessary guidance. We want to thank our family and friends for helping and supporting us. REFERENCE: 1. A HYBRID INTELLIGENT SYSTEM FOR STAMPING PROCESS PLANNING IN PROGRESSIVE DIE DESIGN ;W. Y. Zhang, et. all; Nanyang technological university, 50 Nanyang avenue, Singapore COMPOUND DIE DESIGN: A Case Study; Sneha S. Pawar and R. S. Dalu; ISSN (Online): Impact Factor (2012): DESIGN OF COMBINED PRESS TOOL for the manufacturing of rice Thresher Blade.(Case study) by fissha Birukeyonas and Mitike Degu; Bahirdar university, BahurDar, Ethiopia. 4. ASSEMBLING AND VERIFICATION DESIGN CORRECTNESS OFPRESS TOOLS BY HELP OF SYSTEM CATIA by Miroslava Kostoalova, 2011, ISSN TOOL DESIGN FOR OVAL PUNCHING ; Venkatesh B. Emche and M. D. Pasarkar, (IJITEE) ISSN: , VOL-1, Issue-2, JULY
11 6. Design of Progressive Draw Tool, Vishwanath M.C., Dr.Ramni, Sampath Kumar, Volume 3, Issue 8, August ISSN Feature Based Design Of Progressive Press Tool, H. S. Ismile et. All, Vol. 36, No. 3 PP , AN INTELLIGENT SYSTEM FOR SELECTION OF MATERIALS FOR PRESS TOOL COMPONENTS, Kumar Shailendra, E-ISSN: A Learner s Guide To Press Tools by N.B Suresh 10. PRODUCTION ENGINEERING by P. C. Sharma 11. Die Design Fundamentals, J. R. Paquin, R. E. Crawley 12. Design Data Book PSG College of Technology, Coimbtore 13. Tool Design by Donaldson 145
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