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“Course”

SHEET METAL DIE DESIGN

Submitted by: Zia Mustafa

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Contents
INTRODUCTION TO DIE DESIGN .............................................................................. 6 1.1 DIE OR PRESS TOOL: ............................................................................................. 6 1.2 DIE BLOCK: ............................................................................................................ 7 1.3 PUNCH: .................................................................................................................... 7 1.4 TYPE OF DIES: ........................................................................................................ 8 1.4.1 BLANKING DIE ................................................................................................ 8 1.4.2 BENDING DIE .................................................................................................. 8 1.4.3 FORMING DIE .................................................................................................. 9 1.4.4 DRAW DIE ........................................................................................................ 9 1.4.5 PIERCING DIE .................................................................................................. 9 1.4.6 TRIMMING DIE .............................................................................................. 10 1.4.7 COMPOUND DIE ............................................................................................ 10 1.4.8 PROGRESSIVE DIE ........................................................................................ 11 DIE SET ....................................................................................................................... 12 2.1 DIE SET:................................................................................................................. 12 2.2 PURPOSE OF USING DIE SET: ............................................................................ 12 2.3 COMPONENTS OF DIE SET: ................................................................................ 13 2.3.1 TOP PLATE ..................................................................................................... 13 2.3.3 GUIDE PILLARS:............................................................................................ 13 2.3.4 BOTTOM PLATE: ........................................................................................... 14 2.4 TYPES OF DIE SETS ............................................................................................. 14 2.4.1 REAR PILLAR DIE SET: ................................................................................ 14 2.4.2 CENTRE PILLAR DIE SET:............................................................................ 15 2.4.3 DIAGONAL PILLAR DIE SET: ...................................................................... 15 2.4.4 FOUR PILLAR DIE SET ................................................................................. 16 2.5 SHUT HEIGHT OF THE DIE: ................................................................................ 16 BLANKING TOOL ...................................................................................................... 17 3.1 BLANKING DIE: ................................................................................................... 17 3.1.1 TOP PLATE: .................................................................................................... 18 3.1.2 BOTTOM PLATE: ........................................................................................... 18 3.1.3 BLANKING DIE AND PUNCH: ..................................................................... 18 3.1.4 STRIPPER PLATE: .......................................................................................... 19 3.1.5 PUNCH HOLDING PLATE: ............................................................................ 19 3.1.6 THRUST PLATE: ............................................................................................ 19 3.1.7 GUIDE PILLARS AND BUSHES:................................................................... 20 3.1.8 SPACERS: ....................................................................................................... 20 3.1.9 SHANK: ........................................................................................................... 20 BENDING TOOL ......................................................................................................... 21 4.1 U-BENDING DIE: .................................................................................................. 21 4.1.1 BOTTOM PLATE: ........................................................................................... 22 4.1.2 TOP PLATE: .................................................................................................... 22 4.1.3 BENDING PUNCH AND BENDING DIE: ...................................................... 22 4.1.4 PRESSURE PAD: ............................................................................................ 23 4.1.5 SHANK: ........................................................................................................... 23 4.1.6 LOCATOR: ...................................................................................................... 23 4.1.7 SUPPORT BLOCK: ......................................................................................... 23 2

PIERCING TOOL ......................................................................................................... 24 5.1 PIERCING DIE: ...................................................................................................... 24 5.1.1 TOP PLATE: .................................................................................................... 25 5.1.2 BOTTOM PLATE: ........................................................................................... 25 5.1.3 PIERCING DIE AND PUNCH: ........................................................................ 25 5.1.4 STRIPPER PLATE: .......................................................................................... 26 5.1.5 PUNCH HOLDING PLATE: ............................................................................ 26 5.1.6 THRUST PLATE: ............................................................................................ 26 5.1.7 NEST PINS: ..................................................................................................... 26 TRIMMING TOOL....................................................................................................... 27 6.1 TRIMMING DIE:.................................................................................................... 27 6.1.1 BOTTOM PLATE: ........................................................................................... 28 6.1.2 TRIMMING PUNCH AND DIE:...................................................................... 28 6.1.3 STRIPPER PLATE: .......................................................................................... 28 6.1.4 GUIDE PILLARS AND BUSHES:................................................................... 28 6.1.5 TOP PLATE: .................................................................................................... 28 FORMING TOOL ......................................................................................................... 29 7.1 FORMING DIE: ...................................................................................................... 29 7.1.1 TOP PLATE: .................................................................................................... 30 7.1.2 BOTTOM PLATE: ........................................................................................... 30 7.1.3 FORMING PUNCH AND DIE: ........................................................................ 30 7.1.4 BLANK HOLDER: .......................................................................................... 30 7.1.5 CUSHION PINS: .............................................................................................. 30 DRAW TOOL ............................................................................................................... 31 8.1 DRAW DIE: ............................................................................................................ 31 8.1.1 TOP PLATE: .................................................................................................... 32 8.1.2 BOTTOM PLATE: ........................................................................................... 32 8.1.3 PUNCH HOLDER:........................................................................................... 33 8.1.4 BLANK HOLDER: .......................................................................................... 33 8.1.5 EJECTOR:........................................................................................................ 34 8.1.6 DRAWING PUNCH AND DIES: ..................................................................... 34 8.1.7 THRUST PLATE: ............................................................................................ 35 DESIGINNG OF MAIN COMPONENTS OF A DIE.................................................... 36 9.1DESIGNING OF DIE BLOCKS: ............................................................................. 36 9.1.1 HEIGHT OF DIE BLOCK:............................................................................... 37 9.1.2 DEPTH AND RELIEF ANGLE OF A PIERCING HOLE: ............................... 38 9.1.3 DSITANCE BETWEEN PIERCING HOLE AND OUTER EDGE OF DIE BLOCK: .................................................................................................................................. 39 9.1.4 STNDARD SIZES OF THE DIE BLOCK: ....................................................... 40 9.1.5 DIE BUSHING: ................................................................................................ 42 9.2 DESIGNING OF BLANKING PUNCH: ................................................................. 44 9.2.1 SMALL BLANKING PUNCHES:.................................................................... 44 9.2.2 KEYING THE PUNCH: ................................................................................... 45 9.2.3 PUNCHES FOR LONG BLANKS OR SLOT: ................................................. 46 9.2.4 FLANGED PUNCHES: .................................................................................... 47 9.2.5 CLEARING OTHER COMPONENTS: ............................................................ 48 9.2.6 CUTTING RINGS: ........................................................................................... 49 9.2.7 SHEDDERS: .................................................................................................... 50 9.3 DESIGNING OF PIERCING PUNCH: ................................................................... 51 9.3.1 SHOULDER PUNCHES: ................................................................................. 51 3

9.3.2 GUIDING THE STRIPPER: ............................................................................. 52 9.3.3 BACKING PLATES:........................................................................................ 52 9.3.4 SET SCREWS BACK UP THE PUNCH: ......................................................... 53 9.3.5 LARGE PUNCHES: ......................................................................................... 53 9.3.6 STEPPING SMALL PUNCHES: ...................................................................... 54 9.3.7 QUILL SUPPORT: ........................................................................................... 54 9.3.8 GUIDING THE QUILL: ................................................................................... 55 9.3.9 ONE QUILL – TWO PERFORATORS: ........................................................... 55 9.3.10 SHEDDER: .................................................................................................... 56 9.3.11 IRREGULAR PUNCHES: .............................................................................. 56 9.3.12 RETAINING KEY: ........................................................................................ 57 9.4 DESIGNING OF PUNCH PLATE: ......................................................................... 58 9.4.1 PUNCH PLATE FOR SINGLE PUNCH: ......................................................... 58 9.4.2 IRREGULAR PUNCHES: ................................................................................ 59 9.4.3 KEYED PUNCHES: ......................................................................................... 60 9.4.4 INDIVIDUAL PUNCH PLATE: ...................................................................... 60 9.4.5 THICKNESS OF A PUNCH PLATE: .............................................................. 61 9.4.6 PUNCH PLATE OF A COMPOUND DIES: .................................................... 62 9.5 DESIGNING OF STRIPPER PLATE: ..................................................................... 63 9.5.1 SOLID STRIPPERS: ........................................................................................ 63 9.5.2 MACHINING OF PUNCH OPENING: ............................................................ 64 9.5.3 SPRING STRIPPERS: ...................................................................................... 65 9.5.4 SPRING RETAINED BY STRIPPER BOLTS: ................................................ 66 9.5.5 RUBBER SPRINGS: ........................................................................................ 66 9.5.6 STRIPPER FORCE: ......................................................................................... 67 9.6 PILOTS: .................................................................................................................. 68 9.6.1 PILOT SIZE: .................................................................................................... 68 9.6.2 PILOT LENGTH: ............................................................................................. 69 9.6.3 PILOT OPENING IN THE DIE:....................................................................... 69 9.6.5 BULLET NOSE: .............................................................................................. 71 PRESSES ...................................................................................................................... 72 10.1 PRESS: .................................................................................................................. 72 10.2 CLASSIFICATION OF PRESSES, ACCORDING TO ENERGY SUPPLY: ........ 73 10.2.1MECHANICAL PRESS: ................................................................................. 73 10.2.2 HYDRAULIC PRESS: ................................................................................... 74 10.2.3 PNEUMATIC PRESS: ................................................................................... 75 10.2.4 STEAM PRESS: ............................................................................................. 76 10.2.5 ELECTROMAGNETIC PRESS: .................................................................... 76 10.3 CLASSIFICATION OF PRESSES, ACCORDING TO THEIR CONSTRUCTION:76 10.3.1 C-FRAME PRESSES: .................................................................................... 76 10.3.2 O-FRAME PRESSES OR CLOSED-FRAME: ............................................... 77 10.4 CLASSIFICATION OF PRESSES, ACCORDING TO THEIR WIDTH-HEIGHT RATIO: ......................................................................................................................... 77 10.5 PARTS OF THE PRESS: ...................................................................................... 78 10.5.1 PRESS FRAME: ............................................................................................. 79 10.5.2 PRESS BED: .................................................................................................. 79 10.5.3 BOLSTER PLATE: ........................................................................................ 79 10.5.4 RAM/SLIDE: ................................................................................................. 79 10.5.5 PRESS DRIVE: .............................................................................................. 79 10.5.6 CRANKSHAFT:............................................................................................. 79 4

10.5.7 FLYWHEEL: ................................................................................................. 79 10.5.8 CLUTCH AND BRAKE:................................................................................ 80 10.5.9 DRAW CUSHION ......................................................................................... 80 10.6 CLASSIFICATION OF PRESSES, ACCORDING TO THEIR OPERATION: ..... 81 10.6.1 SINGLE-ACTION PRESS: ............................................................................ 81 10.6.2 DOUBLE-ACTION PRESS: .......................................................................... 82 10.7 PRESS OPERATING PARAMETERS: ................................................................ 82 10.7.1 TONNAGE:.................................................................................................... 82 10.7.2 SHUT HEIGHT: ............................................................................................. 83 10.7.3 STROKE: ....................................................................................................... 83

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INTRODUCTION TO DIE DESIGN
1.1 DIE OR PRESS TOOL: A tool which forms or cuts the flat sheet of metal into desired or required shape and size is called a die or press tool.

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1.2 DIE BLOCK: A die block is the part of the press tool, which has opening or cavity to receive the punch.

1.3 PUNCH: A punch is that part of the press tool, which has protrusion.

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1.4 TYPE OF DIES: According to different operations, basically there are eight types of dies. • • • • • • • • BLANKING DIE BENDING DIE FORMING DIE DRAW DIE PIERCING DIE TRIMMING DIE COMPOUND DIE PROGRESSIVE DIE

1.4.1 BLANKING DIE

A die which cuts off the piece from the metal sheet and the cut off piece becomes the finished part is called Blanking Die.

Sheet Metal strip from which Blank has been cut.

1.4.2 BENDING DIE

A die which bends the flat sheet of metal into angular shape is called Bending Die.

Flat sheet of metal

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1.4.3 FORMING DIE

A die which forms the flat sheet of metal into required shape with plastic deformation.

1.4.4 DRAW DIE

Form Part

A die which transforms the flat sheet of metal into cups, shells, or other drawn shapes is called Draw Die.

Drawn Part
1.4.5 PIERCING DIE

A die which creates the holes or any profile slot in previously blanked, formed, or drawn parts is called Piercing Die.

Piercing

Part

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1.4.6 TRIMMING DIE

A die which cuts extra portion of previously formed or drawn parts that have wavy and irregular edge is called Trimming Die.

Trim part Drawn part Scrap

1.4.7 COMPOUND DIE

A die which performs two different operations during each stroke of the press is called Compound Die. But no progression of strip is involved.

PART

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1.4.8 PROGRESSIVE DIE

Progressive dies are a mixture of various single dies operating as different stations and grouped into the same die shoe. These stations are positioned to follow a proper sequence of operations needed to produce the required part.

Blanking on Second Station Piercing_on first station

Part

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DIE SET
2.1 DIE SET: A die set consists of top plate, guide bushes, guide pillar and bottom plate.

2.2 PURPOSE OF USING DIE SET: • • • • • To increase Tool or Die life To minimize the set up time Easy maintenance of Die Accurate alignment of Punch and Die Easiness of storing

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2.3 COMPONENTS OF DIE SET:
2.3.1 TOP PLATE

The upper working member of the die set is called top plate. The punch is fastened to the top plate. The top plate is mounted to ram of the press. It is made of soft material usually Mild steel (MS).

2.3.2 GUIDE BUSH Guide bushes are precision ground bushes which are press fitted into accurately bored holes in the top plate. It is mad hard material usually High carbon steel.

2.3.3 GUIDE PILLARS:

Guide pillars are precision ground pins which are press fitted into accurately bored holes in the bottom plate. It is mad hard material usually High carbon steel.

Guide pillars and bushes are used to align the punch and die components with a high degree of accuracy.

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2.3.4 BOTTOM PLATE:

The bottom plate is lower member of the die set. The die is fastened to the bottom plate and bottom plate is mounted on the bed of the press. It is made of soft material usually Mild steel (MS).

2.4 TYPES OF DIE SETS

According to Design, there are four types of Die Sets. • • • • 1-REAR PILLAR DIE SET 2- CENTRE PILLAR DIE SET 3-DIAGONAL PILLAR DIE SET 4-FOUR PILLAR DIE SET

2.4.1 REAR PILLAR DIE SET:

Rear Pillar Die Set is used for bending dies.

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2.4.2 CENTRE PILLAR DIE SET:

Centre Pillar Die Set is used for round working area.

2.4.3 DIAGONAL PILLAR DIE SET:

Diagonal Pillar Die Set is used for progressive rectangular working area.

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2.4.4 FOUR PILLAR DIE SET

Four Pillar Die Set is used for heavier press working operation.

2.5 SHUT HEIGHT OF THE DIE:

Shut height is the distance from the bottom plate to the top of the top plate when the tool (Die) is closed position. The height of the pillars must be less than the shut height in order to ensure that the press ram will not strike against the ends of the pillars.

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BLANKING TOOL
3.1 BLANKING DIE:

A die which cuts off the piece from the metal sheet and the cut off piece becomes the finished part is called Blanking Die. A Blanking die consists of the following components.

1-Top Plate 2-Bottom Plate 3-Punch 4-Die 5-Stripper Plate

6- Punch Holder 7-Thrust plate 8-Guide pillar 9-Guide bush 10-Shank

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3.1.1 TOP PLATE:

This is the plate on which Punch Holder or Cutting Punch is fixed. The top plate holds the shank and the bushes. Top plate also absorbs the shock resulting due to the cutting action

3.1.2 BOTTOM PLATE:

It is the base of the tool. The die and pillars are fitted to this plate. The opening for the blank is made in this plate. The plate absorbs the shock resulting due to the cutting action.

3.1.3 BLANKING DIE AND PUNCH:

They are the cutting elements of a blanking tool. They are made of high carbon high steel and are hardened and tempered to 58-62 HRC.

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3.1.4 STRIPPER PLATE:

Its main function is to strip the stock scrap off the punch and to guide the punch into the die. It holds the sheet before cutting.

3.1.5 PUNCH HOLDING PLATE:

Punch is fitted to the punch holder. It is made of mild steel.

3.1.6 THRUST PLATE:

While performing the cutting, the punch will exert an upward thrust. So the punch should be backed up by a hardened (45-50 HRC) plate to avoid the digging on the soft top plate. For this purpose the thrust plate is used.

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3.1.7 GUIDE PILLARS AND BUSHES:

They are used to achieve a well guided movement of the moving part with respect to the fixed part. (Align the die and punch)

3.1.8 SPACERS:

Spacers are used for providing the space for blanks so that blanks will be come out from the die.

3.1.9 SHANK:

Shank is cylindrical component of the die which is used to clamp the upper half of the die to the ram of the press. It is screwed on the top plate.

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BENDING TOOL
4.1 U-BENDING DIE: U-Bending die is used to bend a flat sheet of metal to U-shape. A U-Bending die consists of the following components. 1-Bottom Plate 2-Bending Die 3-Pressure Pad 4-Bending Punch 5-Guide Pillar 6-Guide Bush 7-Top Plate 8-Shank 9-Locator 10-Support Block

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4.1.1 BOTTOM PLATE:

It is the base of the tool. The die and pillars are fitted to this plate.
4.1.2 TOP PLATE:

This is the plate on which Punch Holder or Bending Punch is fixed. The top plate also holds the shank and the bushes
4.1.3 BENDING PUNCH AND BENDING DIE:

Theses are the bending elements of the Die or Tool. These are the made of high carbon steel and are hardened and tempered to 55-58 HRC.

Bending Punch

Bending Die

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4.1.4 PRESSURE PAD:

Pressure Pad is a block which performs three functions. i) ii) iii) Holding the work piece during bending. Serves as bottom block for the setting the bend Acts as ejector.

4.1.5 SHANK:

Shank is cylindrical component of the die which is used to clamp the upper half of the die to the ram of the press. It is screwed on the top plate.

4.1.6 LOCATOR:

Locator is used to locate the part on die block.

4.1.7 SUPPORT BLOCK:

Support Block is used to support the U-bending.

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PIERCING TOOL
5.1 PIERCING DIE: A die which pierce the holes in previously blanked, formed, or drawn parts is called Piercing Die. A Piercing die consists of the following components. 1-Top Plate 2-Bottom Plate 3-Punch 4-Die 5-Stripper 6-Punch Holder 7-Thurst Plate 8-Nest Pins 9-Guide Pillar 10-Guide Bushes

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5.1.1 TOP PLATE:

This is the plate on which Punch Holder or Punch is fixed. The top plate holds the shank and the bushes. Top plate also absorbs the shock resulting due to the cutting action.

5.1.2 BOTTOM PLATE:

It is the base of the tool. The die and pillars are fitted to this plate. The opening for the slug/wastage made in this plate. Bottom plate absorbs the shock resulting due to the cutting action.

5.1.3 PIERCING DIE AND PUNCH:

They are the cutting elements of a Piercing tool. They are made of high carbon high steel and are hardened and tempered to 58-62 HRC.

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5.1.4 STRIPPER PLATE:

Its main function is to strip the part off the punch and to guide the punch into the die. It holds the sheet before piercing.

5.1.5 PUNCH HOLDING PLATE:

Piercing punch is fitted to the punch holding plate. It is made of mild steel.

5.1.6 THRUST PLATE:

While performing the cutting, the punch will exert an upward thrust. So the punch should be backed up by a hardened (45-50 HRC) plate to avoid the digging on the soft top plate. For this purpose the thrust plate is used.

5.1.7 NEST PINS:

The blank component is located by the nest pins before piercing

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TRIMMING TOOL
6.1 TRIMMING DIE: A die which cuts previously formed or drawn parts is called Trimming Die. A Trimming die consists of the following components. 1-Bottom Plate 2-Trimming Punch 3-Guide Pillars 4-Stripper Plate 5-Trimming Die 6-Top Plate 7-Guide Bushes

6 7 3 1

5 4 2

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6.1.1 BOTTOM PLATE:

It is the base of the tool. The Trimming punch and pillars are fitted on this plate. This plate is also made of soft material usually mild steel (MS).

6.1.2 TRIMMING PUNCH AND DIE:

They are the cutting elements of a Trimming tool. They are made of high carbon high steel and are hardened and tempered to 58-62 HRC.

6.1.3 STRIPPER PLATE:

Its main function is to hold the part before cutting.

6.1.4 GUIDE PILLARS AND BUSHES:

They are used to achieve a well guided movement of the moving part with respect to the fixed part. (Align the die and punch)

6.1.5 TOP PLATE:

This is the plate on which Trimming die is fixed. The top plate holds the shank and the bushes. Top plate also absorbs the shock resulting due to the cutting action.

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FORMING TOOL
7.1 FORMING DIE: A die which forms the flat sheet of metal into required shape with plastic deformation is called Forming die. A Forming die consists of the following components. 1-Bottom Plate 2-Forming Punch 3-Guide Pillars 4-Forming Die 5-Top Plate 6-Guide Bushes 7-Cushion pins 8-Blank Holder

5 4 3 7 2 1

6

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7.1.1 TOP PLATE:

The Forming die is fitted to the top plate. The top plate holds the shank and the bushes. This plate is made of soft material usually mild steel (MS).

7.1.2 BOTTOM PLATE:

It is the base of the tool. The Forming punch and pillars are fitted on this plate. This plate is also made of soft material. Drawing punch and dies:

7.1.3 FORMING PUNCH AND DIE:

These are the forming elements of the tool. These are made of High carbon steel and hardened and tempered (57-58 HRC).

7.1.4 BLANK HOLDER:

The purpose of blank holder is to hold the blank firmly during the forming operation to avoid wrinkles on the component.

7.1.5 CUSHION PINS:

Its function is to eject the component out of the forming punch and lift up the Blank holder.

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DRAW TOOL
8.1 DRAW DIE: A die which transforms the flat sheet of metal into cups, shells, or other drawn shapes is called Draw Die A Draw die consists of the following components. 1-Top plate 2-Bottom plate 3-Punch Holder 4-Blank Holder 5-Ejector 6-Nest pin 7-Drawing Die 8-Drawing Punch 9-Thurst Plate 10- Spring 11-Guide bush 12-Guide pillar 13-Compression spring 14-Shank 15-Setting bush

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8.1.1 TOP PLATE:

The drawing punch is fitted to the top plate. The top plate holds the shank and the bushes. This plate is made of soft material.

8.1.2 BOTTOM PLATE:

It is the base of the tool. The Drawing die and pillars are fitted on this plate. This plate is also made of soft material.

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8.1.3 PUNCH HOLDER:

This is the plate which holds the punch. It is usually made of mild steel. This punch holder is located and clamped on to the top plate.

8.1.4 BLANK HOLDER:

The purpose of blank holder is to hold the blank firmly during the drawing operation to avoid wrinkles on the component.

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8.1.5 EJECTOR:

Its function is to eject the component out of the draw die. This plate is connected to the die cushion of the press or spring loaded plate.

8.1.6 DRAWING PUNCH AND DIES:

These are the drawing elements of the tool. These are made of High carbon steel and hardened and tempered (57-58 HRC).

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8.1.7 THRUST PLATE:

During the drawing operation the drawing punch tends to dig into the top plate. To prevent this hardened plate or thrust plate is placed between the punch and the top plate.

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DESIGNING OF MAIN COMPONENTS OF A DIE
9.1DESIGNING OF DIE BLOCKS: There are four factors which will influence design of the die block for any particular die. They are: i) Part size ii) Part thickness iii) Complexity of part contour iv) Type of die. • • Small dies have a solid block. Large die blocks are made in sections for easy machining, hardening, and grinding.

This is an actual photograph of a die block for large piercing die. Large die blocks such as this one are composed of sections for easier machining, hardening, and grinding.

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9.1.1 HEIGHT OF DIE BLOCK:

Height of die block B can be calculated by the following table.

Strip thickness 0 to 1/6 1/16 to 1/8 1/8 to 3/16 3/16 to 1/4 Above 1/4

Die block height B 15/16 1-1/8 1-3/8 1-5/8 1-7/8

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9.1.2 DEPTH AND RELIEF ANGLE OF A PIERCING HOLE:

Section C-C shows the method of machining the die hole and the piercing punch holes. Straight land M is 1/8 inch (3.175mm). Angular relief N is made according to values given in the table. Hole O in the die set is 1/8 inch larger than opening P in the die block to provide 1/16 inch clearance per side.

Strip thickness 0 to 1/6 1/16 to 3/16 3/16 to 5/16 Over 5/16

Angular Relief N 1/4 o 1/2o 3/4o 1o

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9.1.3 DSITANCE BETWEEN PIERCING HOLE AND OUTER EDGE OF DIE BLOCK:

The minimum distance A from die hole to the outer edge of the die block is normally 1-1/8 the thickness of the block B, but this would be increased to 1-1/2 times die block thickness for the larger dies. For very large dies and thick material strip, dimension A might well be made twice the thickness of the die block.

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9.1.4 STNDARD SIZES OF THE DIE BLOCK:

The following table shows the most commonly used sizes of die blocks for small dies.

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The following table shows the most commonly used sizes of die blocks for medium size dies.

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9.1.5 DIE BUSHING:

Hardened die bushings commonly used in large dies where piercing occurs. They conserve tool steel and easily replaced when the bush edges become blunt. The straight press-fit bushing at A is the type commonly used. The bushing is made a slip fit approximately 1/8 inch at its lower end. This correct alignment while pressing in, an important feature for accurate centre-to-centre distance between holes. The inside of the bushing hole is ground for 1/8 inch and the remainder is given angular for proper slug disposal.

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With spring strippers, the top of the bushing made flush with the face of its retainer at B. For heavy material strip, the flanged type used to provide greater area against the die. It is also used when upward pressure would work the bushing upward. Shown at D, a bushing an irregular hole is kept from turning by a flat in the shoulder. This bears against one edge of machined in the retainer. Where space is limited bushing can be kept from turning by a key against a flat ground in the shoulder, as shown in E.

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9.2 DESIGNING OF BLANKING PUNCH:

The size of the blank to be produced determines the type of the punch to use. Design considerations include: • • • Stability, to prevent deflection Adequate screws to overcome stripping load Good doweling practice for accurate location

9.2.1 SMALL BLANKING PUNCHES:

The body diameter A of a small blanking punch is made considerably larger than blanking diameter B. Radius C provides supporting material to give rigidity and prevent deflection of the punch upon contact with the material strip. Section view A shows the punch, punch plate, and punch holder. Plan view B shows the same components inverted as they would appear in the upper righthand view of the drawing.

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9.2.2 KEYING THE PUNCH: Small blanking punches having a cutting end of irregular contour can be kept from turning by a round end key. This key retained in an end milled slot machined in the punch head. Common applications of this construction are small blanking punches for producing, watch, and instrument gears.

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9.2.3 PUNCHES FOR LONG BLANKS OR SLOT: The side of narrow-and-long blanking punches are provided with a radius A. This radius providing extra supporting material for stability to prevent deflection of the cutting end upon contact with the metal strip.

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9.2.4 FLANGED PUNCHES: This type of blanking punch is the most widely used, because it is employed to produce average size blanks. As in Fig. 8-6, flanges are provided fastening the blanking punch to the punch holder by screws and dowels. Only the cutting end of the blanking punch is hardened; the flanges are soft for accurate fitting of dowels at assembly. “Fool –proof” the punch by offsetting one of the dowels to assure correct reassembly in die maintenance.

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9.2.5 CLEARING OTHER COMPONENTS:

When space is limited, a portion of the flange can be removed to provide room for other die components. For good stability flange width A should not be smaller than punch height B.

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9.2.6 CUTTING RINGS: Blanking punches for large circular blanks can be made in two parts to conserve tool steel and sampling heat treating. Cutting ring A is located by a round boss which is part spacer B. This spacer, in turn, and fitted into recess machined in the punch holder and the die set. With this construction, dowels are necessary for positioning the punch.

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9.2.7 SHEDDERS:

Blanks produced from oiled stock tend to cling to the face of the blanking punch. Spring loaded shedder pins, applied to one side of the punch, will break the adhesion and free the blank from the punch face to prevent “double blanking”. Two methods of applying shedder pins are available. At A, the shedder pin for a small blanking punch is made short, headed, and backed up by a spring and socket set screw. The pin is made from drill rod, hardened, and polished. A clearance hole is provided in the punch sharpening. In another method, the shedder can be made long as at B. Its head bears against the top of the blanking punch, and it is similarly backed up by a spring and socket set screw.

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9.3 DESIGNING OF PIERCING PUNCH: Piercing punches are usually the weakest link in the die design. Therefore, the following factors must always be taken into consideration: • Make the punches strong enough so that repeated shock in operation will not cause fracture. Slender punches must be sufficiently guided and supported to insure alignment between punch and die members and to prevent buckling.



9.3.1 SHOULDER PUNCHES:

Probably the most commonly used type, shoulder punches are made from a good grade of tool steel, hardened, and ground all over. Diameter A is a press fit in the punch plate. Diameter B, which extends at least 1/8 inch, is a slip fit for good alignment while pressing. Shoulder C is usually made 1/8 inch larger in diameter than A. Shoulder height D is 1/8 to 3/16 inch, depending on size. Piercing diameter E is always on the high side of tolerance.

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9.3.2 GUIDING THE STRIPPER:

Small punches under 3/16 inch in diameter are usually guided in hardened bushings pressed into the stripper. Larger punches are often guided, particularly when cutting heavy stock if there is a possibility of punch deflection upon contact with the strip. These guide bushings are hardened, the ground on both inside and outside surfaces.

9.3.3 BACKING PLATES:

When heavy stock is being pierced, the punch head is backed up by a backing plate, pressed into a counter bored hole in the punch holder. It prevents the punch head from sinking into the relatively soft material of the die set. Backing plates are made of tool steel, hardened, and ground.

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9.3.4 SET SCREWS BACK UP THE PUNCH:

Two socket set screws back up the piercing punch in this application. This method of retaining piercing punches has become widely used. Its main advantage is the ease with which a broken punch can be removed and a new one inserted without the necessity of dismantling any part of the die.

9.3.5 LARGE PUNCHES:

Punches over 1-1/4 inch in diameter are relieved at the center of the cutting face for ease of sharpening. When cutting heavy stock the annular cutting ring. A is often scalloped to relieve the shock on the press.

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9.3.6 STEPPING SMALL PUNCHES:

A small punch adjacent to a large one is made shorter by two-thirds of the stock thickness. Some material flow occurs as the large punch penetrates the strip. With both punches the same length, the small one would deflected slightly, resulting in a nicked cutting edge and eventual breakage.

9.3.7 QUILL SUPPORT:

Very small peened-head punches can be held in quills and guided in hardened bushing pressed into the stripper. When replacing the punches, simply remove them from their quills and insert new ones. They are backed up by either a hardened plate or socket set screws.

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9.3.8 GUIDING THE QUILL:

Another method of providing lateral support to a small peened head punch is to guide the quill itself in a hardened bushing in the stripper plate. In this way the punch extends from the quill only a very short distance for maximum stiffness.

9.3.9 ONE QUILL – TWO PERFORATORS:

Two or more closely spaced peened head punches can be held in a single quill. The quill is kept from turning by a flat bears against one edge of a slot machined in the punch plate. The quill is guided in a hardened bushing in the stripper and the punches are backed up by a backing plate.

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9.3.10 SHEDDER:

When piercing some thin materials, the slug tends to follow the piercing punch out of the die hole. This can be a serious problem in progressive dies. To over-come the trouble, incorporate a shedder pin in the punch. This headed pin is backed up by a spring and set screw. Piercing punches provided with shedders are available from a number of suppliers.

9.3.11 IRREGULAR PUNCHES:

A good method of keeping an irregular punch from turning is to machine a flat in the punch head. This flat bears against one edge of a slot machined in the punch plate. A snug fit is required.

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9.3.12 RETAINING KEY:

Another good method of keeping an irregular punch from turning is to machine a flat in the punch head, as before, and insert a small round-end key in a slot end-milled in the punch plate. This method is particularly useful in multiple station progressive dies where space is limited.

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9.4 DESIGNING OF PUNCH PLATE: Punch plates hold and support piercing, notching, and cut off punches. They are usually made of soft material MS. Following factors must always be taken into consideration: • • • Adequate thickness for proper punch support. Good dowelling practice to insure accurate location. Sufficient screws to overcome stripping load.

9.4.1 PUNCH PLATE FOR SINGLE PUNCH:

• •

A punch plate for holding a single punch is made square with sufficient thickness. Tow socket cap screws, applied at the corners, resist stripping pressure, while dowels at the other two corners provide accurate location. Minimum distance from plate edges to screw centre, A, is 1-1/2 times screw diameter B.



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9.4.2 IRREGULAR PUNCHES:



Punch plates that hold irregular piercing punches should have a slot machined in top surface to the same depth as the punch head. A flat, ground in the punch head, bears against one edge of this slot to prevent turning.



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9.4.3 KEYED PUNCHES:

Where space is limited, a slot is machined in the top of punch plate to the same depth as the counter bored hole for the punch head. A small round-end key is inserted in this slot. The key engages a flat, machine in the punch head, to keep it from turning.

9.4.4 INDIVIDUAL PUNCH PLATE:

When piercing punches are some distance from each other, they are preferably held in the individual punch plates, as shown.

60

9.4.5 THICKNESS OF A PUNCH PLATE:

Punch plate thickness B should be approximately 1-1/2 times diameter A of the piercing punch. With the table, the die designer can establish punch plate thickness quickly.

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9.4.6 PUNCH PLATE OF A COMPOUND DIES:

Punch plates used in compound dies are made large so they can act as a spacer for inverted block A. Long socket cap screws, applied from top of the die set, passes through clearance hole to the punch plate and are threaded into the die hole.

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9.5 DESIGNING OF STRIPPER PLATE:

Stripper plates remove the material strip from around blanking and piercing punches. Solid strippers are the most frequently used type. Spring strippers should be used when the following condition is present. 1. When perfectly flat, accurate blanks are required, because spring stripper flatten the sheet before cutting begins. 2. When blanking or piercing very thin material, to prevent uneven fracture and rounded blank edges. 3. When parts are to be pressed from waste strip left over from other operations, spring strippers provide good visibility to the operator for gaging purposes. 4. Because stripping occurs immediately, small punches are not subject to breakage.
9.5.1 SOLID STRIPPERS:

Here is the most common method of applying a solid stripper. Plate A, machined to receive blanking and piercing punches, is fastened in position on top of the back gage and front spacer with four button head socket screws. Tow dowels accurately locate the stripper plate in relation to the die block.

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9.5.2 MACHINING OF PUNCH OPENING:

Three methods are used for machining punch opening in the stripper plate. At A, a 1/8 inch straight land is applied from the bottom of the plate. Above the land, angular relief is provided to clear the punch radius when the punch is lowered in die sharpening. At B the cutting diameter of the small punch is kept short for rigidity. The stripper plate is counter drilled for clearance. At C small punches may be guided in hardened bushings pressed into holes machined in the stripper.

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9.5.3 SPRING STRIPPERS:

Views A, B, and C illustrate the operation of a spring Stripper plate. Springs, arranged around the blanking punch, provide stripping pressure. Four stripper bolts, located at the corners, limit stripper travel. View B shows the die in open position, while View C shows the die as it would appear at the bottom of the press stroke. Springs have been compressed ready to strip the material from around the punch upon movement of the punches. View A shows the punch holder, blanking punch, and punch plate inverted as they would appear in the upper right hand view of the die drawing.

65

9.5.4 SPRING RETAINED BY STRIPPER BOLTS:

For medium production dies, springs can be applied around stripper bolts as shown. This method is not recommended for long runs because of increased wear on the stripper bolts, and because of the need to remove the bolts in the event of broken springs.

9.5.5 RUBBER SPRINGS:

For medium and low production dies, rubber springs may be used. These rubber components are available from commercial sources. Dowel pins, pressed into the stripper, retain the rubber springs in position.

66

9.5.6 STRIPPER FORCE:

When spring strippers are used it is necessary to calculate the amount of force required to effect stripping. Stripping force is found by the formula. P = L x T x 855 Where: L = Length of cut. In piercing operations this is the sum of the perimeter of all perforator faces. T = Thickness of stock P = Force, in pounds, to effect the stripping. The constant 855 was derived from an empirical formula

67

9.6 PILOTS: The pilot positions the stock strip in relation with the die opening. This is termed as registering. The strip is normally overfed more than pitch length. When the press is tripped the pilot comes down and engages the prepierced hole. The strip is dragged back into the registry position. When mechanical feeding is employed the strip is underfed. The pilot pulls the strip into registry position. (Fig.1 and Fig.2)

9.6.1 PILOT SIZE:


Diameter of pilot for average work, diameter of hole to be piloted – (0.05 to 0.1) mm For close work, diameter of hole to be piloted – (0.03 to 0.05) mm For accurate work, diameter of hole to be piloted – (0.01 to 0.02) mm





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9.6.2 PILOT LENGTH:

Registering of the strip should be done before the punches come and engage the strip. Therefore the pilot should extend beyond the punch face equal to one sheet thickness.

1-Top plate 2-Back plate 3-Punch holder 4-Piercing punch 5-Pilot

6-Blanking punch 7-Die plate 8-Bottom plate 9-Stopper 10-Stripper

9.6.3 PILOT OPENING IN THE DIE:

If the pilot opening in the die is larger inserted of registering, the material will be drawn into the opening. Diameter of the opening = diameter of pilot + double clearance. 69

9.6.4 PILOT OPENING IN THE BOTTOM PLATE: Through hole is provided in the bottom plate for the following reasons.


Slug produced due to misfeeding can be cleared if by chance the strip jumps the stopper the pierced hole will be alignment with the pilot. The pilot will hit the strip and punch out a deformed slug. Accumulate burrs dislodged from the pierced hole cleared. During piercing operation burr is formed on the pierced hole. The pilots, while entering the prepierced hole, will dislodge the burr.



70

9.6.5 BULLET NOSE:

The most common pilot nose profile is bullet nose. The bullet shape is formed by radius ‘r’ which is equal to piloting diameter. For piloting in holes less than 6mm in diameter the length of radius ‘r’ can be increased to reduce the lateral force due to piloting. Bullet nose is strong, simple to make and smooth in action.

71

PRESSES
10.1 PRESS:

A machine or equipment which is used to transfer one or more forces and movements to a tool or a die for the purpose of blanking or forming a work piece is called a “Press”.

Fig: showing the basic function of a press machine

72

10.2 CLASSIFICATION OF PRESSES, ACCORDING TO ENERGY SUPPLY: There are many types of presses according to energy supply. • • • • • Mechanical Presses Hydraulic Presses Steam Presses Pneumatic Presses Electromagnetic Presses

10.2.1MECHANICAL PRESS:

A press that is driven by mechanical power. Most mechanical presses are driven by a flywheel, crank, and clutch.

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10.2.2 HYDRAULIC PRESS:

Hydraulic presses utilize the pressure of water or other fluid media.

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10.2.3 PNEUMATIC PRESS:

Pneumatic press is operated by pressurized air.

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10.2.4 STEAM PRESS:

Steam presses use pressurized steam.

10.2.5 ELECTROMAGNETIC PRESS:

In electromagnetic press, the ram is moved by the application of electromagnetic force.

10.3 CLASSIFICATION OF PRESSES, ACCORDING TO THEIR CONSTRUCTION: • • C-frame presses or gap-frame O-frame presses or closed-frame

10.3.1 C-FRAME PRESSES:

C-frame construction is often used with smaller capacity presses. Their main advantage lies in the easily accessible work area, which accounts for shorter setup and adjustment times.

00000000000 C-frame press with single and double column.

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10.3.2 O-FRAME PRESSES OR CLOSED-FRAME:

The best type of frame for press work is the fully enclosed O-type with the fewest openings in the side and supports.

O-frame press with double and pillarsupport double column. 10.4 CLASSIFICATION OF PRESSES, ACCORDING TO THEIR WIDTH-HEIGHT RATIO: According to width-to-height ratio, presses can be further categorized as vertical and horizontal presses, inclined or inclinable presses.

77

10.5 PARTS OF THE PRESS: Presses consist of several essential components, assembled within the mass of their frames. But here we will study some essential components. 1-Press frame 3-Bolster Plate 5-Press Drive 7- Flywheel 9- Draw Cushion 2-Press Bed 4-Ram 6-Crankshaft or Eccentric Shaft 8- Flywheel clutch and Brake

Flywheel

Press Frame

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10.5.1 PRESS FRAME:

• • •

The frame of the press must be sturdy and rigid in construction. Press frames are either cast or welded together from segment. Cast frames are used for smaller capacity. The best type of frame for press work is the fully enclosed O-type.

10.5.2 PRESS BED:

Press bed serves as a table to which the bolster plate is mounted.

10.5.3 BOLSTER PLATE:

Bolster plate, sometime called press table, is positioned on top of the press bed. It is heavy plate, ribbed with T slots (to receive T bolts in the assembly of a die).
10.5.4 RAM/SLIDE:

It is the reciprocating member of the press. It is guided in the press frame. The upper tool member is fastened to the slide.
10.5.5 PRESS DRIVE:

The power, which is used to drive mechanical presses, is transformed to the ram with the aid of either: Flywheel (most often used with small dies or where light blanking is performed Flywheel and single-reduction gear Flywheel and multi reduction arrangement
10.5.6 CRANKSHAFT:

To actuate the slide, crankshaft serves as a link between the press drive and the ram.

10.5.7 FLYWHEEL:

The main device located in the crown of a mechanical press that is attached to the power source and regulates the reciprocating motion of the ram.

79

10.5.8 CLUTCH AND BRAKE:

It is a coupling used to connect or disconnect a driving machine member to or from a driven machine member. In a press it connects or disconnects the fly wheel to the main shaft. Brakes should stop the slide when the clutch is disengaged.
10.5.9 DRAW CUSHION

The function of the draw cushion is to hold the blank Holder during deep drawing operation in both types mechanical and hydraulic presses. It prevents the formation of wrinkles in the panel. Cushions can be either hydraulically or pneumatically actuated. A major difference between the two is the larger force offered by the hydraulic one.

80

10.6 CLASSIFICATION OF PRESSES, ACCORDING TO THEIR OPERATION: • • Single-action press Double-action press

10.6.1 SINGLE-ACTION PRESS:

Single-action presses are used for general press work throughout the industry. The number of actions is given by the number of slides or rams.

Single-action press

81

10.6.2 DOUBLE-ACTION PRESS:

A double-action press, as it name implies, has two slides operating along the same axis yet independent in their movement.

10.7 PRESS OPERATING PARAMETERS:

The energy of the press can be calculated by multiplying its average force by the distance through which it must be applied. The value of such energy is measured in inch-tons. The power of the press is the amount of energy which must be exerted during a given time interval. Its unit of measure is the horsepower.

10.7.1 TONNAGE:

The actual force of the press can be calculated as: Pactu = 3.5 √Cdia (tons)

Pactu =tonnage, actual, at the bottom of the stroke Cdia = diameter of the crankshaft

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10.7.2 SHUT HEIGHT:

Shut height of a press is the space reserved for the accommodation of the die. It is measured from top of the bed to the bottom of the slide/ram with the stroke down and adjustment up.

10.7.3 STROKE:

The stroke of a press is the reciprocating motion of a press slide/ram.

83

FORMING, PIERCING OR TRIMMING FORCE CALCULATION: The force required forming or cutting the metal sheet into desired shape or size is calculated by the following formula.

P = (L x T x δ)/1000 tons Where, P= Forming or Piercing or Trimming Force (tons) L = Total Forming, piercing or Trimming length from edges (mm) T = Sheet Thickness (mm) ∆=UTSi.e35kg/mm2

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Process Plan Sheet:

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...The director’s vision of the production of Die Fledermaus was “revenge in fun is fun”. Specific moments in the play where this was supported were in act one when Falke convinces Eisenstein to go to Prince Orlofsky’s ball. Falke has planned to get revenge on Eisenstein for humiliating him after a party. Falke is having fun plotting his revenge and this is portrayed by Falke’s demeanor toward Eisenstein. Falke is cheerful and excited when he finally convinces Eisenstein to put off jail until morning and go to the ball with him. Another specific moment that revenge is portrayed as fun is when Rosalinda is having fun at the ball flirting with her husband, all the while Eisenstein has no idea this is his wife. She steals his pocket watch so that she can reveal later that it was her that he was flirting with. All of this, revenge on Esinstein, was being done to entertain the Prince. The idea that Falke was getting revenge on Eisenstein while at a ball that was meant to be fun and entertaining is another element that the director was envisioning “revenge in fun is fun”. The director’s concept of an “Austrian pastry” was visually conveyed by the pastel lighting, as well as the light and happy music. The costumes of the characters conveyed fluffy and sweet because of the type of fabric that was used and the colors of the fabrics. Some of the costumes had glitter which brings to mind sugar. The costumes were also bouncy and swingy illustrating “light and fluffy”. The set was brightly...

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Research Paper on Assisted Suicide and Dr. Jack Kevorkian

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Assisting Suicide

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