PBR VISVODAYA INSTITUTE OF SCIENCE AND TECHNOLOGY

KAVALI, S.P.S.R.NELLORE (DIST)-524201

A Mini Project on

DESIGN AND FABRICATION OF BLANKING DIE

By

DIPAK BAG & MURALI MANOHAR PANDEY

III Year Mechanical Engg.

Under the guidance of

Dr. Ch.V.S.ParameswaraRao

Prof. & Principal

Rabbani Bhasha

Senior Technician
 PBR VISVODAYA INSTITUTE OF SCIENCE AND TECHNOLOGY
KAVALI, S.P.S.R.NELLORE (DIST)-524201

A Mini Project report

On

DESIGN AND FABRICATION OF BLANKING DIE

By

DIPAK BAG : 12731A0324

MURALI MANOHAR PANDEY : 12731A0357

III Year Mechanical Engg.

Under the guidance of

Dr. Ch.V.S.ParameswaraRao (Prof. & Principal) & Rabbani Bhasha (Senior Technician)

----------------------- --------------------------------------------
B. KONDA REDDY Dr. CH.V.S. PARAMESWARA RAO
(Head of Department) (Principal)
 CONTENTS

PAGE

CHAPTER – 1 : INTRODUCTION 1

CHAPTER – 2 : PLANNING AND EVALUATION OF THE PROCESS 3

CHAPTER – 3 : MATERIAL SELECTION AND PROPERTIES 5

CHAPTER – 4 : DESIGN CALCULATION 10

CHAPTER – 5 : FABRICATION 11

CHAPTER – 6 : EXPLANATION OF THE PROCESS 14

*****
 CHAPTER – 1

INTRODUCTION

Tool design is a specialized phase of tool engineering. The word “Tooling” refers to
the hardware necessary to produce a particular product. A considerable amount of
tooling is the result of work performed by a tool designer. The type of production
will determine to a large extent the type of tooling. The most common classification
of types of tooling is as follows:

1. Cutting tools, such as drills, reamers, milling cutters, broaches, and taps.
2. Jigs and fixtures for guiding the tools and holding work piece.
3. Gages and measuring instruments.
4. Sheet – metal press working dies for all types of sheet – metal fabrication.
5. Dies for plastic moulding, die casting, permanent moulding, and investment
casting.
6. Forging dies for hot and cold forging, upsetting, extrusion, and cold finishing.

The basic task of the tool designer is to provide drawings of a tool or set of
tools to produce the work piece. He will be provided with a blueprint of the work
piece to be manufactured, the name and specifications of the machine to produce
the work piece, and the number of work pieces required. If large number of work
pieces is needed, an expensive tool may be justified. If only a few work pieces
are needed, the tool must be inexpensive. In all cases, the tool must be made as
economically as possible for the required services. The tool should be easy and
safe to operate; it should also look practical and attractive, but it certainly should
not have unnecessary elaborate trimmings or needless complexity. In order to
complete his task the tool designer may have to produce a complete set of
drawing showing (1) an assembly drawing, (2) one or more subassemblies, if the
design is complex, (3) a details drawing of each part, (4) a complete list of parts
needed to make the tool.

The tool designer must have knowledge of standards and procedures. The greatest
economy can be affected where standard parts (screws, bushings, handles,
clamps, and so on) can be worked into new tools.
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 Since they are made in large numbers, standard parts can be manufactured at a
lower cost than special jobs. Furthermore, standard parts can be salvaged from
obsolete tools and used again. Knowledge of procedures is important in modern
organizations. This includes methods used by the plant in manufacturing, in
trucking or conveying stock or parts from one department to another, in
inspecting material and products, in drafting in realizing blueprints and stock
lists, and in filling tracings and prints which is a part of the assets of a tool
designer.

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 CHAPTER – 2

PLANNING AND EVALUATION OF THE PROCESS

THE DESIGN PROCEDURE

When a new and different design is called for, some type of design
procedure is followed to utilize the designer’s time to best advantage, to prevent
mistakes, and to bring forth the best and correct design. The design procedure
followed by the experienced tool designer is probably loose and informal because
he is able to take shortcuts he has learned through practice. The beginner, however,
should follow a deliberate and organized procedure in designing his product.

STATEMENT OF THE PROBLEM

The first step in the design procedure is to define the problem in a clear
and simple statement of the functional needs. The manufacturing engineer usually
provides the tool designer with the problem. He has determined a need for necessary
tools and assigns the job to the tool designer. The tool designer will receive a part
print, information on why the tool is needed, what the capabilities of the tool must
be, the type of machine the tools must be used on, the number of parts to produced,
and other pertinent information concerning the part. The problem statement should
identify the problem in one or two sentences.

THE NEED ANALYSIS

The need analysis, sometimes called the pre design analysis, pinpoints the
problem in terms of functional needs. The problem is analyzed by asking who, why,
how, when, what, and where questions about the functional requirements of the
problem statement. All information supplied by the manufacturing engineer is
examined, and all questions that arise are listed on paper to provide a permanent
record.

RESEARCH AND IDEATION (SKETCHES)

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 In the research of the design, information and data based on the needs
analysis are gathered. This information will include such items as the dimensions of
the part to be held or produced, the kind of material from which the part is made, the
tolerances of the part, the dimensions, of the machine, the limitations of the machine,
and the amount of tonnage to blank the part.

THE FINISHED DESIGN

The finished design may not be actual finished product, for even in the
final stages of drawing changes and additions may be necessary. However, an
accurate drawing must be completed before the toolmaker is able to begin
construction. The drawing will probably consist of a three view (or) orthographic
drawing, which will be drawn to scale according to the tool – drawing procedures
established by the company.

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 CHAPTER – 3

MATERIAL SELECTION AND PROPERTIES

CREATERIA FOR SELECTION OF MATERIALS:

Tools materials selected for die depends upon the physical and chemical
properties. In most cases the choice of materials also depends on the availability
and economics.

The basic application of materials in tool design is tool steels. But cast iron,
other steels and non – ferrous materials may be successfully used. The basic
properties which are looked upon for tool design may be listed as follows:

1) HARDNESS: Hardness is the ability to resist penetration, or the ability to with

stand abrasion.

Hardness forms an important property in the selection of tools materials as the

tools is subjected to abrasion or wear. The wear resistance or abrasion
resistance of material is not determined by hardness alone, since it varies with
the alloy content. The most widely used methods of measuring hardness are:

1) Rockwell Hardness and (2) Brinell Hardness

2) TENSILE STENGTH: This physical property of materials is the value obtained by
dividing the maximum load observed during tensile testing by the specimen’s
cross sectional area. Tensile strength is of less importance in tools and dies
except in soft or medium hard ferrous or non-ferrous materials.
3) COMPRESSIVE STRENGHT: This forms an important property in tool design. It is
the maximum stress which a metal can withstand without facture on application
of a compressive force.
4) SHEAR STRENGTH: This is an important physical property especially in designing
tools when subjected to torsion it may defined as the value of stress necessary
to cause rupture in torsion.

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5) YIELD STRENGTH: This is the property of materials which limits its strength in
application. It may be defined as the stress level at which a material will show a
permanent elongation after the load is released.
6) MODUUS OF ELASTICITY (Bending): This is the measure of stiffness of indicated by
the slope of the line generated below the elastic limit. This is an important property
while designing long tools and machine parts.
7) MODULUS OF ELASTCITY (Torsion): It is measured in torsion test and is the ratio of
unit shear stress to the displacement caused by it for unit length in elastic range.
This is useful in designing tools subjected to torsion.
8) FATIGUE, CORROSION: Fatigue is defined as a tendency of a metal to break under
conditions of repeated cyclic stresses, well below its tensile strength. Usually in
punches and other impact tools the fracture starts from a localized concentration
of stress which expands and leads to the failure of the tool. Hence the stress
concentration and defects are kept as low as possible as there is a strong tendency
of material to break under fatigue. Hence fatigue plays an important role in
designing a machine tool.

The tool material gets eroded due to frictional heat which causes the lubricant to
break down resulting in chemical or electro chemical attack on the tool material.

FERROUS TOOL MATERIALS:

The materials usually used in construction of the die tools are ferrous materials.
The supporting components of fixtures are usually made of low carbon steels while
wear pads are made of Hardened tool steels. Hence depending upon the functional
requirement of the tool, the materials are selected.

TOOL AND DIE STEELS: The main five principle properties considered during the
selection of a material are resistance, Abrasion resistance, Shock resistance,
Resistance due to the movement of distortion in hardening and cutting ability.

WATER HARDENINGS TOOL STEELS: This group includes carbon and carbon
vanadium types of steels. These carbon steels are original tool steel and they have
low cost, abrasion resisting and shock resisting qualities, ease of machinability, and
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ability to take a keen cutting edge. These steels are shallow hardened and are
readily available.

OIL HARDENING TOOL STEELS: These steels are manganese oil hardening tool
steels, readily available and of low cost. These steels have less movement then
water hardening steels, and are of equal toughness with water hardening steels.
The wear resistance is slightly better than water hardening steels of equal carbon
content.

AIR HARDENING DIE STEELS: These steels have minimum movement in hardening
and have higher toughness then oil hardening die steels with equal or greater wear
resistance.

HIGH CARBON HIGH CHROMIUM DIE STEELS: These types of steels find wide
application for long run dies and they have fairly tough and wear resistance. (This
steel is used currently for making the die.)

SHOCK RESISTING TOOL STEELS: These steels contain less carbon and have higher
toughness. They are applied where heavy cutting or forming operations are
required, and where breakage is a serious problem.

HOT WORK DIE STEELS: These steels have good hardness with good wear
resistance and shock resistance. They are air hardened and on occasions re used
for cold working operations. These steels have relatively low carbon content and
intermediate to high alloy content.

TUNGSTEN AND MOLYBDENUM HIGH SPEED STEELS: These steels have good red
hardness and abrasion resistance. They have higher toughness then many of the
other die steels. These steels are hardened by conventional methods or carburized
for cold work applications. Grind and machining becomes difficult because of
increase in their carbon content.

LOW ALLOY TOOL STEELS: These steels are used for special die applications and
where fatigue and toughness are important consideration.

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FINISHING STEELS: These are occasionally applied where extremely high wear
resistance is required.

CAST IRON: Cast iron is an alloy of iron and carbon containing from 2 to 4 percent
carbon, 0.5 to about 3.0 percent silicon, 0.4 to 1.0 percent manganese, plus
phosphorus and sulphur. Other alloy may be added depending on the properties
desired. The high compressive strength and ease of casting the gray iron are utilized
in large forming and drawing dies to produce such items as automobile panels,
refrigerator cabinets, bath tubs etc.

STAINLESS STEEL: Stainless steels are corrosion resistant alloy that are used where
other steels would be attacked by oxidation. They derive their high resistance to
corrosion from the presence of chromium.

Thus steels are used in tooling where a non – magnetic material may be required
and corrosion is a problem.

NONFERROUS TOOL MATERIALS:

ALUMINUM: Duralaluminum is used a facing over from blocs. Its composition is

copper, 4.0 percent, manganese, 0.5 percent, magnesium 0.5 percent, with
aluminum and normal impurities constituting the remainder.

Aluminum bronze cast to the specified die shape is used for forming and drawing
stainless steel without scratching or galling.

MAGNESIUM: Sheet magnesium and magnesium alloys are used as a facing

material over blocks. Their application is limited to very short production runs.

ZINC – BASE ALLOYS: Zinc – base alloys are quickly cast into punch – and – die shape
at low cost. The production of experimental parts with such dies can prove out the
both the part and the die before permanent tooling is started.

LEAD – BASE ALLOYS: Lead punches, composed of 6 to 7 percent antimony and the
remainder lead, have been used with Kristie dies. These, again, are used on limited
– production runs.

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CAST BERRYLLIUM COPPER ALLOYS: Cast alloys of beryllium, cobalt, and copper
have characteristics comparable with the aluminum bronze.

BISMUTH ALLOYS: The alloys of bismuth are used briefly as a matrix material for
securing punch – and – die parts in a die assembly, and as cast punches and dies
for short – run forming and drawing operations.

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 CHAPTER - 4

DESIGN CALCULATIONS

The load required to blank a part of diameter, D, thickness, and shear strength, fs is
given by,

Fsh = πDTfs

Where,

D = Diameter of the blank, mm

T = thickness of the strip, mm

fs = shear strength, N/mm2

Here, the material of the strip is galvanized steel.

Its shear strength, fs = 65 N/mm2

The load required to pierce out a diameter 88 mm in KN is,

Fsh = (πDTfs)/1000
= 3.14 x 88x1 x 65 = 17.96 KN
1000
Die Design

Die plate thickness, Td= Fsh1/3 = 12.2 mm (minimum)

Die opening= 88 mm

Punch Diameter= 88 – 5% of 1.2= 87.94 mm

Punch length= 56mm

Punch plate thickness= 25 mm

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 CHAPTER - 5

FABRICATION

DIE: This pertains to the female part of the complete production tool. The purpose
of which is to produce piece parts, consistently to required specifications.

PUNCH: A punch is a male member of a complete die which mates or acts in

conjunction with the female die to produce a desired effect upon the material being
worked.

BOLSTERS: The top bolster is to support the punch, while the bottom bolster
supports the die.

STRIPPERS: Stripping is the act of removing the work from the punch and this is
performed by the device called stripper. With a motivated punch, the stripper acts to
arrest the stock material, permitting the moving punch to withdraw from it.

STOCK GUIDES: These are used to guide the stock material during the operation.
Stock guides for low production are usually made in the form of pins or rails, i.e.,
Instead of hardening the entire rail, the diameter can use localized of sports along
the gauging edge. The design of stock guides are avoided as the stripper itself can
act as stock guides.

PROGRESSIVE DIE: It is possible to use a series of die – punch elements at

different locations. One operation is performed at each station and the metal stock is
advanced to the next station. Thus a continuous operation is possible such an
assembly of dies is called a progressive die.

STATION: The successive positions into which the stock strip is registered are the
basic divisions of a progressive die. These basic divisions are called ‘Stations.’

ADVANCE: The advance distance is the exact distance at which the stock strip is
relocated for each successive press stroke. This distance is usually specified simply
as the advance.

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FEED: The feed distance is the distance the stock strip is moved either manually or
mechanically, between sequences.

THE FABRICATION PROCESS

PLATES: All the plates were made to size by facing operation on the lathe machine.
Rough cutting and then finishing was done on all the sides of the plates. The plates
were located on the lathe by a 4 jaw chuck and machined.

MANUFACTURE OF THE PUNCH AND LOCATION

The blanking punch is made by plain turning on lathe. A suitable

head was providing on punch for proper clamping. The punch plate was bored
through for punch insertion.

STOP PIN

A stop pin (obtained from market), which is spring loaded was screwed
into the thread made on the die block. The height of the stop pin above the die block
surface can thus be adjusted by lifting the stop pin in the bore.

DIE BLOCK

A suitable taper necessary for free fall of blank was provided by taper
turning on the previously bored hole. The hole size obtained at the end of the taper
i.e., at the bottom of the die block was maintained through the bottom plate by boring
it on the lathe. This is shown in Fig.

CLEARANCE:

Clearance is the space between the mating members of a die set. Proper clearances
between cutting edges permit the fractures to meet and the fractured portion of the
sheared edge has a clean appearance. Excessive clearance will cause prolonged burrs
on the product which may be disadvantageous in the use of the product. While the
advantage is that the wear of the tool is decreased and the tool life is increased. Too
small a clearance will result in a good product with a negligible burr. While this
helps in the very good use of the product. It decreased the life of the tool; hence the
optimum clearance is required in order to strike a balance, which may be lying
between 6 to 7½ percent of the material thickness.

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ANGULAR CLEARANCE: It is defined as that clearance below the straight
portion of a die surface introduced for the purpose of enabling the blank or the slug
to clear the die. Angular clearance is usually given between ⅟4th - 1 ½0 per side.

Observations of the product - Blank

1. A slight burr can be seen on the edge which is due to the result of a slight extra
clearance. This defect as well can be removed by decreasing the clearance
between the punch and the die opening. But, the main disadvantage due to this is
that it decreases the life of the punch and die block because of excessive wear
between them due to friction.
2. The blank is having a small curvature which makes it look like a dish. This is
happening due to the pilot, coming in contact with the punched hole.
3. The fracture between the blank and the strip to be blanked can be distinctly seen.
This fracture starts from punch and extends to the top of the die opening.
4. The diameter of the blank is 88 mm.

INDUSTRIAL APPLICATIONS OF PROGRESSIVE TOOLS:

1. E and I laminations of the transformers can be manufactured by a progressive

press tool without loss of any material.
2. Manufacturing of clutch plates.
3. Manufacturing of Electrical Appliances.
4. Manufacturing of Fan Blades.
5. Manufacturing of Lock Levers.
6. Manufacturing of Washers.
7. Manufacturing of Keys.
8. Manufacturing of Leaf Springs.

METHOD OF PRODUCING BLANK:

The female part of the die is fixed on the table of UTM machine
(UTM is used to obtain the required hydraulic force) and the strip is fed through the
opening provided for it. The male part is then assembled and force is applied in
downward direction with the help of valve.

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 CHAPTER – 6

EXPLANATION OF THE PROCESS

ACTION OF BLANKINGDIE: When the press is tripped the ram drives the punch
through the stock material into the die opening, thereby producing an opening in the
stock material by cutting out the blank .This blank remains in the die opening when
the punch is withdraw and is pushed through the die by the blanks or slug produced
subsequently.

STRIPPING: After the blanking has taken place, the punch is returned to the open
position by the press as it completes the cycle. The stock material clings to the punch
and will remain on the punch unless something is done to prevent it. The stripper
keeps the stock material from travelling with the punch on the return stroke. As the
stock material is held back by the stripper, the punch is withdrawn from the material
on the return stroke.

REACTION OF THE STOCK MATERIALS

Critical stages of shearing action on metal:

FIRST STAGE (PLASTIC DEFORMATION):

The stock material has been placed on the die and punch is driven towards the die.
The punch contacts the stock material and exerts pressure upon it. When the elastic
of the stock material is exceeded plastic deformation takes place.

SECOND STAGE (PENERATION):

As the driving force of the ram continues, the punch is forced to penetrate the stock
material and the blank is displaced into the die opening a corresponding amount.
This is the true shearing portion of the cutting cycle from which the term shearing
action is derived.

THIRD STAGE (FRACTURE):

Further continuation of the punching pressure then causes fractures to

start at the cutting edges of the punch and the die. These are the points of greatest
stress concentration. These three stages of shear action are responsible for the
characteristic appearance of the piece parts produced by blanking.
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DESIGN DRAWINGS:

Fig: MALE DIE(Third angle projection)

Fig: FEMALE DIE(Third angle projection)

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 IMAGES OF PUNCH DIE MANUFACTURING

Fig: male and female die

Fig: Blank product

FIG: BLANKING DIE SET

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