DIE & PUNCH

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 DIE & PUNCH

MAIN PROJECT REPORT

Submitted in partial fulfillment of the requirement for the award of degree

of

Bachelor of Technology

in

Mechanical Engineering

Submitted by

AMIT JAISWAL (5808614)

Under the esteemed guidance of

DR. .........................,B.Tech, M.Tech.,Ph.D

Head of Department

Of

Mechanical Engineering

.................................. ENGINEERING COLLEGE

(Affiliated to ...................................... University)

2014-2015

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 TABLE OF CONTENTS

S.NO. TOPIC PAGE NO.

1 CANDIDATE’S DECLARTION 4
2 CERTIFICATE 5
3 ACKNOWLEDGEMENT 6
4 ROLE AND RESPONSIBILITIES 7
5 PERSONAL ENGINEERING ACTIVITY 8
6 INTRODUCTION 9

7 DIE FORMING 9

8 DIE COMPONENTS 10
9 PROCESSES 11
10 PUNCHING 19
11 PUNCHING CHARACTERISTICS 20
12 DIE AND PUNCH DESIGN 24
13 CONCLUSION 28
14 REFERENCES 29

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 CANDIDATE’S DECLARTION

I hereby certify that the work which is being presented by Amit Jaiswal, Ajay
Singh Chauhan, Rajeev Kumar, Raman Kumar, Vijay Kumar in partial fulfillment
of requirement for the award of degree of B.Tech. in MECHANICAL ENGINEERING
submitted at KALPI INSTITUTE OF TECHNOLOGY under KURUKSHETRA
UNIVERSITY, KURUKSHETRA is an authentic record of my own work carried out
under the supervision of Er. Harish Kumar Sharma (HOD) and Er. Vikas Kunnar.

Project Member:

Amit Jaiswal [5808614]

Ajay Singh Chauhan [5808615]
Rajeev Kumar [5808608]
Raman Kumar [5808606]
Vijay Kumar [5808613]

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 CERTIFICATE

This is certify that the dissertation entitled “ DIE & PUNCH ” by RAJEEV
KUSHWAHA, AMIT JAISWAL, SANDEEP ANAND SHARMA, MANISH KUMAR
TRIVEDI, PERVEZ KHAN,& DIVYANSH submitted to the Department of
mechanical engineering, Kalpi Institute Of Technology, Ambala in the partial
fulfillment of requirement for the award of Degree of Bachelor of Technology in
mechanical engineering is a record of bonafide work done by him under my
supervision and guidance during the session 2014-15. This work has not been
submitted to any other university or institute for the award of any degree or
diploma.

Head of department & project Guide

Mr.........................

Department of mechanical engineering

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 ACKNOWLEDGEMENT

First of all we would like to thank our project guide Mr. ......................
Assistant Professor, Mechanical engineering Department, Kurukshetra
University who has given valuable support during the course of our
project by clarifying our doubts and guiding us with her novel ideas.

We would like to thank Prof. .........................., Head of department,

mechanical engineering, Kurukshetra University.

We extend our sincere thanks to our Dean ....................................

Department of mechanical engineering for giving us this wonderful
opportunity to work in desired area of interest.

We extend our sincere thanks to all teaching staff of mechanical

engineering department, those who helped us in completing this
project successfully.

Lastly we also thank the people who directly or indirectly gave us

encouragement and support throughout the project.

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Role and Responsibilities

My roles and responsibilities includes:

 Prepare a requirement document to reach expectations of project and to

come up with functionalities which are needed to be implemented.
 Documentation of expected output for various aspects with accepted
margin error was also documented.
 To design overall system based on workflow requirements.
 Discussion with the project guide and Head of Department on ways to
improve the design and to optimize performance.
 Choosing suitable components and methods based on the configurations
availability and requirements.
 Testing and remedies.
 Recommendations

As a trainee mechanical engineer, I wanted to work on a project work

that would showcase my engineering knowledge. I got the opportunity
to work on DIE & PUNCH. This project was very important as it
evaluated my skills and talents in my company.

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PERSONAL ENGINEERING ACTIVITY

As a mechanical engineer, before undertaking any task I checked the

feasibility of the project. In this project, my role is as team members.
This report provides an insight into the design and fabrication of a DIE
& PUNCH.

I wanted to know more details of the project before commencing;

hence, I researched the topic thoroughly by referring to journals and
articles online. Additionally, I obtained more information by taking
references about the topic.

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INTRODUCTION

DIE

A die is a specialized tool used in manufacturing industries to cut or shape

material mostly using a press. Like molds, dies are generally customized to the
item they are used to create. Products made with dies range from simple paper
clips to complex pieces used in advanced technology.

Die forming

Progressive die with scrap strip and stampings

Forming dies are typically made by tool and die makers and put into production
after mounting into a press. The die is a metal block that is used for forming
materials like sheet metal and plastic. For the vacuum forming of plastic sheet
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only a single form is used, typically to form transparent plastic containers (called
blister packs) for merchandise. Vacuum forming is considered a simple molding
thermoforming process but uses the same principles as die forming. For the
forming of sheet metal, such as automobile body parts, two parts may be used:
one, called the punch, performs the stretching, bending, and/or blanking
operation, while another part, called the die block, securely clamps the workpiece
and provides similar stretching, bending, and/or blanking operation. The
workpiece may pass through several stages using different tools or operations to
obtain the final form. In the case of an automotive component there will usually
be a shearing operation after the main forming is done and then additional
crimping or rolling operations to ensure that all sharp edges are hidden and to
add rigidity to the panel.

Die components

The main components for die tool sets are to 1000:

 Die block - This is the main part that all the other parts are attached to.
 Punch plate - This part holds and supports the different punches in place.
 Blank punch - This part along with the blank die produces the blanked part.
 Pierce punch - This part along with the pierce die removes parts from the
blanked finished part.
 Stripper plate - This is used to hold the material down on the blank/pierce die
and strip the material off the punches.
 Pilot - This will help to place the sheet accurately for the next stage of
operation.

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 Guide, back gauge, or finger stop - These parts are all used to make sure that
the material being worked on always goes in the same position, within the die,
as the last one.
 Setting (stop) block - This part is used to control the depth that the punch goes
into the die.
 Blanking dies - See blanking punch
 Pierce die - See pierce punch.
 Shank - used to hold in the presses. it should be aligned and situated at the
center of gravity of the plate.

Processes:

 Blanking: A blanking die produces a flat piece of material by cutting the

desired shape in one operation. The finished part is referred to as a blank.
Generally a blanking die may only cut the outside contour of a part, often used
for parts with no internal features.

Three benefits to die blanking are:

1. Accuracy. A properly sharpened die, with the correct amount of clearance

between the punch and die, will produce a part that holds close dimensional
tolerances in relationship to the part's edges.
2. Appearance. Since the part is blanked in one operation, the finish edges of the
part produces a uniform appearance as opposed to varying degrees of
burnishing from multiple operations.

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3. Flatness. Due to the even compression of the blanking process, the end result
is a flat part that may retain a specific level of flatness for additional
manufacturing operations.
 Broaching: The process of removing material through the use of multiple
cutting teeth, with each tooth cutting behind the other. A broaching die is
often used to remove material from parts that are too thick for shaving.
 Bulging: A bulging die expands the closed end of tube through the use of two
types of bulging dies. Similar to the way a chef's hat bulges out at the top from
the cylindrical band around the chef's head.
 Bulging fluid dies: Uses water or oil as a vehicle to expand the part.
 Bulging rubber dies: Uses a rubber pad or block under pressure to move the
wall of a workpiece.
 Coining: is similar to forming with the main difference being that a coining die
may form completely different features on either face of the blank, these
features being transferred from the face of the punch or die respectively. The
coining die and punch flow the metal by squeezing the blank within a confined
area, instead of bending the blank. For example: an Olympic medal that was
formed from a coining die may have a flat surface on the back and a raised
feature on the front. If the medal was formed (or embossed), the surface on
the back would be the reverse image of the front.
 Compound operations: Compound dies perform multiple operations on the
part. The compound operation is the act of implementing more than one
operation during the press cycle.
 Compound die: A type of die that has the die block (matrix) mounted on a
punch plate with perforators in the upper die with the inner punch mounted in

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 the lower die set. An inverted type of blanking die that punches upwards,
leaving the part sitting on the lower punch (after being shed from the upper
matrix on the press return stroke) instead of blanking the part through. A
compound die allows the cutting of internal and external part features on a
single press stroke.
 Curling: The curling operation is used to roll the material into a curved shape.
A door hinge is an example of a part created by a curling die.
 Cut off: Cut off dies are used to cut off excess material from a finished end of a
part or to cut off a predetermined length of material strip for additional
operations.
 Drawing: The drawing operation is very similar to the forming operation
except that the drawing operation undergoes severe plastic deformation and
the material of the part extends around the sides. A metal cup with a detailed
feature at the bottom is an example of the difference between formed and
drawn. The bottom of the cup was formed while the sides were drawn.
 Extruding: Extruding is the act of severely deforming blanks of metal called
slugs into finished parts such as an aluminum I-beam. Extrusion dies use
extremely high pressure from the punch to squeeze the metal out into the
desired form. The difference between cold forming and extrusion is extruded
parts do not take shape of the punch.
 Forming: Forming dies bend the blank along a curved surface. An example of a
part that has been formed would be the positive end(+) of a AA battery.
 Cold forming (cold heading): Cold forming is similar to extruding in that it
squeezes the blank material but cold forming uses the punch and the die to
create the desired form, extruding does not.

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 Roll Forming Stand

 Roll forming: a continuous bending operation in which sheet or strip metal is

gradually formed in tandem sets of rollers until the desired cross-sectional
configuration is obtained. Roll forming is ideal for producing parts with long
lengths or in large quantities.
 Horning: A horning die provides an arbor or horn which the parts are place for
secondary operations.
 Hydroforming: Forming of tubular part from simpler tubes with high water
pressure.
 Pancake die: A Pancake die is a simple type of manufacturing die that
performs blanking and/or piercing. While many dies perform complex
procedures simultaneously, a pancake die may only perform one simple
procedure with the finished product being removed by hand.
 Piercing: The piercing operation is used to pierce holes in stampings.
 Transfer die: Transfer dies provide different stations for operations to be
performed. A common practice is to move the material through the die so it is

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 progressively modified at each station until the final operation ejects a finished
part.
 Progressive die: The sheet metal is fed through as a coil strip, and a different
operation (such as punching, blanking, and notching) is performed at the same
station of the machine with each stroke of a series of punches.
 Shaving: The shaving operation removes a small amount of material from the
edges of the part to improve the edges finish or part accuracy. (Compare to
Trimming).
 Side cam die: Side cams transform vertical motion from the press ram into
horizontal or angular motion.
 Sub press operation: Sub-press dies blank and/or form small watch, clock, and
instrument parts.
 Swaging: Swaging (necking) is the process of "necking down" a feature on a
part. Swaging is the opposite of bulging as it reduces the size of the part. The
end of a shell casing that captures the bullet is an example of swaging.
 Trimming: Trimming dies cut away excess or unwanted irregular features from
a part, they are usually the last operation performed.
 Pillar set: Pillar set are used for alignment of dies in press movement.

Steel-rule die

Steel-rule die, also known as cookie cutter dies, are used for cutting sheet metal
and softer webs, such as plastics, wood, cork, felt, fabrics, and paperboard. The
cutting surface of the die is the edge of hardened steel strips, known as steel rule.

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These steel rules are usually located using saw or laser-cut grooves in plywood.
The mating die can be a flat piece of hardwood or steel, a male shape that
matches the workpiece profile, or it can have a matching groove that allows the
rule to nest into. Rubber strips are wedged in with the steel rule to act as the
stripper plate; the rubber compresses on the down-stroke and on the up-stroke it
pushes the workpiece out of the die. The main advantage of steel-rule dies is the
low cost to make them, as compared to solid dies; however, they are not as
robust as solid dies, so they're usually only used for short production runs.

A steel-rule die

A steel-rule die

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 Steel-rule die in a press

Rotary die

In the broadest sense, a rotary die is a cylindrical shaped die that may be used in
any manufacturing field. However, it most commonly refers to cylindrical shaped
dies used to process soft webs, such as paper and cardboard. Two rules are used,
cutting and creasing rules. This is for corrugated boards whose thickness is more
than 2 mm. Rotary dies are faster than flat dies.

The term also refers to dies used in the roll forming process.

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Wire pulling

Main article: Draw plate

Wire-making dies have a hole through the middle of them. A wire or rod of steel,
copper, other metals, or alloy enters into one side and is lubricated and reduced
in size. The leading tip of the wire is usually pointed in the process. The tip of the
wire is then guided into the die and rolled onto a block on the opposite side. The
block provides the power to pull the wire through the die.

The die is divided into several different sections. First is an entrance angle that
guides the wire into the die. Next is the approach angle, which brings the wire to
the nib, which facilitates the reduction. Next is the bearing and the back relief.
Lubrication is added at the entrance angle. The lube can be in powdered soap
form. If the lubricant is soap, the friction of the drawing of wire heats the soap to
liquid form and coats the wire. The wire should never actually come in contact
with the die. A thin coat of lubricant should prevent the metal to metal contact.

For pulling a substantial rod down to a fine wire a series of several dies is used to
obtain progressive reduction of diameter in stages.

Standard wire gauges used to refer to the number of dies through which the wire
had been pulled. Thus, a higher-numbered wire gauge meant a thinner wire.
Typical telephone wires were 22-gauge, while main power cables might be 3- or
4-gauge.

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PUNCHING

Punching is a metal forming process that uses a punch press to force a tool, called
a punch, through the workpiece to create a hole via shearing. The punch often
passes through the work into a die. A scrap slug from the hole is deposited into
the die in the process. Depending on the material being punched this slug may be
recycled and reused or discarded. Punching is often the cheapest method for
creating holes in sheet metal in medium to high production volumes. When a
specially shaped punch is used to create multiple usable parts from a sheet of
material the process is known as blanking. In forging applications the work is
often punched while hot, and this is called hot punching.

Process

Punch tooling (punch and die) is often made of hardened steel or tungsten
carbide. A die is located on the opposite side of the workpiece and supports the
material around the perimeter of the hole and helps to localize the shearing
forces for a cleaner edge. There is a small amount of clearance between the
punch and the die to prevent the punch from sticking in the die and so less force
is needed to make the hole. The amount of clearance needed depends on the
thickness, with thicker materials requiring more clearance, but the clearance is
always less than the thickness of the workpiece. The clearance is also dependent
on the hardness of the workpiece. The punch press forces the punch through a
workpiece, producing a hole that has a diameter equivalent to the punch, or
slightly smaller after the punch is removed. All ductile materials stretch to some
extent during punching which often causes the punch to stick in the workpiece. In

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this case, the punch must be physically pulled back out of the hole while the work
is supported from the punch side, and this process is known as stripping. The hole
walls will show burnished area, rollover, and die break and must often be further
processed. The slug from the hole falls through the die into some sort of
container to either dispose of the slug or recycle it.

Punching Characteristics

 Punching is the most cost effective process of making holes in strip or sheet
metal for average to high fabrication
 It is able to create multiple shaped holes
 Punches and dies are usually fabricated from conventional tool steel or
carbides
 Creates a burnished region roll-over, and die break on sidewall of the resulting
hole
 It's quick

Geometry

The workpiece is often in the form of a sheet or roll. Materials for the workpiece
can vary, commonly being metals and plastics. The punch and die themselves can
have a variety of shapes to create an array of different shaped holes in the
workpiece. Multiple punches may be used together to create a part in one step.

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Extruded holes with the punch and die used to create them. No pilot hole was
used on the left.

Usually, the punch and die are close to the same dimensions, creating a sheared
edge when they meet. A punch that is significantly smaller than the die can be
used to produce an extruded hole where the punch displaces the punched
material to the sides, forming a tube perpendicular to the punched sheet.

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Equipment

Most punch presses are mechanically operated, but simple punches are often
hand-powered. Major components of this mechanical press are the frame, motor,
ram, die posts, bolster, and bed. The punch is mounted into the ram, and the die
is mounted to the bolster plate. The scrap material drops through as the
workpiece is advanced for the next hole. A large computer controlled punch press
is called a CNC turret punch. It houses punches and their corresponding dies in a
revolving indexed turret. These machines use hydraulic, pneumatic, or electrical
power to press the shape with enough force to shear the metal.

Forces

The punch force required to punch a piece of sheet metal can be estimated from
the following equation:[4]

F = 0.7tL(UTS)

Where t is the sheet metal thickness, L is the total length sheared (perimeter of
the shape), and UTS is the ultimate tensile strength of the material.

Die and punch shapes affect the force during the punching process. The punch
force increases during the process as the entire thickness of the material is
sheared at once. A beveled punch helps in the shearing of thicker materials by
reducing the force at the beginning of the stroke. However, beveling a punch will
disort the shape because of lateral forces that develop. Compound dies allow
multiple shaping to occur. Using compound dies will generally slow down the
process and are typically more expensive than other dies. Progressive dies may be

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used in high production operations. Different punching operations and dies may
be used at different stages of the operation on the same machine.

Related processes

Other processes such as stamping, blanking, perforating, parting, drawing,

notching, lancing and bending operations are all related to punching.

Plastics

Punching in plastics fabrication usually refers to the removal of scrap plastic from
the desired article. For example, in extrusion blow molding it is common to use
punching dies to remove tails, molding flash (scrap plastic) and handle slugs from
bottles or other molded containers.

In shuttle machinery, the containers are usually trimmed in the machines, and
finished containers leave the blow molding machine. Other blow molding
equipment, such as rotary wheel machinery, requires the use of downstream
trimming. Types of downstream trimming equipment include detabbers for tail
removal, rotary or reciprocating punch trimmers, and spin trimmers.

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DIE AND PUNCH DESIGN:

DIE

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SQUARE DIE

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PUNCH

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SQUARE PUNCH

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 VILET

SQUARE VILET
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CONCLUSION

After completing the project, conclude that our project is simple in construction

and compact in size for use. Manufacturing of machine is easy and cost of the

machine is less.

REFERENCES

 Degarmo, Black & Kohser 2003, pp. 430–431.

 Twede, Diana; Selke, Susan E. M. (2005), Cartons, crates and corrugated board:
handbook of paper and wood packaging technology, DEStech, p. 436, ISBN
978-1-932078-42-8.
 Soroka, Walter (2008), Illustrated Glossary of Packaging Terminology (2nd ed.),
DEStech, p. 64, ISBN 978-1-930268-27-2.
 Halmos, George T. (2006), Roll forming handbook, CRC Press, p. 4‑46, ISBN
978-0-8247-9563-4.
 Todd, Robert H., Dell K. Allen, and Leo Alting. Manufacturing Processes
Reference Guide. New York: Industrial Press Inc.1994.Pg 107.
 Peter Ulintz, Hole Extrusions--Part 1 Metalforming Magazine, Oct. 2011.
 O. D. Lascoe, 6B: Design Considerations for Stamping, Handbook of Fabrication
Processes, ASM International, 1988; page 435.
 Kalpakjian, Serope; Schmid, Steven R. (2006). Manufacturing Engineering and
Technology (5th edition ed.) p. 428.

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