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CHAPTER 4
Specification
Stainless Steel 409L
1.5mm
Carbon : 0.012%, Nickel : 0.15%, Chromium :
21.5%, Molybdenum : 0.030 % Nitrogen:
Shear strength
Ultimate Tensile strength
0.009%
400 N/mm
500 N/mm
Bend developed length of hinge when curls were unwrapped as shown in Fig 4.3 is determined
as follows:
DEVELOPED LENGTH
L1 = 21.5mm
L2 = A/180(I.R + Kt/2)
= x90/180(4 + 0.5x1/2)
L2= 7.06mm
L1 = D
= (5) 2
= 31.4mm
Where,
t = thickness of sheet (mm)
D = diameter of hole (mm)
FS= shear strength (kg/mm2)
Blanking (S.F) 2
(S.F) 2 = KL2tFS
1000
= 1.2 280 1 40.77
1000
(S.F) 2= 14T
Where,
K = Factor of Safety
L2 = Cut length (mm)
t = Thickness (mm)
FS = Shear Strength (kg/mm2)
Type of fit
Tool Elements
H7/g6 (sliding fit)
10
11
12
13
14
15
16
17
SNX63
Tonnage (T)
63
100
300
50.8
900520
120
870
7.5
CHAPTER 5
FINITE ELEMENT ANALYSIS OF PRESS TOOL ELEMENTS
Finite element analysis (FEA) is a computerized method for predicting how a product reacts to
real-world forces, vibration, heat, fluid flow, and other physical effects. Finite element analysis
shows whether a product will break, wear out, or work the way it was designed. It is called
Structural analysis consists of linear and non-linear models. Linear models use simple
parameters and assume that the material is not plastically deformed. Nonlinear models
Maximum
320.22MPa
0.0016462
158.71MPa
Minimum
12.965MPa
0.000122
-554.57MPa
Equivalent Strain
Maximum
67.663MPa
3.3x10-4
18.846MPa
Minimum
1.0822MPa
1.7x10-5
-21.44MPa
Maximum
47.17MPa
2.4x10-4
12.577MPa
Minimum
0.33628MPa
2.5x10-6
-11.99MPa
5.5 Results
1.
2.
3.
Description
Piercing punch
Blanking punch
Bending punch
Analysis result
Theoretical result
Stress
329.22MPa
Stress
320.8MPa
Strain
1.6x10-3
Strain
1.60x10-4
Shear stress
158.71MPa
Shear stress
164.61MPa
Stress
67.66MPa
Stress
57.93MPa
Strain
3.3x10-4
Strain
2.8x10-4
Shear stress
18.846MPa
Shear stress
33.83MPa
Stress
47.77MPa
Stress
18.39MPa
Strain
2.4x10-4
Strain
6.1x10-5
Shear stress
12.577MPa
Shear stress
23.5MPa
5.6 Summary
Finite element analysis of press tool elements deals with determination of stresses, strains and
shear stresses induced in punches for the load applied. Analysis was carried out in ANSYS work
bench 14 software and Solid 187 element was used for meshing of punches. After the Finite
element analysis was carried out on the critical elements of press tool it was observed that the
resultant stress and strain values were well within the allowable yield stress (i.e. 1650 Mpa) of
the material. The results obtained from Finite element analysis were compared with theoretical
values and were found to be approximately nearer. Table 5.4 shows the results.