PROJECT MEMBERS
• Team Leader : Mr. Khaleel Ahmed
• Members
: Mr. Radhakrishnan V K
Mr. Sugmar V
Mr. Sourabh Kr. Mishra
• The compound tool project was
manufactured as a part of faculty training
program on press tool refreshment
conducted during the period of January 20
2010 to 10 February 2010. Our project
component is a washer having OD 21mm
and ID 15.5mm.
• To manufacture a compound tool
• The process planning and follow of the project by using
macro and micro level process planning
• Exposure to industrial techniques and manufacturing
methods comprising of precision machining like CNC,
Wire EDM, Cylindrical Grinding.
• Knowing the various methods of inspection of the tool
parts and components
• Developing the knowledge about various fits and
Tolerance
• Exposure to tool try out and suggesting further
corrections
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Component name : Washer
Operation
: blanking and piercing
Material
: Aluminum
Sheet thickness : 1mm
Shut height
: 115.0mm
• Piece parts produced from compound
tools are very accurate and identical as all
operations are carried out in single station.
• The burr will be formed on the same side.
• Scrap stocks from other tools can be
economically employed to produce pieces
parts.
• The components will have better flatness.
INDIRECT KNOCKOUT
•
In addition to the shedder and the knockout rod, it consists of
a knockout plate and transfer pins as shown in the figure.
•
The location and number of transfer pins depend on the size
and shape of the blank.
DIRECT KNOCK OUT.
In a knockout system if the knockout rod is directly in contact
with the shedder, the system is known as direct knock out
system.
• Shut height is the distances from the bottom of the
bottom plate to the top of the plate when the tool is
in closed condition.
• The height of the pillars must be less than the shut
height in order to ensure that the ram will not strike
against the ends of the pillars.
• If possible the pillars should be so designed to
accommodate the reduction in the shut height,
Which will be due to re-sharpening of the punch and
die.
• The die sets consists of a bottom plate and top plate
together with guide pillar and bushes. The guide pillars
• And bushes align the top bottom plates.
THE ADVANTAGES OF DIE SETS ARE :
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Accuracy of set up
Improved piece part quality
Increased dies life
Minimum set up time
Easy maintenance
Alignment of punch and die
• Raw materials received
• Tool assembly drawing and detailed
drawing
• Standard items.
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Elements manufacturing
Stage inspection of all elements
Die set assembly
Tool assembly
Trials – T0,T1,T2
Component inspection
• The following precision and conventional
processes were employed
• Wire EDM
• CNC
• Cylindrical grinding
• Surface grinding
• Milling
• Turning
• Drilling
DETAIL OF ELEMENT
MANUFACTURING
Pos. no
: 02
Quantity
: 01
Material
: MS
Size
: 25X100X132
• Pre machined and ground
• Co-ordinate drilling including tooling hole and
dowel hole Ø 6H7X2nos
• Boring of guide bush holes Ø 22H7X2 nos
and Ø 28X10mm Deep for transfer plate
• Completed drilling, tapping , counter boring as
per drawing
Pos No
: 03
Quantity
: 01
Material
: MS
Size
: 25X100X132
• Pre machined and ground
• Co-ordinate drilling tooling hole and dowel hole
Ø6H7 X 2nos
• Boring of guide pillar holes Ø15H7 and Ø16H7
and limit screw counter bore Ø17X15mm depth
X4nos
• Completed drilling, tapping , counter boring as per
drawing
Pos. no
Quantity
Material
Size
• Pre Turned
: 06
: 01
: MS
:Ø15/16X100
• C.G of Ø15/16g6 for Sliding fit & Ø15/16p6 for
Press fit with Bottom Plate
Pos. no
Quantity
Material
Size
• Pre Turned
: 07
: 02
: MS
:Ø25X50
• Reaming of Ø15/16H7 for Sliding fit with Guide Pillar
• C.G of Ø22p6 for Press fit with Top Plate using mandrel
Pos no
Quantity
Material
Size
:
:
:
:
16
01
MS
20X50X72
• Pre machined and ground
• Co-ordinate drilling tooling hole and dowel hole Ø6H7 X 2nos
• Finishing of counter bore for shedder seating Ø 30 X 10mm
depth
• Wire EDM of Die profile Ø 21.00mm
•
Completed drilling, tapping ,as per drawing
A
A
Pos. no
Quantity
Material
: 15
: 01
: MS
Size
:Ø40X26
• Pre machined and ground
• Co-ordinate drilling & Wire EDM of Ø10.56
• C.G of Ø21.00 by using mandral
• Completed drilling of Screw & Dowel holes as
per drawing
POS.NO. : 15
MAT.
: MS
QTY
: 01
A
A
Pos. no
Quantity
Material
:
:
:
11
01
MS
Size
:
10X50X72
• Pre machined and ground
• Co-ordinate drilling tooling hole, strip guide hole
Ø4H7 X 4nos and stopper hole Ø 5H7
• Wire EDM of Die profile Ø 20.96mm
• Completed drilling and tapping as per drawing
A
A
: 04
Quantity
: 01
Material
: MS
Size
:15X50X72
• Pre machined and ground
• Co-ordinate drilling tooling hole, dowel hole
Ø6H7 X 2nos and Ø12H7 for piercing punch
• Finishing of counter bore Ø16 X 5mm depth for
locating piercing punch
• Completed drilling as per drawing
Pos. no
Pos. no
Quantity
Material
: 12
: 01
: MS
Size
:Ø29X15
• Pre machined and ground
• Co-ordinate drilling & Wire EDM of
Ø10.5H7
• C.G of Ø20.96 by using mandrel
POS.NO. : 12
MAT.
: MS
QTY
: 01
Pos. no
Quantity
Material
: 14
: 01
: MS
Size
:Ø15X35
• Pre Turned
• C.G of Ø 10.50 for piercing & Ø12k6 for
fitment with punch holder
POS.NO. : 14
MAT. : MS
QTY
: 01
Top assembly :
At first Die set Assembled, ensured
perpendicularity of guide bush with top plate and guide
pillar with bottom plate and parallelism also maintained.
The piercing punch is fitted to the punch holder
with H7/k6 fit head is fleshed in line with the punch
holder.
The back plate is positioned such that the
screw holes and dowel holes are in line with the holes in
the punch holder.
The shedder is made to slide in the die plate.
Piercing punch is made to slide in the shedder
(H7 / g6)
The shudder is actuated with the help of transfer
pin and transfer plate and knock out rod
Top plate, punch holder and die plate are clamped
with the help of screws and alignment with the
help of dowels.
Shank is fitted to the top plate
Bottom assembly :
The blanking punch is fitted to the
bottom plate with screws and dowels . The strip guide
pins and stopper are fixed to the stripper plate.
The stripper plate is engaged over the blanking
punch with the help of limit bolts. Springs ,washers are
inserted between stripper and bottom plate for actuating
the stripper.
Top parallelism of stripper plate is checked after tightening
the bolts.
The top half and bottom half in closed condiction top
parallelism is checked.
• Die plate :
Strip guide pin relief hole made through
instead of blind hole.
• Blanking punch:
One dowel hole drilled in wrong position.
• Shedder:
Inside diameter made to diameter 10.56mm
instead of diameter 10.5 H7
• We could able to complete our plan as per
macro and micro level planning
• We achieved Top and Bottom plat co-ordinate
drilling as per drawing within Tolerance
• Die set Assembled properly and it is functioning
well
• All plates coordinate achieved as per drawing
with in Tolerance
• Knockout mechanism functioning as per
requirement
• Traveling stripper functioning as per requirement
• Importance of macro & micro level process
planning
• Importance of advance tooling manufacturing
method
• Importance of die set assembly
• Importance of stage & final inspection of tool
elements
• Various method of punch & die alignment
• Care to be taken while tool trails (check list)
• Team work co-ordination improved.
• Drawing reading skill improved.
• Measuring skill & drafting skill improved by dismantling
old tools & preparing detail drawings & Assembly.
• Leadership Quality
• Priority level by m/c allotment of tool elements
• Concept of tool fitting elements improved
• Exposure to C.A.R/ APQP
• Communication skill improved
• Concept of allowance for machining operations
INDIVIDUAL BENEFIT
Mr. Khleel Ahmed
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Team work
Exposure to Macro & Micro level
Exposure to APQP
Selection of Die materials
Preactor software appllications
Modular tooling concept
Change is every body's business
INDIVIDUAL BENEFIT
Mr. Radhakrishnana
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Team work
Macro & Micro level
APQP Importance
Various methods of Tool Manufacturing
Selection of Die materials
INDIVIDUAL BENEFIT
Mr. Sugumar v
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Team work
Macro & Micro level
APQP Importance
Various methods of Tool Manufacturing
Drawing reading Skill improved
Machining skill improved
Inspection methods improved
Concept of SMED and fine blank
Tool asembling Techniques improved
• Leadership skill improved
• Communication and presentation skill
improved.
• Gained kowledge of various formats and
procedure for manufaturing of tools in
industries.
INDIVIDUAL BENEFIT
Mr. Sourabh Kr. Mishra
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Team work
Application & Importance APQP.
Application of Macro & Micro level.
Latest methods of Tool Manufacturing.
Application & Importance about CAR.
Learn about various methods & techniques used by Industries.
Learn various Soft Skill like Bullet Proof leadership, Team Work .
Get Refreshed about Fine Blanking ,Trouble Shooting.
Tool trouble shooting and corrections of component achieved
Mr. N. Dinesh
[email protected]
09447008766
Mr. Khaleel
[email protected]
09886424399
Mr. Radhakrishna
[email protected]
09449232335
Mr. Promodh
[email protected]
09487342657
Mr. Mahesh
[email protected]
09846299354
Mr. Sugmar
[email protected]
09778332549
Mr. S.Deenadayla
[email protected]
09786339744
Mr. Sourabh Kr. Mishra [email protected]
09973684965