Professional Documents
Culture Documents
Raja Aziz Raja Maarof Institute of Product Design and Manufacturing UniKL IPROM
References
Suchy, I., Handbook of die design; McGraw Hill 2nd Ed., Suchy, design;
2006. Boljanovic, Boljanovic, V., Sheet Metal Forming Processes and Die Design, Alkem, Design, Alkem, 2004. Alvarez, W., Roll Form Tool Design: Fundamentals, Fundamentals, Alkem, Alkem, 2006. Szumera, Szumera, J., The Metal Stamping Process, Alkem, 2003. Process, Alkem, Spitler, Spitler, David (tech. reviewer), Fundamentals of tool reviewer), design, design, Society of Mechanical Engineers, 2003. Paquin, Paquin, J. R., Die design fundamentals, Industrial Press, fundamentals, 1986
Credit hours
Four (4) credit hours (2K, 2P) Lecture (room nr 2038)
Two credit hours Two hours per week Every Tuesday, 0830 1030 hrs
Main topics
Sheet metal die design principles Press machine specifications Die plates and insert materials Detail single die design Detail design for progressive dies, incorporating piercing, blanking, bending, forming, embossing, etc. Deep Drawing Dies Casting Dies Basic operation and design knowledge of specialized dies Large and Super Large Stamping Dies
Assessment
Coursework, 60%
At least two assignments: total 40% At least one on sketching (at 10%) At least one on Die design using CAD system
(SolidWorks / Catia / Inventor) (at 30%)
At least one test (mid semester): 20% Approx 30% on theory Approx 70% on practical using CAD system
Product design Flat Blank design Strip layout design Die design
Die commissioning
Cutting clearance
Normally 2 to 5% of strip thickness per side Die clearance: total clearance (both sides) Less than 1% per side: to use fine blanking technology 26 July 2011
L = a + b + c + - n.v L = flat blank length a, b, c = flange length (outer side) n = number of bendings v = bending factor
= 0 to 90
= >90 to 165
Springback by bending
r1 = kR . (r2 + 0.5.s) 0.5.s
r1 = bending radius on tooling r2 = bending radius on product kR = springback factor s = sheet thickness
1 = 2 / kR
1 = bending angle on tooling 2 = bending angle on product / workpiece
Springback by bending
Dpunch
Blanking
Ddie = blank dimension on product
Ddie
Die clearance, 2U
Both sides
Punch (Schneidstempel) (Schneidstempel) Die (Schneidplatten) (Schneidplatten) Hole (Lochen) (Lochen) Blanking (Ausscheiden) (Ausscheiden)
Burr direction
Stripping force
Function:
To strip punches from strip layout
Spring
Types
Elastomer / urethane (normally for stripper spring) Coil (round & rectangular cross sectional type) Leaf
21 feb 2012
Web design
Minimum web width is required:
To have a stable strip layout During forward motion Avoid sagging To have sufficient thrust force to hold the strip Insufficient thrust, the strip will be pulled by the
punch, hence damaging the strip
To reduce scrap. Optimise material utilization, MatlUtil (flat blank area / pitch area) To have sufficient thrust force to hold the strip. Insufficient thrust, the strip will be pulled by the punch, hence damaging the strip To avoid incomplete blank / punch operation To avoid deformation on web, hence strip pitch distance will be distorted To minimise strip overhang
Web design
a = Web
width at external profile b = Web width between profiles
Gap
x t y
Die design
Standard plates
Top, pressure, punch holder, stripper, thrust Bottom, die, guide fence
German design
Die design
Japanese design
Die design
Datum (normally die top position) Closed position
Piercing / blanking punches Bending punches Drawing punches Spring maximum load condition
0 Die plate
Die design
Opening position
Spring pre-load condition. Better life span pre Spring selection Elastomer / urethane spring
Higher force (approx. 20 times higher than coil spring: 150kN) Lower compressible length (approx. 20%)
Coil spring
Higher compressible length (up to 50%) Max. load approx. 7kN
Gas spring
Linear load increase (300N to 180kN) Drawing and deep drawing process
Disc spring
Die design
Punches safety level Opening and closed positions Piercing / blanking punches Bending punches Drawing punches Punch stroke Die total stroke
Die life
Small life volume (<50k): Single die High life volume: Progressive die E/E: product life of 200k to 300k in two years Automotive: product life of 500k to 2mil in five to seven years
Case study
Die life of 500k in six years Monthly volume required: 500k / 6yrs / 12mths = approx. 6,945 monthly
Production data
Eight hours per shift 22 days per month
Fb
b1
Ff
Opposing spring
Zug = Travel
D d1 d2 b1 b2 s Cut Sheet Diameter First Stage Punch Diameter Second Stage Punch Diameter First Stage Drawing Factor Second Stage Drawing Factor Sheet Thickness
Guide fence
Horizontal top: -2 to - 3 Horizontal bottom: -0.1 to -0.2 Vertical: 0 to -0.05
In mm
Dimensioning
Die plate assembled in ground plate
Vertical: 0 to +0.1 Horizontal: -0.1 to 0
Die materials
Inserts
Materials: HSS, DF2, SKD11, SKH Hardness: HRC 55 63 (normally lower than punches for maintenance purpose. Insert to break rather than punch)
Standard parts
Guide pillars & bushes (SUJ2,) bolts
Burr
Higher than specification Wrong direction
Dented: Foreign materials Different thickness / surface thinning Elongated hole (bend after hole punch) Wrinkle surface Torn off Springback Surface crack Rusty
Wrinkle
Surface thinning
Design Raw materials and standard parts Machining Heat treatment Handling Delivery Administration Profit margin Quotation
Design cost
RM / hr Design duration
Design objective (based on problem statement) Design needs analysis Research ideas Design alternatives Final design
Machining cost
Machine type
Milling Turning Grinding Wirecut Diesink Welding
Machining cost
Heat treatment
RM / kg rate RM for special requirement
Material Heat treatment method Electrical furnace Induction Process control
Handling cost
Machine setting Assembly and dismantling Quality control Progress control Storage RM/hr
Delivery
Transportation mode
Lorry or car or motorcycle (depreciation) Driver Petrol Maintenance (tyre wear, engine oil, etc) (tyre Toll
RM / km
Weight category , e.g. Less than 150 kg at RM1/kg Others at RM2/kg Size or volume category
Apportionment: % to be budgeted on
capital expenditure, e.g. supporting machines, furniture, forklift, etc RM/hr Eg. Eg.
Admin staff payroll: Total RM50,000 per month Power & utility: RM5,000 per month Building depreciation or rentals: RM10,000 month 2 shifts, 8 hours / shift, 22 days / month. Equals to 352 hours / month
Administration cost
Administration cost
Admin cost / month: RM65,000 Rate: RM65,000 / 352 hours RM185 / hr For e.g. 50 projects per year.
Apportionment equals 1/50. or RM3.70 / hr / project
Profit margin
% of total production cost % value depends on:
Difficulty level Timeline given by customer Wisdom: Can others do it? Rule of thumb
Quotation to customer
Project name Project reference number Price Warranty Delivery date
Amortisation
Definitions (ref: Wikipedia)
of capital expenditures of certain assets under accounting rules, particularly intangible assets, assets, in a manner analogous to depreciation is the distribution of a single lump-sum cash lumpflow into many smaller cash flow installments, as determined by an amortization schedule
Cost summary
Item Design Raw material Std. part Machining Heat treatment Handling Delivery Admin Total Profit margin Quotation Basis Hrs Kg L/s Hrs Kg Hrs Km, weight, volume Hrs % 50 to 200 Rate (e.g.) RM25/hr RM7/kg As manufacturer list RM5 to RM60/hr RM5/kg RM5/hr RM5 to RM60/km RM4 RM
Cost summary
Forming technologies
Forming
automation High Speed Forming Machine Fineblanking
Design samples
Special designs
Sensors in die
Ball catch
Strip utilization
Strip utilization
Calculation:
= Utilization efficiency (%) R = Nr of row A = flat blank surface area (inclusive holes) V = Strip pitch B = Strip width
R.A = V.B