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Compound Press Tool Design & Analysis

This document describes the design and manufacturing of a compound press tool for making washers. It includes calculations of cutting force, economy factor, assembly and 3D views of the press tool. Key parameters are defined for the draw die such as blank diameter, punch diameter, thickness, draw ring radius, and clearance. Calculations are shown for blank holder pressure, blank holder force, draw force, and total ram force required. The final part meets quality tolerance limits.

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178 views34 pages

Compound Press Tool Design & Analysis

This document describes the design and manufacturing of a compound press tool for making washers. It includes calculations of cutting force, economy factor, assembly and 3D views of the press tool. Key parameters are defined for the draw die such as blank diameter, punch diameter, thickness, draw ring radius, and clearance. Calculations are shown for blank holder pressure, blank holder force, draw force, and total ram force required. The final part meets quality tolerance limits.

Uploaded by

xuân quân lê
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Design & Manufacturing of Compound

Press Tool for Washer

aa
Trip layout
Tool Design
6.2. Calculations
6.2.2 Economy Factor
6.2. Calculations - 6.2.2 Economy Factor

From the above table Scrap Bridge thickness is 4.35mm taken


6.2.4 Cutting Force:
CUTTING FORCE = 60X693X3 =
124740/1000 = 124.7 ~125 TONE
SAFETY CONST x (125+25)
= 1.2x150 = 180 TONE
7. Assembly and 3-
D View of Press
Tool
7. Assembly and
3-D View of
Press Tool
7. Assembly and 3-D
View of Press Tool
DESIGN OF DRAW DIE FOR
CYLINDRICAL CUP FORMATION
PARAMETERS OF DRAW DIE

Where: D =Blank diameter, d1=Inside work piece diameter


after the first drawing operation, T = Material thickness,
Rp=Draw ring, Ri=Punch radius, dp=Outside work piece
diameter after the first drawing operation
• Rp= 0.8[(D-d1) X T] 0.5…….(1)[5]
• h0= (3/5) X T …………….(3)[5]
• C = T + k (10T) 0.5 ……..... (4)[5]
C = clearance, T = material thickness, k = coefficient
Blank Holder
Pressure (Pd1) -
The value of
blankholder
pressure is
decided on the
basis of sheet
metal material
which is to be
deformed.
The blank holder force :
Fd1= (π/4) [D2-d12] Pd1 .…………….. (5)[5]
Draw force:
Pdraw = A St nc ln(Ec)………………...(6)[6]
A = π d1 T, A-area of cross section of a shell, T-
Thickness of sheet metal, St- Ultimate tensile
strength of material,
E- Cupping strain factor, nc - Deformation
efficiency of drawing process,
The cupping strain factor E:
E = [(D/d1) +1]/2 ………………(7)[6]
A. Input parameters-
Sheet metal (Input
part) detail:
Press data :
 Shut height 340mm
 Clamping slot dimension 50mm (thick) X 30mm(width)
X45mm (depth) for M28 clamping bolt, pitch of clamp slots
from center of press is 75 mm.
 Front to back maximum size 650mm
 Left to right maximum size 550mm
 Number of strokes per minute 20
 Make-union
 Maximum capacity 160 ton
 No cushion pins for blank-holder
 Travel of blank-holder as per shape of output component.
• Travel of blank-holder as per shape of output component
As the depth of drawn component is 25mm, blank-holder travel is
kept 26mm for proper holding 1mm before the start of operation.
• Various parameters
 Blank Diameter (D)=110 mm
 Punch diameter (d1)=59 mm
 Thickness of sheet (T)=0.8 mm
• Draw ring radius (Rp) Rp = 0.8 X [(D-d1) X T] 0.5=5.10 mm≈5 mm
• Clearance value between punch and cavity (C) C = T + k √ (10 X T)= 0.99
mm≈ 1mm
• Cavity diameter (d0) D0= 59+0.99= 59.99 mm≈ 60 mm
• Blank-holder pressure (P) is decided based on the finite element analysis of
metal flow. From method plan report and table 2 the value is selected as
1.17MPa
• Blank-holder force (Pd1) –Pd1 = P X area of sheet metal holding=1.17 X
[1102 - (π/4) X 592]=10.958 kN
• Draw Force (F) –F= A X St X nc X ln(E)
A= π X d1 X T=148.28 mm2, Cupping strain factor (E), E = [(D/d1) + 1]/2= 1.43
From fig.6, nc=2.3
F=148.28 X 260 X 2.3 X ln(1.43)= 39.035 kN
• Total ram force required (T) = Draw force + Blankholder force
= F + Pd1= 39.035 + 10.958= 49.993≈50 kN
RESULTS AND DISCUSSION
• The C.M.M. report indicates the part produced is within
the tolerance limits which are decided by quality
control department.

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