Press Tool

Press tool is a device by which the sheet metal can be converted into required shape by various press operations. It can also be defined as a device used for punching out sheet metal components from the stock strip by a device called press. Various cutting and non-cutting tools will be loaded between fixed table and moving ram of a press. The pressure when exerted from top and bottom sides by the press, the component is produced according to the punch and dies profiles in the tool. The component is produced from a press tool is applicable in different aspects like automobile parts.

For each automotive body panel, the sheet metal stamping process requires two distinct Types of

equipment: the stamping press and a set of stamping dies. The set of stamping dies represents custom manufacturing equipment used to make specific product geometry. The stamping press represents flexible manufacturing equipment, capable of producing many different automotive body panels (hood, door, fender, etc.) simply by changing the stamping dies. Thus, a particular stamping press produces an individual panel in batches, making the setup of the dies critical to controlling the process mean.

Sheet metal panels require multiple die operations using either a single press or a series of presses in a press line. Stamping dies and presses have numerous input variables (tonnage, shut height, press parallelism, counterbalance pressure, nitrogen pressure in dies, press speed, etc.) that can influence stamping panel quality, especially during die setup. The resultant geometry of the sheet metal panels depends, in part, on these settings. Using the same press settings each time a particular die is set would help reduce long run variation in the associated panels. Unfortunately, the relationship of the numerous press settings and other process input factors (incoming material, blank size, etc.) on panel geometry is not well documented or understood by manufacturers. For example, many of the input

variable settings use a single value for the entire panel. Individual panels, however, have multiple features in different areas that are not necessarily controlled by the same set of input variable settings. This situation limits the ability to bring the process back to the target value when SPC charts exhibit out-of-control conditions for certain features, especially if other features do not change .In addition, none of the process input variables possess a direct cause-and-effect relationship with a panel feature. For example, increasing the tonnage by some amount will not cause a predictable change in a panel feature, as it does in machining where adjusting the position of a cutting tool has a predictable impact on the process mean.

Sheet metal stampings have now replaced many components which were earlier cast or machined. Material economy & the resultant reduction in weight and cost , high productivity , use of unskilled labor , & a high degree of possible precision have rendered presswork indispensable for many mass production goods such as electronics appliances , steel furniture, utensils & automotives. The entire top of a car can be finished to size from a single sheet metal. There is no need for further machining as in the case of castings or forgings.

Metal Stamping is the process of taking blank sheet metal of various thickness and material, and forming it into different shapes by different operations.

Today’s modern technology demands technique to produce quality products at an affordable price to gain an edge over competitors .Sheet metal stamping plays a major role in fulfilling the requirements of modern technology.

The design & analysis of press tools by computer simulation will be highly beneficial to analyze process assessment capabilities & thereby saving lot of expenditures by avoiding repeated and costly tryouts.

High speed stamping & Terminal tool with multiple operation & multi stage tool with higher accuracy.

Capabilities:
• Blank Development
• Drawing Tool
• Forming Tool
• Bending Tool
• Progressive Tool
• Compound Tool
• Panel Dies

Another kind of press is a set of plates with a relief, or depth-based design, in them. The metal is placed between the plates, and the plates are pressed up against each other, deforming the metal in the desired fashion. This may be coining or embossing or forming. A punch press is used for forming holes. Capping Presses form caps from rolls of aluminium foil at up to 660 per minute.

Progressive stamping is a manufacturing method that can encompass punching, coining, bending and several ways of modifying the metal, combined with an automatic feeding system. The feeding system pushes a coil of metal through all of the stations of a progressive stamping die. Each station performs one or more operations until a finished part is made per the requirements on the print. The final operation is a cut-off operation, which separates the finished part from the carrying web. The carrying web, along with metal that is punched away in previous operations, is considered scrap metal.

STATEMENT OF THE PROBLEM

Design, Manufacture & Analysis of Press tools as a set of stage tools for Front Right/Left Disk Protector is the subject considered for this project work.

A new component is usually manufactured without giving enough attention to simulation & analysis aspects, by trial & error process in order to obtain a part without defects. Even the previous experience of designers is not enough to decrease the number of trial, rework on tool & redesign cycles.

OBJECTIVE OF THE STUDY

The prime objective of the study is to design a set of tools to produce the component that exceeds the expectations of the customer in Aspects like Quality, Cost & On time delivery, it holds out the strong probability of achieving the following:

1. A die or set of dies that combines maximum production and least maintenance with “lowest feasible cost, for the desired or expected life”.

2. Maximum utilization of the least expensive stamping material that will satisfactorily function.

3. Most efficient press working practices.

4. A stamped product that consistently meets sales and service requirements of shape, dimensions, strength, finish, style and utility.

SCOPE OF WORK

The basic concept involved in this method to attain the objective is the systematic and correct tool design, a well planned approach has been employed. The methodology consists of the following as detailed here and in the subsequent chapters.

· Component analysis.

· Step by step approach to die design.

· Selection of tooling materials.

· Tool fabrication.

· Tool assembly and tryout,

· Tool cost estimation.

DRAFTING OF ASSEMBLY.

All tool elements were done in AUTOCAD. This stage involved making the drawings of assembly, individual tool elements etc.

MAKING WIRE CUTTING 2D PROFILES

The tools had wire cut profiles in the die and shedder. Making auto cad wire cut profiles for the tools was another task.

PREPARING 3D MODELS

The punch, die and shedder of certain tools needed to be CNC machined. For this 3D models of the punch, die and shedders were made in Power Shape.