Abstract – Sheet metal working processes are widely used in almost all industries such as automotive, defense, medical and mechanical. The main advantage of using the metal machining process is to improve the production rate and reduce the cost per part. Nowadays many people are working to develop punches with innovative ideas. This project is also based on a new design for punching. The project mainly focuses on different operations performed on a single punch configuration in a single stroke, currently these operations are performed
in three separate configurations that lead to reduced production rate and increased cycle time at cost as well.
Theoretical calculations were done to calculate the cutting force, required tonnage, Von-Mises stresses, fatigue life, buckling load and total deformation. 3D parts are modeled in CATIA-v5 and saved in .stp file format so they can be imported from any analysis software. As per the requirements of companies, CAD drawings are designed in AUTOCAD software. The various analyzes such as Von-Mises stress analysis, fatigue life are performed on Ansys 14.0 bench analysis software and the results are compared with the theoretical results. The results are within 5% of the allowable limit.
INTRODUCTION
Forming processes such as piercing, blanking, stamping and bending are widely used in the manufacture of sheet metal parts and bring together various processes for the manufacture of sheet metal parts. Piercing and Blanking are metal shearing processes in which the input sheet material is sheared into a target shape. In stamping, the piece of stamped material is the product and in punching, the stamped material is scrap while the rest of the strip is the product, as shown in Figure. In this project, blanks and perforations are used to produce components. Blanking is one of the processes in which the sheet undergoes brutal deformation, as the sheet is separated to have the
slug and part.
Design and analysis of molding and drilling punches PROBLEM STATEMENT
The objective of this project is to reduce the cycle time of the existing process of milling, stamping and component drilling operations. All these operations need to be combined into a single punch configuration with a suitable tool design. The monthly volume of the component is 4,000 to 6,000 nos. Consequently, the company needs cycle time reduction and cost reduction in these hinges as well to face global competition. The existing
The operations cycle time is approximately 4 minutes. After implementing this project, we can expect this to happen in 30 seconds.
Download report:
