PROJECT GUIDES:

Mr. M K KHAN
MANAGER(TRG)

Mr. N. S. PETER
SENIOR TRAINING OFFICER

Mr. ALBERT F. D.
 We are submitting this project as a part of
fulfillment of the course i.e. diploma in tool
and die making at Nettur technical training
foundation, Dharwad Karnataka in the year
2006-2007

SHIVSHANKAR K
UBED M B.
SAJID T
AMARESH J
CHETAN P
SHANKAR. TELI
 We are very much thankful to the
honorable persons who have guided us
properly during our project. we acknowledge
their valuable guidance by which we were able
to complete the project successfully

We express our sincere thanks to

MR.R.VENKATES
MR.M.K.KHAN
MR.ALBERT.F.D
MR.N.S.PETER

We express our thanks to Mr. K.Venugopal

(director training) who has given an
opportunity to carry out and complete project
successfully & all others who have helped
&co-operated with us in completing this
project.
• INTRODUCTION
• TOOL MANUFACTURING PROCEDURE
• OPERATION INVOLVED IN THE TOOL
• ELEMENTS OF THE TOOL
• WORKING OF THE TOOL
• HEAT TREATMENT
• QUALITY ANALYSIS
• ESTIMATION
• ASSEMBLY &COMPONENT DRAWING
• INSPECTION REPORT
• PROCESS PLANNING
• BIBILOGRAPHY
• CONCLUSION
NTTF started in the year 1964,with the
heks Swiss contact society of Swiss in
the press tool moulds &jigs &fixtures
Where the trainees are trained
systematically in the both practical
&theoretical knowledge with the
advanced AutoCAD, PRO-E, UG,
CNC &other latest technology .
We the trainees of diploma in tool
&die making of NTTF Dharwad are
presenting this project on the actuator
clip tool.
Progressive tools are the press
tools in which two or more
stations are incorporated under
each stations one or more
operations will take place. in this
the trip must move from first to
the last stages to produce
complete component.
In progressive tools, in
between the working station idle
stations may also be incorporated
on the die to simplify the die
construction or to provide
sufficient strength to the die.
ADVANTAGES:
1.The biggest advantages of the
progressive tools lies in the fact that the
components remains as an integral part of
the strip till the last stations, this
facilitates easy feeding of the strip from
one stations to another
2.Greater accuracy than using a number of
single stage tools.

DISADVANTAGES:
1.Since progressive tools have more
working stations the skilled involved in
maintaining the accuracy between the
station is greater.
2.Higher tool maintenance cost.
3.Higher material wastage due to certain
restriction in strip layout.
DIFFERENT TYPES OF OPERATIONS
CARRIED IN PRESS TOOLS:
In addition to piercing &
blanking various other
shearing &non shearing
operations can be carried
out in press tools. they are:
SHEARING OPERATION:
* NOTCHING
* PARTING OFF
* LANCING
* SHAVING
* TRIMMING

NON SHEARING
OPERATIONS:
* BENDING
* FLANGING
* COINING
* EMBOSSING
* DRAWING
* CURLING
THE FOLLOWING OPERATIONS ARE USED IN
THE PRESS TOOLS:
1.BLANKING

The operation of cutting or shearing the

piece of stock to predetermining counters is
blanking. in blanking a flat stampings are
produced and entire periphery cutout pieces is
called blank .

2.PIERCING
The operation of cutting or shearing a
piece out of stock predetermining counters is
called piercing. is done to inside counter of the
components.

3.PILOTING
It is the operation a pin or projection will be
provided for location work in subsequent
operation from a previous counters for higher
accuracy.
4.NOTCHING
It is a operation where various shapes
made to cut from edge of the strip, blank or
part.
5.CUT-OFF
It is usually used in finely stage of the
tool, to separate component from the strip
where no scrap or waste is obtained.
6.BENDING
Bending is the operation of causing
deformation to sheet metal in a straight line
along, across or in angle to its side to obtain a
new configuration in bending. the
deformation is a single plane only.
7.FORMING
Forming in general , refers to all
operation that impart a change of shape to
blank or component without causing change
in thickness .
ELEMENTS OF THE PRESS TOOL:

PUNCH & DIE

PUNCH HOLDER
THRUST PLATE
STRIPPER
TOP PLATE &BOTTOM PLATE
SHANK
STOPPERS
GUIDE PILLAR
SCREWS & DOWELS
GUIDE BUSH

DIE PLATE:
Die plate is one of the main
object of the tool. it is having cavity opening
for producing component shapes die plate is
made of superior non shrinking tool steel and
hardened up to 60-62HRC
 PUNCHES
CUTTING PUNCHES:
They do the operations like blanking ,
piercing, notching, trimming, etc.

NON-CUTTING PUNCHES:
They do the operations like bending
,forming, drawing etc.

DIE –PLATE
It is the most important element of
the tool. this is mounted on the
bottom plate. die punch plate is the
cutting element of the tool which gives
the blank size & shape. this is made
out of high carbon high chromium
material . It is hardened & tempered
to 60-62 HRC. Die plate thickness is
decided on the basis of stock material
being cut.
CARBIDE DIES
Tungsten carbide is used as a die
material for blanking piercing,
trimming, forming, drawing, &
swaging operations. They are used
where the production rates are high &
the parts have closer tolerances.
Carbide dies are widely used to
produce electrical laminations at lower
costs per piece compared with steel
dies.
TOOL MANUFACTURING
PROCEDURE:

THE METHOD OF MANUFACTURE DEPENDS

UPON THE SIZE AND SHAPE OF PUNCH &DIE.
CYLINDRICAL PUNCHES AND
CORRESPONDING DIES/ INSERTS CAN BE
MANUFACTURED EASILY ON LATHE AND
CYLINDRICAL GRINDER,AND ASSEMBLED IN
PUNCH PLATE AND BOTTOM PLATE. THE
CENTERED DISTANCE BETWEEN PUNCHES
AND CORRESPONDING HOLES MUST BE
EXACTLY EQUAL OTHER WISE THE PUNCHES
WILL NOT ENTER IN THE STRIPPER AND DIE
HOLES ALTHOUGH A LITTLE VARIATIONS
(0.01-0.02). IN CENTER DISTANCE WILL NOT
PREVENT ASSEMBLY IT WILL MAKE THE DIE
CLEARANCEAROUND THE PUNCH UNEQUAL
LEADING TO UNEVEAN BURR IN WORKPIECE.
OFFCOURSE, ALL THE CONSTITUENTS, I.E.
PUNCH PLATE &STRIPPER PLATE AND DIE
CAN BE JIG BORED SEPERATELY VERY
ACCURATELY,BUT THIS CAN INCREASE TOOL
COST IN IMMENSELY.
 MANUFACTURING
PROCESS
Manufacturing may be divided into two parts
1.Part manufacturing
2.Aseembly

PART MANUFACTURING;
we machined all the parts as per the
drawing, grounded and kept allowances for all the
plates requiring hardening. Then we did the required
finishing operations.

2.DIE SET ASSEMBLY

A two pillar die set was selected as in
progressive tool the force exerted on the punch is
more.
We machined top plate and bottom plate our
self.
According to the drawing the holes were
bored by CNC milling machine.
After boring the plates were taken to
inspection and bored dimensions were noted down.
The bushes were turned and sent for hardening .Back
of hardening the pillars and bushes were sent for
cylindrical grinding
 After hardening the sub assembly of the
die set was completed by fitting them in
there positions

3.Sub assembly

The alignment of the punch and die

was checked by keeping the shim equal to
the sheet thickness that is 0.4mm.
the punches were kept over the die
inserts and checked for the clearance, when
found correct the hole from the punch
transferred to punch holder and assembled
later.
 SUBCONTRACT REPORT:
After making references by the
grinding, the punches and tool elements were
sent for wire cutting.
WIRE CUTTING
DETAILS
First we did the all the primary
operations for the plates and punches. Next
these elements were sent for hardening and
tempering. For wire cutting the tool elements
were taken to BUSHAN Tooling private
limited, Bangalore.
The wire cutting was done based on
the data provided by the designers in CADD.
SURFACE GRINDING
DETAILS
As the size of the most of the plates
of the tool was vary large and it could not be
accommodated on our machines. So the
plates were sent for surface grinding to a
near by industry.
 ELEMENTS OF THE
TOOL
1.TOP PLATE
Top plate is the made up of
mild steel. It is the top most portion
2.BOTTOM PLATE
This plate gives cushioning
effect as well as provides enough surface for
the tool to be clamped on the press bed.
Progressive die is mounted on this plate .The
parallel blocks are clamped under this plate.
3.PUNCH HOLDER
This plate is also called punch
plate. All the punches are accurately held in
this plate. This plate should be thick enough
to accommodate punches perpendicular. This
made out of MS
 4.PUNCH
This is the cutting element of
the tool. Punch gives the hole size
&component shape. This made out of
HCHCr material. Punches are hardened &
tempered to 58-60 HCR.The punch of the
length in normal position is kept up to 60mm.

5.DIE PLATE
This is most important tool
element. This is mounted on bottom plate Die
plate is the cutting element of the tool which
gives the blank size and shape. This is made
out of HCHCr material. Dies are hardened &
tempered to 60-60 HRC.Die plate thickness is
bases of stock material being cut.

6.BACK PLATE
This plate is known as thrust
plate. This plate is mounted on top of punch
holder. It is made out of medium carbon
steel. It is hardened &tempered to 45-
48HRC. Punch heads have direct contact with
this plate, which will prevent the penetration
to the top plate during punching operation.
 7. PILOT
The pilot positions stock strip
in relation with die openings. Usually the
strip is over fed then the actual pitch length.
When the press moves down the pilot comes
down and engages the pre pierced hole, thus
dragging the strip back into theregestry
position.
8.BENDING PUNCH
Bending punch deforms
portions of flat blanks to some positions, the
line of bend straight along its length.
9.SHAVING PUNCH
It is the operation of removing
small amount of material from around the
edges of the blanks or hole.
10.STRIPPER PLATE
The main function of the
stripper is to strip the stock material from the
punches after each stroke. In addition the
stripper may act as guide the punches
 11.STOPPER
After each and every stroke of the
press the strip has to fed forward for one
pitch length. This can done by means of
stopper. It is made up of EN31 material,
hardened tempered up to 45-48 HRC.

12.SETTING BLOCK
These are provided to arrest the
further downward movement of the top half
of the tool. The function setting block is to
prevent further damage of tool.

14.STRIP LIFTER
It is used to lift the strip parallel to
the die surface to accommodate easy feeding
due to the cam bending operation. It is made
up of D2 material and tempered 52-56HRC
 15.CAMASSEMBLY
It is due to force by means of
its profile. Here the cam was used for
bending operations eight stage. A a sliding
fit is maintained between cam and cam
holder. In the bottom plate the movement of
cam through the cam holder channel is the
restricted by using dowel at one end. It
contains bending punch along with cam
retainer. the other end of the cam lies of the
cam retainer. a knocking punch is threaded
to the top plate and its length can be adjusted
by using cam nuts. material of the cam is
En31 hardened up to 54-56 HRC
as soon as the
tool is closed that cam actuator comes and it
hits the cam which the results in the upper
movements of the bending punch. When the
actuator looses its contact the cam during the
rivers stroke of the press cam comes back to
the original position with help of spring.
 16. GUIDE PILLAR:
GUIDE PILLARS PRECISION GROUND
WHICH ARE press fitted accurately bored holes in
the stripper plate. They engages the die bushing to
align punch and die components with a high degree
of closeness and accuracy

17.GUIDE BUSH
guide bush are accurately ground sleeves
which are use to align the guide pillars.

18.STANDERD ELEMENTS
Standard elements like screws,dowels,grub
screws supplied by the customer.
•Even though the plastic is
replacing the sheet metal, the
sheet metal is also playing very
important role in the industries .
The demand for the tools occupy a
major field of sheet metal toolings
which gives components at
economic rates.
•The under taken project work
involves manufacture of 18 Stage
Progressive Tool for Actuator Clip
component for ABB. This
manufacturing process involves the
designing, manufacturing,
inspection, assembly & trial. It
gives insight to various difficulties
faced by us & the solutions which
we have adopted
• The ACTUATOR CLIP is
the component which is used in the
PRODUCT DETAILS
•Component Name:- ACTUATOR CLIP

•Is There Any Sample Reference :- No

•Material Of The Component :- Brass

•Shear Strength :-

•Thickness Of The Component :-0.4mm

 PRESS TECHNICAL
DATA
The first and foremost consideration for
choosing a press is
the tonnage required for the operation of press
Tool, similarly the table
size, throat, stroke and shut height of the press
should suit the press tool. We can mount and
operate a Press Tool if the above requisites are
met.

Always a Tool is manufactured only after

considering the type of press.
A standard specification of the press is:

1)Type of constructions: Cast steel or welded steel.

2)Power source: Manual, mechanical, or pneumatic

3) Operating speed: Low, medium or high speed.

4)Type of frame: Gap frame, straight sided or

“C”frame.
5)Capacity of frame :10tons, 20 tons, 40 tons, 80 tons,
100 tons etc.

6)Size of the bed : 450x710, 560x710, 560x900.

7)Facilities available :Strip straighter, feeding
equipment, safety switches etc.
 DESIGN
CALCULATION

1) CUTTING FORCE
Cutting force is that force which has to
act on the stock material in order to blank or
slug.This determines the capacity of the press to
be used for the particular tool.

Cutting force = L x S x Tmax.

L-length of periphery to be cut in

mm. =
S-stock thickness in mm.
= 0.4 mm
Tmax – shear strength in N/mm2
=

Cutting force =
=
Press force =Cutting
force+Stripping force

(20%of cutting force)

=
 2) CUTTING
CLEARANCE:

Cutting clearance is the gap

between a side of a punch and the
corresponding side of a die opening on
one side of the edge, when the punch is
entered into the die opening. Therefore the
cutting clearance should always be
thought of and expressed as the amount of
clearance per side.

Cutting Clearance =C X S X (T max/10)

= 0.005x0.4x()
= mm/side
 3) SCRAP BRIDGE:

Side bridge = 1.2 x sheet

thickness
= 1.2 x 0.4mm
= .48mm

4) ECONOMY FACTOR:
Stock material conservation being a
decisive factor in press working, the tool
designer should try out every possible means to
attain this, without sacrificing the accuracy
requirement of the piece part. Economy of any
layout in percentage of the are of the strip is
found out by the following formula.

Economy Factor =Area of blank x100xNo. of

rows
Pitch x width
 SHEARING
THEORY:
The name shearing stands for the
method of cutting sheets or stocks
without forming chips. The material is
stressed in section which lies parallel
to the forces applied. The forces are
applied either by means of shearing
blades or punch and die. The force
necessary to bring rupture of the
material depends primarily upon the
shearing strength and stressed section
or the stressed area and secondly upon
the shape, condition and position of
the shear blades.
 Critical stages of
shearing
STAGE 1:

The pressure applied by the punch on the stock

material tends to deform into the die opening when the
elastic limit is exceeded by further loading, a portion of
material will be forced into the die opening in the form of an
embossed pad on the lower face of the material and will
result in corresponding depression on its upper face. This
stage imparts a radius on the upper edge of the opening in
the strip and on the lower edge of the punched out
material, this is called the stage of
plastic deformation.
 STAGE 2:
As the load further increased, the punch
will penetrate the material to certain depth and
fotce an equality thick portion of metal into the
die. This satge imparts a bright polished finish
(cut band) on both, the strip and blank or slug.
This is the

penetration stage .
 STAGE 3
In this stage fracture will start from both
upper and lower cutting edges. As the punch
travels further, these fractures will extend
towards each other and eventually meet, causing
complete separation. This stage imparts a dull
fractured edge. This is the fractured stage.
 HEAT TREATMENT

Heat treatment is a process of heating and

cooling the metals under definite condition to
change their properties according to the process
used, steel can be hardened to resist cutting
action, scratching, indentation or penetration by
other materials. In some cases steel are softened
to permit further machining.

In this process internal stresses can be

removed from the metals and grain structure may
be altered.The metals are made more resistant to
wear, heat and corrosion.

The process involved in heating

treatment:

Heating: Steel is heat treated to temperature

called austenising
temperature i.e. above 723c.
Soaking: The steel is held at this temperature for
a period of time. This period is called
as soaking period. This results in formation of
homogeneous austenite.
Cooling: Then steel is cooled back to a lower
temperature at a
particular cooling rate to obtain desired
properties.
 HARDENING:

PURPOSES:
i.To increase the
hardness.
ii.To increase cutting
ability.
iii.To increase wear
resistance.

PROCEDURE:
After reaching the required temperature
the steels are soaked. After soaking, the steels
are cooled rapidly to room temperature
exceeding the critical cooling rate. Due to fast
cooling the austenite is converted into
martensite which is a very hard phase.
Therefore hardened steels will possess high
hardness and brittleness.
Steels are quenched usually in water,oil or salt
solutions. Complicated shapes of steels should
be quenched in oil to avoid cracking and
distortion. Low alloy steels are quenched in oil
and high alloy steels are quenched in forced
air.
Successful hardening requires
following two conditions.
Formation of homogeneous
austenite.
Rapid cooling of steels in
suitable media.
 TEMPERING :

The structure of the steels after

hardening is not suitable for engineering
applications. Therefore structure of steels
should be improved.It is done by the means of
tempering.
It may be defined as heating the steels
to a temperature below the lower critical
temperature slowly to get a desired
combination of hardness and toughness. All
hardened steels must be tempered after
hardening immediately.
PURPOSES:

i.To avoid failure of steel by

cracking.
ii.To remove the internal
stresses produced during
quenching.
iii.To avoid change in
dimensions and properties of
steel.
 NORMALISING:

• PROCEDURE
It is similar to annealing process. But
there is a slight change with respect to cooling.
The usual normalizing temperature is between
800ºC-930ºC. The holding time at this temp is
½ hr to 2hrs. After this steels are cooled to
room temperature. Since air cooling is faster
than the furnace cooling this process is quicker
than annealing Therefore normalised steels
will have finer pearlite, more hardness, more
strength and toughness than annealed steels.

• PURPOSES:

To improve the machinability

of low carbon steels.
To obtain the desired
microstructure and mechanical
properties.
To refine the grain size.
To homogenize the
microstructure.
 TEMPERATURES:

For hypoeutectoid steels 820-870ºC.

For hypereutectoid steels - 790º -- 840ºC.

• PURPOSES:

i. To make the steels soft and reduce

hardness.
ii. To relieve internal stresses.
iii. To improve machinability.
iv. To restore ductility.

• TYPES

i. Box annealing.
ii. Bright annealing.
iii. Stress relief annealing.
iv. Spheridise annealing.
v. Isothermal annealing.
vi. Process annealing.
 1)TOOL DESIGN PROCEDURE
STUDY OF THE COMPONENT

The first step in the design

procedure is to define the
problem in a clear and simple
statement of the functional
needs. The Tool Designer will
receive the part print,
information, why the tool is
needed? What capabilities the
Tool must be of? What type of
machine tool must be used? The
number of parts to be produced
and other pertinent information
concerning the part.
 2)CONCEPT DESIGN.

The research and sketches

should be combined into one or two
tentative design solutions, which
may consist of rough working,
showing the side and top view and
perhaps one end view if needed.
An isomeric or perspective sketch
may be made if desired although
the Tool designer is not as
concerned with visual aspects of the
design decided upon
 3) DESIGN
CONSIDERATIONS.

Before staring any design

some major considerations are
required to be made which can
solve majority of the problems
while designing the Press Tool,
Mould, Jigs and Fixtures.
Considerations are as follows.
 4) MANUFACTURING
CONSIDERATIONS.

In any design, manufacturing process

should be easy, simplified and majority of the
operation should be carried out in-house.

Last but never the least it is very

much necessary to think about the
maintenance of tool. If due to any reason
some parts break then it should be easily
manufactured in short times, idle time is
reduced.
 1
5

PARALLEL BLOCK 02
BOTTOM PLATE 01
STIPPER RET.PLATE 01
TOP PLATE 01
TOP PARALLEL 01
PUNCH HOLDER 04
CAM HOLDER 01
EXT.TABLE 01
EX.TABLE HOLDER 01
SHANK 01
 2
5

TRANSFER GUIDE 01
TRANSFER PIN 01
DIE BACK PLATE 04
PH.BACK PLATE 04
PUNCH BLOCK 01
STRIPPER INSERT 04
SETTING PLATE 03
KNOCKING PUNCH 01
CAM 01
EXT.GUIDE 02
STRIP GUIDE 06
 3
5

DIE INSERT 04
GUIDE PILLAR 04
GUIDE BUSH 04

BALL CAGE 04
SETTING BLOCK 02

WASHER 50
DIE BUSH 05
STRIP GUIDE BUSH 05
PIERCING PUNCH 06
PITCH CUTTER 01
 4
5

PROFILE PUNCH 11
LIFTER 10
COININGPUNCH 02

THRUST PIECE 02
INDENTOR 01
PILOT 15
ANG.FORM DIE 02

PRE-FORM DIE 01

ANG.FORM PUNCH 02

PRE-FORM PUNCH 01
 5
5

BENDING DIE 06
CARRIER 01
BACK PLATE 14
BENDING PUNCH 06
DOWEL BUSH 24
SPRING WASHER 04
PILLAR HOLDER 04
CONECTING HOLDER 01
LOCATING PIECE 01
STANDARDS
 TOP PLATE:
QUANTITY : 01No.
MATERIAL : Mild steel.
SIZE :
30X180X240mm
MACHINING : Premachining,
Grinding,
OPERATION CNC spotting
boring,
bench work
HARDENING : Not required
FUNCTION : The punch
and the
punch
assembly is
clamped to
the top plate
and also the
shank
is fixed to
the top plate
CRITICAL DIM : Guide bush
holes
(H7/g6fit
and pitch)
 BOTTOM PLATE

QUANTITY : 01No
MATERIAL : Mild steel
SIZE : 36x180x240mm
MACHINING : Premachining,
Grinding,
OPERATION CNC spotting
boring,
bench work
HARDENING : Not required
FUNCTION : It is the base plate
on which
whole bottom
assembly is
mounted and it
should have
sufficient
thickness to with stand
the load.
CRITICAL DIM : Guide pillar holes
and
pitch (H7/p6 fit)
 PUNCH HOLDER:

QUANTITY : 04No.
MATERIAL : Mild steel.
MACHINING :
Premachining,Grinding,
OPERATION cavity milling,
bench work
HARDENING : Not required
FUNCTION : It holds the
punch
in exact
position
CRITICAL DIM :Cavity
dimension,
(H7/k6 fit)
 PUNCH:

MATERIAL :D2
MACHINING :Premachining,
Grinding, profile OPERATION
milling & grinding, bench work
HARDENING :58-60 HRC
FUNCTION :Main element of
the tool
which bends the
required
length of
component
GUIDE PILLAR:

MATERIAL : EN30
MACHINING : Premachining,
Cylindrical OPERATION
Grinding, bench work
HARDENING : CH52-55 RC
FUNCTION : To align the top
assembly
with bottom
assembly
GUIDE BUSH:

MATERIAL :EN30
MACHINING :Premachining,
Cylindrical
OPERATION Grinding,
internal
Cylindrical
Grinding
HARDENING :CH52-55 RC
FUNCTION :To align the
top assembly
with bottom
assembly
DIE PLATE :

MATERIAL : D2
MACHINING
:Premachining, Grinding,
OPERATION cavity milling,
3-d .
profile
milling,
bench work
HARDENING :60-62 HRC
FUNCTION :It’s also a main
element
of the tool which
does
the cutting
operation
CRITICAL DIM :Cavity
dimension
•Increasing the stock material thickness,
increases the severity.
•Increasing the bend angle increases the
severity.
•Decreasing the bend radius increases the
severity.
•The bend angle is the angle included
between the two extreme positions of the
bend radius. It originates at the bend axis.

0.5T
T -
0.33

T BEND AXIS

90°
BEND LINES
90°
R

OUTER SURFACE INNER SURFACE

BEN BEND ALLOWANCE

DA
BEN REA
DA
NGL
E
The Principle of Bending involves:

• Selection of material of length equal to

neutral fiber.
• Stressing it beyond elastic limit,

PLASTIC DEFORMATION DUE

TO BENDING
4 METHODS to OVERCOME SPRING
BACK
in ‘V’ BENDING DIES
•Over Bending
•Corner Setting
•Offset Punch Method
•Angular Punch Relief
ƒ Estimation or estimating is an
art of the cost, which is likely to
be in cured on the manufacture
of an article, before it is actually
manufactured.
ƒ Thus it is the calculation of
the probable cost of an article
before the manufacturing status.
ƒ In estimation, the profit or
loss of an article can be
determined before the article is
manufactured. It is also involves
predetermination of the quantity
machine time, labour required
etc.
ƒ
 Ø Estimation helps in
deciding the manufacturing and
selling policies.
Ø Estimation also helps in
filling up the tenders.
Ø A particular material
should be purchased from the
market or to be manufactured
can be decided in estimation.
Ø Estimation helps in
modification of design.
Ø Estimation helps in
modification of design amount
of overheads.
RAW MATERIAL
The cost of the raw materials used
in manufacturing of a tool is called as the
material cost. The material cost is divided
as direct and indirect material. The material
cost is that which becomes part of the Tool.
It is the material which can be measured
and charged directly to coat of the tool like
bottom plate, top plate, die and punch etc,
the in direct material cost is the one which
can not be traced has part of the tool, like
cotton waste, coolant etc.

MACHINING COST

The machining cost is calculated by

estimating the machine time taken during
each manufacturing process for each part
of the Tool and each machining operation
has its own cost and is calculated in
rate/hour.
 OVERHEADS

Some expenses such as factory render,

insurance, depreciation, salaries of staffs, maintenance
of plant, repair charges are indirectly involved in the
manufacturing of a Tool. These are called overheads
and they will vary according to the volume of output.
BEFORE TAKING THE TOOL
FOR THE TRYOUT
Following points need to be followed in order:

Never mount the Tool in press, which is

not suitable for testing particular tape of
i.e., the Tool size should be with in press
specification
Prior to mounting the Tool make sure
that the press is in good working order and
has necessary safety guards and
accessories, its safety devices are in order,
and the clearance in slide guides are
properly adjusted.
Clean the press‘s bed and mount the
Tool
Always use mechanical handling
devices to mount heavy weight Tools
Don’t mount the press Tool on the
press unless the distance between the two
bolster plate (fixed half and movable half)
of the press is more that the shut height of
the Tool.
 Secure the Tool in the press reliably using, T-
nuts, clamps, bolts &
washers.
Adjust the stoke and daylight of the Tool as
necessary for the operation.
Carry out the tryout and collect the samples
inspection of the samples will be done and if all of
them of under the dimensional requirements then the
Tool is ready for production purpose and if there is
some deviation then re-work has to be done and again
tryout operation to be repeated.
ƒ Inspection is a means
of measurement of quality by using
some prescribed standards such
hardness tensile strength,
dimensional accuracy; wear
resistance, surface finish, chemical
composition and functional
requirement.
ƒ The philosophy of
inspection in only “Preventive” and
not “remedial”. The short inspection
is the method of measuring and
checking the quality of teams of
specified standards.
Master file - NTTF

Tool Design - Cyril.Donaldson

Basic Die Making - EugenEOstergards

Die design Handbook - F.W.Wilson

 *CONCLUSION*
In the project work , the designing
and manufacturing is done for only one stage
press Tool for. PRAB ENGINEERS HUBLI.
Economical manufacturing process are
suggested by keeping in view with the in
house facilities, and the Tool is designed to
meet the specification OF the press.
The Tool can also be designed and
manufactured without any of the above
analysis but success and economy of Tool is
not assured.
Completion of this project report has
gained us a great confidence and knowledge
and great experience in Tool designing, Tool
manufacturing estimation and costing etc
this project report highlight some of the main
subjects which are very important for a Tool
making in this day today life last but not
least, this project will be a future reference to
us.
 WORKING OF THE
TOOL
The working procedure of the tool is as
given below:-
STAGE# 1
Pitch cutting & also piercing (dia.3) for the piloting hole
takes place.
STAGE # 2
Piloting, coining & piercing (dia.2 x 4nos.) is done in this
stage.
STAGE # 3
Piloting & profile piercing is done in this stage.
STAGE # 4
Piloting, piercing & profile piercing takes place when the
strip is stopped at this stage.
STAGE # 5
In this stage only piloting is done.
STAGE # 6
Piloting & profile piercing is done here.
STAGE # 7
This stage is same as the previous one where piloting &
profile piercing happens.
STAGE # 8
In this stage FORMING takes place along with piloting.
This is the stage from where the component starts getting
its shape.
STAGE # 9
Only piloting is done here.
 STAGE # 10
The tenth stage is for the piloting & PRE-FORMING up
to a depth of 0.4mm to take place. The shape is got by
the mating punch & die.
STAGE # 11
Only piloting takes place here.
STAGE # 12
In this stage, UPWARD BENDING is done with the help
of the bending dies acting from bottom mounted on
the carrier actuated by a spring loaded CAM. Piloting is
also done.
STAGE # 13
Only piloting takes place here.
STAGE # 14
PROFILE PIERCING is done to give the outer shape to
the 2 consecutive components.
STAGE # 15
Here ,the PRE-BENDING of the 45 degrees bend is
done against a punch & die.
STAGE # 16
Here ,the FINAL BENDING of the 45 degrees bend
takes place.
STAGE # 17
This is an IDLE stage.
STAGE # 18
The final stage of the tool where PARTING-OFF is done
to produce 2 components , which were earlier joined
by the scrap bridge.
 WORKING OF THE
TOOL
The working procedure of the tool is as
given below:-
STAGE# 1
Pitch cutting & also piercing (dia.3) for the piloting hole
takes place.
STAGE # 2
Piloting,coining & piercing (dia.2 x 4nos.) is done in this
stage.
STAGE # 3
Piloting & profile piercing is done in this stage.
STAGE # 4
Piloting, piercing & profile piercing takes place when the
strip is stopped at this stage.
STAGE # 5
In this stage only piloting is done.
STAGE # 6
Piloting & profile piercing is done here.
STAGE # 7
This stage is same as the previous one where piloting &
profile piercing happens.
STAGE # 8
In this stage FORMING takes place along with piloting.
This is the stage from where the component starts getting
its shape.
STAGE # 9
Only piloting is done here.