FORMING DIE DESIGN AND MANUFACTURINF OF STRAP AND SPRING SEAT

By :Makarand Godse Pranav Joshi Anuj Rege

Under the guidance of :Prof. R.J.Chaudhari

Carried out in :- Autoline Industries Ltd.

Problem Statements
Design a die for component strap, of material E34, for a screw jack to be assembled
A component of thickness 3.8 mm of material E34, is to be manufactured for holding the spring on an axle of 0.75 ton capacity truck. The press tool is to be designed for the given dimensions

Component Strap

Component Spring Seat

Objective Of Project
The specific objectives of the project are: To study the component drawing of sheet metal given by the Autoline Industry accordingly design the type of die. Based on the component drawing and die, design and model the press tool with the help of CAD Software. Carry out Component Analysis. Manufacturing of the forming die. Cost analysis of die & component.

Design Procedure Of Forming Die

Determination of force (press tonnage) required for the operation.
Press Tonnage = Perimeter * Thickness = 19.905 ton. = 20 ton (approx.)

Selection of press for requisite force, work piece size and shape.
Mechanical press of 50 ton capacity.

Determination of shut height of the tool.

Shut Height = 210mm

Design Procedure Of Forming Die

Selection of die hardware

.
.

Allen Screws 24, Dowel Pins 14 Size: M8.

Drawing die plan and selection of pillar die set.

Diagonal die post set is selected

Deciding punch length and mounting.

Punch Height = 71.2mm, Attached directly to top plate by 4 Allen screws, 2 Dowel pins

Finding centre of pressure.

Design Procedure Of Forming Die

BENDING FORCES
Force = 1.33 L * Sut * t / w = 9.248 KN where L = Developed Length =366mm Sut = Ultimate Tensile Strength =40 N/mm 2 t = thickness = 3.8mm w = width between 2 contact pts on die = 8t = 30.4

BENDING ALLOWANCE
B = * 2 * pi * (r + k) / 360

20.57 mm for R= 11.2 Degree 17.57 mm for R= 9.25 Degree 10.83 mm for R= 5 Degree

SPRINGBACK
For Low carbon steel = 1 to 2 Degree

STRIP LAYOUT

Layout 1 No of components - 150 (Selected) Front scrap = Back scrap = 4 mm (Std.) Bridge = 4 mm Feed = 164 mm

Layout 2 No of components 140

Manufacturing of Forming Die

Manufacturing of Die/Punch/Pad. Operations performed:
Milling Operation Plain Milling, Face milling Surface Grinding Drilling Jig Boring Tapping CNC Machining Hardening up to 58 to 60 HRC

Manufacturing of Die
Manufacturing of Top Plate/ Bottom Plate. Operations Performed:
Milling Operation Surface Grinding Drilling Jig Boring Tapping Gas Cutting

Manufacturing of Die
Manufacturing of Guide Bush/ Guide Pillar. Operations Performed
Facing Turning Cylindrical Grinding Case Hardening 1 1.5mm depth

Cost Analysis Of Die

Cost = (Weight of part * Current cost of material in the market)/10 6 Weight = Volume * Density Example :- Top Plate volume = length * width * thickness = 450 * 300 * 50 = 6750000 mm3 Density (Mild Steel) = 7.86 g/ cm3 Hence,

Weight = 53.055 Kg Rate Of M.S in market = 65 per Kg

Cost Of Top Plate = Rs. 3448.58

Cost Analysis Of Component

Cost analysis of component : Sheet Size = 3.8 * 2500 * 1250 Sheet Weight = Volume * density = 93.22 Components per sheet = 130 Component Wt/Pc = 0.72 Raw Mtl. Rate = 31.10 Gross Mtl. Cost/Pc = 22.30 Blank Size = 190*122 Scrap Rate = 0.326 Scrap Rate = 18 Scrap Recovery/Pc = 5.87 Final raw material cost of component = 22.30 5.87 = 16.43

Cost Analysis Of Component

Conversion Costs Shear = 0.35* 16.43 = 0.25 Blanking = 0.48 Pierce = 0.12 Form = 0.48 Cam Notch = 0.48 Restrike = 0.28 Debure = 0.40 * 0.391 = 0.40 TOTAL = 2.25 Inventory carrying cost (1.5%), Labor overheads(10%), Rejection(0.5%) Profit(10%), Transport(1.5%)

GRAND TOTAL = 21.39

Analysis Of Component
Tryout was carried out on the forming die for spring seat. Blank for the component was obtained by wire cut. Blanking Die was suggested. Problems observed after forming of the blank were wrinkles on the bend radius, which are in permissible limits. Bulging of metal occurs at the bending corners, which is in permissible limits. for elimination of errors, the design of the component has been modified. Also to achieve specified tolerances, development of blank is modified. Cam notch operation is suggested.

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