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  • Tooln Die Design Part One

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    Tool and Die Design PTB 31304 Raja Aziz Raja Ma'arof Institute of Product Design and Manufacturing UniKL IPROM July 2007-2008 Sheetmetal Die Making flow sheet metal product Ordered volume volume per batch Forming machine Forming machine selection die commissioning Sheetmetal product design Dimensioning tolerances Positioning tolerances Burr direction Tensile strength (Rm) Thickness Surface pressure material content blank sheet design Cutting clearance normally 2 to 5% per side Less than 1% per side: to

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    Tool and Die Design PTB 31304 Raja Aziz Raja Ma'arof Institute of Product Design and Manufacturing UniKL IPROM July 2007-2008 Sheetmetal Die Making flow sheet metal product Ordered volume volume per batch Forming machine Forming machine selection die commissioning Sheetmetal product design Dimensioning tolerances Positioning tolerances Burr direction Tensile strength (Rm) Thickness Surface pressure material content blank sheet design Cutting clearance normally 2 to 5% per side Less than 1% per side: to

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    595 views14 pages

    Tooln Die Design Part One

    Uploaded by

    azizmaarof
    Tool and Die Design PTB 31304 Raja Aziz Raja Ma'arof Institute of Product Design and Manufacturing UniKL IPROM July 2007-2008 Sheetmetal Die Making flow sheet metal product Ordered volume volume per batch Forming machine Forming machine selection die commissioning Sheetmetal product design Dimensioning tolerances Positioning tolerances Burr direction Tensile strength (Rm) Thickness Surface pressure material content blank sheet design Cutting clearance normally 2 to 5% per side Less than 1% per side: to

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 14

    Tool and Die Design

    PTB 31304
    Raja Aziz Raja Ma’arof
    Institute of Product Design and Manufacturing
    UniKL IPROM
    July 2007-2008
    Sheetmetal Die Making flow
    Sheet metal product
    Ordered volume
    Volume per batch

    Forming machine

    Forming machine
    selection

    Sheet metal die


    design…
    Sheetmetal Die
    Blank design Design…
    Strip layout design

    Die design

    Machining

    Assembly

    Trial and trouble


    shooting

    Die commissioning
    Sheet metal product design
     Dimensioning tolerances
     Positioning tolerances
     Burr direction
     Tensile strength (Rm)
     Thickness
     Surface pressure
     Material content
    Blank sheet design
     Cutting clearance
     Normally 2 to 5% per side
     Less than 1% per side: to use fine blanking
    technology
     Bending factor / processes
     Drawing factor / processes
    Strip layout design
     Production volume (yearly, monthly)
     Type
     Single
     Compound
     Transfer
     Progressive (normally Prduction Vol >50k)
     Burr direction
    Strip layout design (2)
     Strip flow
     Scrap flow
     Product flow
     Force calculation
     Cutting
     Stripping
     Spring
     Bending
     Drawing
     Force centre point
    Cutting force (Fcut)
     Tensile strength (δ) [N/mm2]
     Shear Stress (ζ) = 0.7 – 0.9 δ
     Fcut = ζ [N/mm2] x Acut [mm2]
     Fcut = ζ [N/mm2] x Lcut [mm] x tcut [mm]
     Where:
     Acut = Cutting cross sectional area
     Lcut = Cutting length
     tcut = Material thickness
    Strip layout design (3)
     Pitch puncher
     No auto-feeder machine
     ‘U’ profile; material overcut to
    avoid obstruction of strip flow
     Based on material thickness
     Pitch stopper
     Fixed on guide fence or die
    plate (more precise)
     Web / bridge design
     Web / bridge
     Based on material thickness
     Pitch and width
     Optimise material utilization,
    ηMatlUtil (flat blank area / pitch
    area)
    Strip layout design (4)
     Bullet Casing, Mini Stapler
     One-side carrier
     Consider also:
     Burr direction
     Strip flow (on die or with spring-activated guide lifter)
     Strip over hang condition
    Strip layout design (5)
     Hinge, Door Bracket
     Centre carrier
    Strip layout design (6)
     Cap
     Two-side carrier
    Strip layout design (7)
     Opening and closed conditions
     Punches and dies
     Displacement (closed to open positions)
     Punch and blank processes
     From top preferred
     Scrap downwards
     Strip level position during forward direction
     On die plate preferred. No over hang. No guide lifter.
    Bend down on product parallel to flow (slot on die
    plate)
     At a distance above die plate. Bend on product
    perpendicular to flow. Drawing process
    Strip layout design (7)
     Force calculation
     Cutting (pierce, blank, etc.), bending, drawing
     Spring
     Stripping
     Drawing
     Return (bending, levelling)
     Strip carrier
     Stamping machine selection

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