Progressive Press Tool

International Academy of Engineering and Medical Research, 2017 Volume-2, ISSUE-5 Published Online May 2017 in IAEMR (http://www.iaemr.com)

DESIGN OF PROGRESSIVE PRESS TOOL FOR STATOR LAMINATION USING PRO/ENGINEER B.Evangeline Department of Mechanical Engineering D.V.R.C.E.T, Medak, Telangana, India Email- evangeline.bulla@gmail.com

Abstract— Among the various conventional methods, press tools are used in the industry to achieve high output, economy in the material utilization, long life of the working parts of tools, safety and minimum cost of operation. The computer aided design and manufacturing technology has dissolved the traditional separation between design and production. For this approach, the press tool was designed by CAD software called ProEngineer at Central Institute of Tool Design. The computer interactive design and manufacturing features in Pro-Engineer were utilized from conceptual stage to the model of press tool. A six stage progressive tool for a sheet metal was designed. It relied on the cutting forces in each stage, stock thickness and total press tonnage.

Keywords—Press tool, Pro-engineer, and stator lamination.

Based on the data, design goes through the following steps.

1) Strip layout.

2) Cutting force calculating.

3) Shearing clearance between punch and die.

4) Creation of bill material.

5) Drafting of assembly and different parts.

In addition to the basic data listed above only the following input was required for designing and drafting of blanking dies using Pro-engineer.

1) Type of blanking and piercing profiles.

2) Dimensions of blanking contour with tolerances 3) Thickness of stack.

4) Center of pressure.

5) Dimensional details of all parts of the tool.

III.

I.

INTRODUCTION

Press working is defined as a chip less manufacturing process by which various components are made from sheet metal. The machine used for press working is known as press tool. The main features of a press are: a frame which supports a ram or a slide and a bed, and a source of mechanics for operating the ram in line and normal to the bed. The ram is equipped with suitable punches and a die block assembly. The cutting operations were performed by progressive press tool for the stator lamination by using pro-engineer.

II.

DETAILS OF COMPONENT

The material of the component used was silicon steel with a thickness of 0.5mm. The stator lamination was one of the parts used in a ceiling fan. Below is Pro-engineer representation of the component.

DEVELOPMENT OF PRESS TOOLS USING PRO-ENGINEER

The design of press tools required the following data.

1) Component drawing.

2) Work piece material.

3) Press equipment details.

4) Accuracy of work piece.

5) Number of work piece to be manufactured.

6) Total life of the tool in terms of number of components produced.

7) Safety Requirements.

Fig 1.

Stator Lamination

International Academy of Engineering and Medical Research, 2017 Volume-2, ISSUE-5 Published Online May 2017 in IAEMR (http://www.iaemr.com) THE OPERATIONS PERFORMED BY 8) Stripper Force= 2697.075 kg PROGRESSIVE PRESS TOOL Below is the Pro-engineer representation of the partial The list of operations to be performed in order of the stages of assembly of the press tool. progressive type were as follows: IV.

1) Stage 1: Cropping and Piercing.

2) Stage 2: First piercing stage.

3) Stage 3: Idle.

4) Stage 4: Second piercing stage.

5) Stage 5: Idle.

6) Stage 6: Final Blanking.

Below is the Pro-Engineer representation of the cutting operations.

Fig 3. Partial Assembly of press tool VI.

DIMENSIONING OF THE DIE ELEMENT

1)Thickness of die block=36mm 2) Thickness of stripper plate=27mm 3) Thickness of punch holder=18mm 4) Thickness of bottom bolster=62 mm 5) Thickness of top bolster= 44.28 mm 6) Die Clearance= 1 degree Below is Pro-engineer representation of the final assembly of the press tool for stator lamination.

Fig 2. Six stage cutting operations

V.

THE DESIGN CALCULATIONS

Percentage of stock utilization for the component strip: 1) Area of raw material A1=16,640 mm2 2) Area of component, A2 = 12,661.26 mm2 3) Percentage of Wastage =0.314 4) Percentage of Stock utilization=68.6 % 5) Shearing force of silicon steel=40 kg/mm2 6) Total length of the shearing perimeter=1798.05mm 7) Total Shearing force required to produce the component = 44951.25 kg

Fig 4 Final Assembly of the Press Tool for Stator Lamination

International Academy of Engineering and Medical Research, 2017 Volume-2, ISSUE-5 Published Online May 2017 in IAEMR (http://www.iaemr.com) VII. CONCLUSION The design results in a press tool achieved a high output, economy in the use of material, long life of the working parts of the tools, convenient and safe operation at the minimum cost of manufacturing.

Using Pro-engineer the high end computer aided design and manufacturing software from the conceptual stage to design, analysis and manufacturing was done. This resulted to cut short time cycle so that new jobs can be taken up quickly.

Better tool designing and drafting with greater number of design proposals within the time schedule, quality manufacturing and accuracy of tooling.

The sheet metal component can be manufactured relying on the design within very close tolerance and eccentricity, reducing the production and manufacturing costs and thereby increasing the probability of industries. The use of computers based method for design, analysis, manufacturing was thus an effective means of increasing the quality and productivity and hence its use should be encouraged which in return will result in building up of national economy.

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REFERENCES

The Past,The Present and The Future- Computer Integrated Manufacturing vol 2R.U.Auyers, W.Haywood, M.E Merchant, J.Ranta, H.J Warneke.

Basic Die Making- Eugene Osteguard.

Advance Diemaking- D.Eugene Osterguard A Text Book of Production Engineering – P.C Sharma Computer Aided Engineers-R.C Edney Prentice Hall International.

Fundamentals and Working Pro/ENGINEER- PTC Corporation.

An Introduction to Pro/ENGINEER.-SDC Ltd Tool Engineering Parameters- Indian Society of Tool Engineers, C.I.T.D,Hyderabad.

AUTHORS AUTOBIOGRAPHY

B.Evangeline was born in Guntur district, India, in 1980. She received her B.Tech degree in Mechanical Engineering from Jawaharlal Nehru Technological University, Hyderabad, in 2002 and also her Master of Science degree in Mechanical Engineering from University of Nevada, Las Vegas, USA in 2006. Her areas of research and study interest include Energy, Fluid Mechanics, Heat and Mass Transfer, Engineering Thermodynamics, Finite Element Methods, Engineering Mechanics, Mechanics of Solids and Computational Design.