NOVATEUR PUBLICATIONS

International Journal of Research Publications in Engineering and Technology [IJRPET]

ISSN: 2454-7875
VOLUME 3, ISSUE 7, July-2017
DESIGN AND MODIFICATION OF PIERCING DIE TO INCREASE TOOL LIFE
AND PRODUCTIVITY
SURYAWANSHI ARVIND G.
Department of Mechanical, S.S.I.E.M.S. Parbhani, Maharashtra, India, [email protected]

MULE JAI Y.
Head Department of Mechanical, S.S.I.E.M.S., Parbhani, Maharashtra, India Email- [email protected]

JOSHI YOGESH B.
Department of Mechanical S.S.I.E.M.S. Parbhani, Maharashtra, India Email- [email protected]

ABSTRACT: blanking/piercing is widely used because of its high

Now days, manufacturing sectors replaced productivity and cost performance. However, for precise
most expensive and casted components by means of holes conventional press blanking/piercing shows poor
sheet metal parts. From this phenomenon the cost of quality with rough sheared surface, and generally needs
the products and the weight of the components are further finishing operations such as lathing or grinding
reduced as much as possible. The cost of tooling in [4]. The cost of tooling in sheet metal industries
sheet metal industries contributes a considerable contributes a considerable part to the overall cost of
part to the overall cost of manufacturing a manufacturing a component. It is therefore imperative to
component. It is therefore imperative to keep down keep down this cost by ensuring that the tool works for a
this cost by ensuring that the tool works for a long long period in production without interruption. One way
period in production without interruption. In this of achieving this objective is to reduce the stress on the
project a Piercing Die is design and develop which tool during punching/blanking [5].
consist of number of parts like housing, punch,
punch holder, striper, cutting die, top plate, bottom II. COMPONENT STUDY:
plate etc. for piercing a 12 hole work piece, by Name of Component – Rotor Head Flange
considering various important parameters of die Material – Fe 510 C UNI10025-92 / ST52
such as Causes of bur, causes of failure of punch, cost Thickness – 10/12mm
effect of failure, tool life, productivity etc. These
problems bring the piercing die to improve tool life,
increasing productivity, without increase in trial cost
in design.
KEYWORDS: Piercing Die, Piercing Punch, Bohler
K110, Alcroma Coating (AlCrN), CATIA V5, Ansys
Workbench 14.5.

I. INTRODUCTION:
Fig. 1.Hole Piercing Design& job
In this project different aspects of Sheet metal press
Depending on one page report and observation we
tool dies are explained in details. The topics cover in this
found the following manufacturing issues in Die,
project include: what is Press tool, its importance and
 Punch broken after certain lot in between 500 to
types, how it is operated, study of Rotor flange 12 hole
1200 jobs.
piercing die and its design and development of some
 Central diameter and individual diameter of 12 holes
parts of piercing die. Press tool manufacturing is one of
issue.
the widely emerging trends in production area. Basically
 Stripper plates loosen due to wear and tear between
sheet metal components are produced using press tools.
punch and punch holder due to excessive load.
As the name it suggests press tool means manufacturing
 Job Ejection issue during removal of job from die.
the sheet metal components by applying the
 Chip off of punch during operation.
predetermined force. The components manufactured
 Due to failure of die job production get disturb and
using this process possess high dimensional accuracy
effects on delivery time and quantity.
therefore automobile and aircraft firm depend largely on
press tools [1]. To provide holes and blanks for high
strength metal sheets, conventional press
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 NOVATEUR PUBLICATIONS
International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 7, July-2017
L = Length of Cut in mm (From CAD Data)
T = Thickness in mm
τ = Shear Strength in Kg/mm2

Material used for Rotor flange is Fe 510/ ST-52

so, Tensile Strength is 490-630 N/mm2

Fig. 2. Photographs of Job and Punch Issues Shear strength = 50% of tensile strength for a
round punches,
2.1 IMPORTANT CONSIDERATIONS IN PIERCING
PUNCH DESIGN: So, Shear strength = 315 N/mm2
 The design of punch mainly depends on the plan Dia of punch is 12.35mm
area to be pierced.
 Its design is also depends upon the pressure which Therefore,
is required to penetrate through the work piece. Circumference = 2πr
 Depending on the method of mounting punch in die. = 2 x π x 6.175
 The punch must withstand maximum piercing = 38.7987 mm
pressure.
 Small punches required support to avoid breakages. There are 12 punches used in die,
 The hole pierced in the sheet is a tapered one, with
minimum opening equal to punch size near the top. So, total length of cut is,
 The maximum size of the hole at the bottom depend L = 38.7987 x 12 = 465.5840
on the die opening which depends on die clearance mm
 The punch is made equal to the hole size shown on τ = Tensile Strength in
component. Kg/mm2 = 315/9.81 = 32.11 Kg/mm2
 Heavy burr observe on the edges of holes.
Chemical Composition and Mechanical Properties/ Shear Force = L x T x τ
Physical Properties, Bohler K110 material is used in = 465.5840 x 12 x 32.11
High-duty cutting tools, blanking and punching tools & = 179398.82 Kg
small moulds for the plastics industry where excellent
wear resistance is required. Increased demands for B. STRIPPING FORCE:
improved productivity and cost efficiency K110 is more Stripping Force = 20% of Total Shear Force
suitable. Dimensionally stable, high car bon, high- = x 179398.82 = 35879.76 Kg
chromium (12%) steel. Particularly suit able for air C. PRESS FORCE:
hardening. Good toughness. Press Force = Total Shear Force + Stripping
Table -1 Chemical Composition Bohler K110 Force
C Si Cr Mn Mo V = 179398.82 + 35879.76
1.55 0.30 11.30 0.30 0.75 0.75 = 215278.58 Kg

Table -2 Mechanical Properties/ Physical Properties Press force in Tonnage = 215.278 Tons
Properties Values Approx. 215 Tons
Density 7.70 Kg/Dm3
Thermal Conductivity 20.0 W/(M.k) D. PRESS TONNAGE:
Specific Heat 460 J/(Kg.k) Press Capacity = (Total Shear Force + Stripping
Electrical Resistivity 0.65 Ohm. Force) / 70%
Modulus of Elasticity 210 X 103 N/mm2
Elongation Fracture 1.54 % The ratio of the punch diameter to the stock
Fracture Toughness 14.8 Mpa/m2 thickness must satisfy the condition
Yield Point 1999 MPa

d/t= 1.10 minimum

2.2 THEORETICAL CALCULATIONS: =1.0291
A. SHEAR FORCE CALCULATION Where,
Shear Force = L x T x τ d = punch diameter

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 NOVATEUR PUBLICATIONS
International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 7, July-2017
t = thickness of punched material Table -3 Average Cost of One Punch
Material Turning Vacuumed Grinding Coating Total
Punch
Cost cost Hard Cost Cost Cost cost
This is less than allowed.
D2
Punch 54/- 18/- 32/- 85/- - 189
2.3 PIERCING PUNCH MODEL ANALYSIS: K110
ANSYS is the tool to analyze the part of solid Uncoated 140/- 20/- 40/- 90/- - 290
modeling in the solid works. It provides the stress result K110
Coated 140/- 20/- 40/- 90/- 1060/- 1350
with the design cycle. It helps to predict the part to
perform under load. Whenever the problem arise related
III. EXPERIMENT AND RESULT:
to design, need of comprehensive analysis of the product
On the basis of analysis data a proper suitable
is required.
material K110 is ordered from the supplier. Rough
As the prime objective of this paper is to analyses
Turning design is given to the operator to make a punch
the rigidity characteristics of a punch with various
ready for the heat treatment. The shape and size of the
design features, it is perfectly justified to set the top
material get changed after heat treatment, so proper
surface of the punch fixed. Thus the boundary condition
tolerances are given on machining. These tolerances are
corresponds to simply setting those nodal points on the
given on the basis of material deflection behavior on
top surface to zero [5].
heat treatment. Heat Treatment given is Vacuum heat
treatment.
ANALYSIS OF MODIFIED PUNCH MODEL - K110
Heat treatment specification
MATERIAL:
=Heat treatment + Double tempering
Categorization - Normal
Require Hardness – 56 to 58 HRC

Fig.3. Modified Punch Design

Fig. 4. Punch Model Modified (2D) & (3D)
Fig. 9. Graph Temperature vs. Time (min)

3.1 COATING FOR PUNCH:

Table -4 Coating Properties
Resid Max.
Coat
Coati ual Serv Coat Coatin
Micro Coating ing
ng C Stres ice ing g
Hard Thicknes Tem
Mate OF s Tem Colo Struct
ness s(µm) p.
rial (GPa p. ur ure
(Co)
) (Co)
As per Brig
AlCr 0. 110 <50 Monol
3500 applicati -0.3 ht
Fig. 5. Meshing of Punch Model Modified (3) N 35 0 0 ayer
on Grey
Fig. 6. Von-Mises Stress Distribution Modified (3)

Chart -1 Coefficient of
Friction[Source:www.oerlikon.com]
Fig. 7. Strain Distributions Modified (3)
Chart -2 Micro Hardness [Source: www.oerlikon.com]
Fig. 8. Total Deformations Modified (3)

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 NOVATEUR PUBLICATIONS
International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 7, July-2017
ADVANTAGES: IV. CONCLUSION:
 Tools are heavily stressed in production with high This thesis is completely described about the
mechanical and thermal strain. These demands Piercing Punch die parts individually through analytical
fulfilled by ALCRONA PRO, the top level all-rounder calculations and these parts are analyzed by the finite
for cutting, punching and die casting. element methods with close meshing analysis. This die
 With this coating we were able to significantly excel design specifically designed for the JBMS, Pvt. Ltd.
the performance curve. industry which is facing the problems regarding their
 This results in an extremely wear resistant coating own criteria. By implementing this type of die design to
with excellent hot hardness and thermal shock compete few recommendations such as,
stability.  Increase of production rate/batch
 Significantly increased cutting speed possible.  Increases Tool Life
 Increase utilization and productivity.  Get a possible product in a die
 Broad application range.  Reduction of man power
 Vastly improved tool lifetimes compared to  Decrease the maintenance cost, Rework cost, man
conventional all-round coatings. power require
 Top results in both wet and dry machining and at As in this we used K110 material which is highly cost
the highest of cutting speeds. material but gives sufficient hardness for coating
 Increased machine utilization and productivity. Alcroma (AlCrN) coating and applying against probably
 Significantly strengthened performance profile. hard raw material with high thickness. Coating gives
good coefficient of friction which helps to remove punch
3.2 TRYOUTS: from the job during production. Which leads in log life of
In experimental set up we prepares a die set up punch, eliminate burr, dimensional accuracy etc.
by changing the punch one by one with suitable new
designed punch holder and check the proper alignment. REFERENCE:
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International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 7, July-2017
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