MODULE - I

MOULD AND DIE DESIGN :

Mould and die design involves creating the tools (molds or dies) used to shape raw materials into
desired products, crucial for manufacturing processes like injection molding, die casting, and
STAMPING.
Here's a more detailed breakdown:
 Molds: These are used in processes like injection molding (for plastics) and casting (for
metals) to create the cavities into which molten material is poured or injected.
 Dies: These are used for shaping sheet metal and other metal forms, often in processes like
stamping.
 Materials: Molds are often used for plastics, while dies are more common for
metalworking.
 Processes: Molds are used in processes like injection molding and casting, while dies are
used in processes like stamping and die casting.
IMPORTANCE OF DESIGN:
 Accurate design and production of molds and dies are essential for ensuring the quality of
the final product.
 Specialized design and manufacturing solutions are used to optimize production efficiency
and reduce errors.
APPLICATIONS:
 Injection Molding: Creating plastic parts for various industries.
 Die Casting: Manufacturing metal components under high pressure.
 Sheet Metal Stamping: Forming metal sheets into desired shapes.
TYPES OF MOLDS AND DIES:
 Injection molds: For producing thermoplastic parts.
 Blow molds: For creating hollow plastic objects.
 Extrusion dies: For producing long, continuous shapes.
 Compression molds: For creating composite products.
 Die casting dies: For die casting processes.
 Stamping dies: For sheet metal forming.
Design Considerations:
 Material Selection: Choosing appropriate materials for the molds and dies based on the
application and the material being shaped.
 Cavity Design: Ensuring accurate and efficient filling of the mold or die cavity.
 Cooling System: Designing an effective cooling system to control the temperature of the
mold or die during the process.
 Ejection Mechanism: Implementing a reliable mechanism for removing the finished
product from the mold or die.
PRESS TOOLS:
To understand the press tool and die process it is important to know what a press tool and die are.
A press tool is embedded in a press machine, and it is designed to shape or cut metal using force.
The die helps define the shape and size of the cut piece. This process is used to produce a pre-
designed component in large quantities. The components that a press tool and die can produce
depend on the construction and configuration of that tool and die. Basically, a press tool is an
assembly of a tool and a die, a few other parts, and accessories. In lay man’s terms, a press tool
and die design process work somewhat like our teeth. The set of upper teeth could be compared
to the tool and the set of lower teeth to the die. Together they can cut or make an impression to
form a component.
press tools components:
The different types of press tool components are:
 Structural Components – Holds working components together. Example- Upper shoe,
shank.
 Working Components– Actively contributes to the stamping process. Example- Punches
 Guiding or Locating Components– Responsible for accurate alignment of the worksheet
and overall design. Example-dowel pins
 Stripping Components– Removes blanks and unwanted scraps from the final product.
Example- Push-off pins
 Fastening Components– Holds all the parts together. Example- die block.
 Feeding Components– Pushes the metal sheet inside the die. Responsible for the rate of
production. The more feeding components, the more production speed.
Design of Press Tools:
The first step to designing the press tools is to understand their configuration. A simple press tool
consists of:
 Ram (Slide)
 Shank
 Punch holder
 Die holder
 Backup Plate
 Punch Plate
 Die
 Stripper
 Guideposts
Apart from this, the prerequisite to designing an accurate press tool is the application and metal
part geometry. It must also meet the production time demand without compromising on the final
quality.
The design of press tools starts with computing the required dimensions like force, shut height,
die thickness, margins, etc This helps in creating the most accurate strip layout and placing
different dies at the appropriate places. The design process also involves selection of hardware,
die plan, and identifying the center of pressure and scrap disposal.
Proper tool designs ensure good quality output. Therefore, it is necessary to outsource the metal
stamping tools to experts like Eigen Engineering. Such experts ensure the design allows
maximum utilization of material at an optimum time and cost.
Press tool operations:
Different press tool constructions lead to different operations. They are: bending, blanking,
forming, piercing, drawing, cutting off, parting off, embossing, coining, notching, shaving,
lancing, dinking, perforating, trimming, curling and so on. The components produced through
the press tool and die process are used in various industries such as defense, food processing
industry, packing industry, textile industry, automobile industry, and aircraft manufacturing
industry.
Types of Press Tools:
1. Simple tool: This can perform piercing and blanking operations.
2. Combination tool: It is where the cutting and forming of the component are carried out in a
single stroke.
3. Progressive tool : Progressive tool is a combination of bending, coining, punching and
perhaps other modifying processes. A metal strip is fed into the machine and as it progresses
different operations are performed at different stations. This is achieved by designing a strip
layout. If the number components are designed to utilize 70% of the strip then we can conclude
that the component is well designed. Since this includes several operations such as, notching,
piercing, semi-notching, blanking or shaping all at the same time, it saves time and resources.
4. Compound tool: It is a combination of blanking and piercing in a single stroke. It works
differently from progressive and stage press tools. Say if your client requires washers. Instead of
blanking the sheet and then piercing it separately, you could accomplish both tasks at the same
time. This could be achieved by designing the punch and the die in way that it could achieve
both piercing operations and blanking operations simultaneously.
5. Bending tool: It is a tool with two options: V-bend tool and U-bend tool. This is used to bend
a component into a shape that is specified.
6. Drawing tool: It is a process of axial elongation through application of axial force.
Manufacturing of press tools and die is a complicated task and so is the process. Accurate
measurements and alignment are an essential part of the process. It is this process that produces
tools resulting in the manufacture of components that are helping us live a civilized life and
helping us to improvise day after day.
JIGS AND FIXTURES:
Introduction The successful running of any mass production depends upon the inter-
changeability to facilitate easy assembly and reduction of unit cost. Mass production methods
demand a fast and easy method of positioning work for accurate operations on it.
JIGS:
It is a work holding device that holds, supports and locates the work piece and guides the cutting
tool for a specific operation. Jigs are usually fitted with hardened steel bushings for guiding or
other cutting tools. a jig is a type of tool used to control the location and/or motion of another
tool. A jig's primary purpose is to provide repeatability, accuracy, and inter-changeability in the
manufacturing of products. A device that does both functions (holding the work and guiding a
tool) is called a jig.
FIXTURES:
It is a work holding device that holds, supports and locates the work piece for a specific
operation but does not guide the cutting tool. It provides only a reference surface or a device,
What makes a fixture unique is that each one is built to fit a particular part or shape. The main
purpose of a fixture is to locate and in some cases hold a work piece during either a machining
operation or some other industrial process. A jig differs from a fixture in that a it guides the tool
to its correct position in addition to locating and supporting the work piece.
DIFFERENCE BETWEEN JIGS & FIXTURE:
1. jigs are work holding device that holds, supports and locates the work piece and guides the
cutting tool for a specific operation but. fixtures are also work holding device that holds,
supports and locates the work piece for specific operation , does not guide the cutting tool.
2. Jigs are not clamped to the drill press but Fixtures should be securely clamped to table unless
large diameters to be drilled.
3. The jigs are special tools particularly in drilling, reaming, tapping and boring but Fixtures are
specific tools used particularly in milling machine, shapers and operation. slotting machine and
operation.
4. Gauge blocks are not necessary with jig but Gauge blocks may be provided for effective
handling in case of fixture.
5. Jigs are Lighter in construction but fixtures are Heavier in construction.
ADVANTAGES OF JIGS & FIXTURE:
1. Productivity: Jigs and fixtures increases the productivity by eliminating the individual
marking, positioning and frequent checking. The operation time is also reduced due to increase
in speed, feed and depth of cut, because of high clamping rigidity.
2. Interchangeability and quality: Jigs and fixtures facilitate the production of articles in large
quantities with high degree of accuracy, uniform quality and inter-changeability at a competitive
cost .
3. Skill reduction:- There is no need for skill-full setting of work on tool. Jigs and fixtures
makes possible to employ unskilled or semi skilled machine operator to make savings in labour
cost
4. Cost reduction:-Higher production, reduction in scrap, easy assembly and savings in labour
cost results in ultimate reduction in unit cost.
BASIC PRINCIPLES OF JIGS AND FIXTURES DESIGN:
1. LOCATING POINTS: Locating the work is a prime necessity and requires suitable facilities.
The correct setup ensures smooth insertion of a workpiece in the proper position and removing a
workpiece from a jig without operational hassles or time consumption. The workpiece position
needs to be precise with the guiding tool in the jig or setup pieces in the fixture.
2. Foolproof: A foolproof design of jigs and fixtures does not permit a tool or workpiece to be
placed in any other way other than the intended one.
3. Reduction of idle time: Jigs and Fixtures must be designed in such a way that ensures smooth
loading, clamping, machining, and unloading of a
4. Weight of jigs and fixtures: A jig and fixture must be compact, easy to handle, and low cost
regarding the number of materials used without giving up stiffness and rigidity.
5. Jigs provided with feet: Some jigs require feet so that they can be placed on the table firmly.
6. materials for jigs and fixtures: Jigs and Fixtures are usually created with hardened materials
to resist wear & tear and avoid frequent damage—for example, Mild steel, Cast iron, Die steel,
High-speed steel, Caesium.
7. Clamping device: A suitable clamp is rated for its strength. It should be able to hold a
workpiece firmly in its position while bearing the strain of the cutting tool simultaneously,
without springing.
BROAD RULES OF JIGS & FIXTURES DESIGN:
 Compare the production cost of work between the existing tools and the tool to be made and
see if the manufacturing price is not more than the expected gain.
 Determine location points and outline clamping arrangement.
 Make sure the clamping and binding pieces are as quick to act & efficient as possible.
 Make the jig and fixture foolproof.
 Make sure the locating points are adjustable.
 Do avoid intricate clamping arrangements.
 Round all corners.
 Make sure the operator has handles to make handling tasks easier.
 Provide ample amount of clearance.
 Provide holes for chips to escape.
 Systematically locate clamps to resist the pressure of the cutting tool while machining.
 To avoid springing action, place all clamps in proximity opposite to the bearing point of the
workpiece.
 Test the jigs before putting them in a shop.
THE 3-2-1 PRINCIPLE:
Locating a part to be machined involves mainly three steps:
Supporting, Positioning, and Clamping.
Two main intentions when placing a job on a jig/fixture are:
 Precisely positioning the part at the desired coordinates.
 Curbing all six degrees of movement so that the part cannot budge.
An extensively used method for obtaining these objectives is the 3-2-1 principle or six degrees
of freedom for part location.

The 3-2-1 method is a work-holding principle where three pins are located on the 1st principle
plane, i.e., either XY, YZ, ZX. And two pins are located on the 2nd plane perpendicular to the
1st plane, and at last, one pin on the plane is mutually perpendicular to the 1st and 2nd planes.
The aim is to constrain the movement of the workpiece along all three axes.
DESIGN OBJECTIVES OF JIGS AND FIXTURES:
Before sitting down to design jigs/fixtures, the designer must consider the following points:
 The tool must be foolproof to prevent any mishandling or accidental usage by the operator.
 Easy to operate for increasing efficiency.
 Easy to manufacture using the lowest costs.
 Its ability to weather the tool life instead of appropriate materials.
 Must be consistent at producing high-quality parts.
 Must be safe and secure to use.
The designer must know the basics of the process and the tools associated with it for which the
jig/fixture is designed.
Overall objectives to look out for a while developing such tools are:
 Cycle time.
 Type of Jig/Fixture.
 Part Assembly sequence or Machining locations.
 Joining or machining process.
 Clamping method and clamping sequence.
 Required output accuracy.
 Type of equipment to be used with the jig.
 Method of ejecting finished output and transferring it to the next. Platform, whether the
manual or automatic mode.
 The type of material, recommended weight, number of spots involving welding
TYPES OF JIGS:
1. Template Jig:
The template jig is the simplest of all the models. The plate, having two holes, acts as a template
fixed on the component to be machined. The drill is guided through these template holes, and the
required holes are drilled on the workpiece at the same relative positions as on the template.
2. Plate Jig:
A plate jig improves the template jig by incorporating drill bushes on the template.
The plate jig is employed to drill holes on large parts, maintaining accurate spacing with each
other.

3. Channel Jig:
Channel jig is a simple type of jig having a channel-like cross-section. The component is fitted
within the channel and is located and clamped by rotating the knurled knob. The tool is guided
through the drill bush.

4. Diameter Jig:
A diameter jig is used to drill radial holes on a cylindrical or spherical workpiece.
5. Leaf Jig:
The leaf jig has a leaf that may be swung open or closed on the work for loading or loading
purposes.

6. Ring Jig:
Ring jig is employed to drill holes on circular flanged parts. The work is securely clamped on the
drill body, and the holes are drilled by guiding the tool through drill bushes.
7. Box Jig:
Box jig is of box-like construction within which the work is rigidly held so that it can be drilled
or machined from different angles at a single setting depending on which face of the jig is turned
toward the tool.

TYPES OF FIXTURES:
1. Turning Fixtures:
These fixtures are generally mounted on the nose of the machine spindle or a faceplate, and the
workpieces hold them. The fixture may have to be provided with a counterweight or balance the
unbalance fixture whenever necessary.

2. Milling Fixtures:
Milling fixtures are typically mounted on the nose of the machine spindle or a faceplate, and the
workpieces hold them. The table is shifted and set in the proper position about the cutter. The
workpieces are located in the base of the fixture and clamped before starting the operation.
3. Broaching Fixtures:
Broaching fixtures are used on different broaching machines to locate, hold and support the
workpieces during the operations, such as keyway broaching operations, such as keyway
broaching, hole broaching, etc.

4. Indexing Fixtures:
Several components need machining on different surfaces such that their machined surface
surfaces or forms are evenly spaced. Such elements must be indexed equally as many as the
number of surfaces to be machined. The holding devices (jigs or fixtures) used are made to carry
a suitable indexing mechanism. A fixture having such a device is known as an indexing fixture.
5. Grinding Fixtures:
These fixtures may be the standard work-holding devices, such as chucks, mandrels, chuck with
shaped jaws, magnetic chucks, etc. For external surface grinding, cylindrical grinding utilizes
plain or tapered mandrels. The workpiece is located and held on the mandrel with the help of the
bore so that the external surface may be machined truly concentric to the bore. For internal
grinding, the chuck is the most standard fixture. For holding irregularly shaped components, the
fixture is designed the same as turning or boring fixtures.

6. Boring Fixtures:
This fixture incorporates almost all the prevailing principles of jig and fixture design; their
construction need not be as sturdy as that of the milling fixtures because they never have to bear
as heavy cutting loads as involved in milling fixtures because they never have to endure as heavy
cutting loads as involved in milling operations.

7. Welding Fixtures:
Welding fixtures are carefully designed to hold and support the various components welded in
proper locations and prevent distortions in welded structures. For this, the locating element needs
to be careful; clamping has to be light but firm, and the placement of clamping elements has to
be clear of the welding area. The fixture must be pretty stable and rigid to withstand the welding
stresses.

DIFFERENT TYPES OF LOCATORS:

1. Flat Locator : Flat locators are used for location of flat machined surfaces of the component
Three different examples which can be served as a general principle of location are described
here for flat locators

2. Cylindrical locator:
A cylindrical locator is shown in Figure. It is used for locating components having drilled
holes. The cylindrical component to be located is gripped by a cylindrical locator fitted to the
jig‟s body and inserted in the drilled hole of the component. The face of the jig‟s body around
the locator is undercut to provide space for swarf clearance.
3. Conical locator:
A conical locator is illustrated in Figure 4.5. This is used for locating the workpieces having
cylindrical hole in the workpiece. The workpiece is found located by supporting it over the
conical locator inserted into the drilled hole of the workpiece. A conical locator is considered as
superior as it has a capacity to accommodate a slight variation in the hole diameter of the
component without affecting the accuracy of location. Degree of freedom along z-axis can also
be restrained by putting a template over the workpiece with the help of screws

4. Jack pin locator:

Jack pin locator is used for supporting rough workpieces from the button as shown in Figure .
Height of the jack pin is adjustable to accommodate the workpieces having variation in their
surface texture. So this is a suitable method to accommodate the components which are rough
and un-machined.

5. Drill bush locator:

The drill bush locator is illustrated in Figure. It is used for holding and locating the cylindrical
work pieces. The bush has conical opening for locating purpose and it is sometimes screwed
on the jig’s body for the adjustment of height of the work.

6. Fixed vee locator:

This is quick and effective method of locating the workpiece with desired level of accuracy.
This is used for locating the circular and semi-circular type of workpieces as shown in Figure .
The main part of locating device is Vee shaped block which is normally fixed to the jig.

This locator can be of two types fixed Vee locator and adjustable Vee locator. The fixed type
locator is normally fixed on the jig and adjustable locator can be moved axially to provide
proper grip of Vee band to the work piece
CLAMP:
To restrain the workpiece completely a clamping device is required in addition to locating device
and jigs and fixtures A clamping device holds the workpiece securely in a jig or fixture against
the forces applied over it during on operation
Basic requirement of a good clamping device are listed below :
 It should rigidly hold the workpiece
 The workpiece being clamped should not be damaged due to application of clamping
pressure by the clamping unit
 The clamping pressure should be enough to over come the operating pressure applied on the
workpiece as both pressure act on the workpiece in opposite directions
 Clamping device should be capable to be unaffected by the vibrations generated during an
operation.
PRESS WORKING TERMINOLOGY:
Before designing the sheet metal stamping process Press tool, it is necessary to understand the
configuration and components of the press tool. The press tool consists of Punch/ Punches, Die,
Punch Plate, Backup plate, Stripper, ejectors many more components. To better understand the
main components of the press and dies, just have a look at the given figure.

Ram ( Slide): Moving Component of the press which transfers the mechanical or hydraulic force
from the Flywheel /hydraulic system to the Press tool for sheet metal stamping.
Shank: The shank is used as a part for installing the top die in the slide of the press machine.
Punch Holder (Upper Shoe): This is the upper part of the die set which contains guidepost
pushing. The whole upper section (generally contains Punch, punch plate) of the die set is
mounted on the upper shoe.
Die Holder (Lower Shoe ): This is the lower part of the die set which contains guidepost. The
whole lower section (Generally contain die, stripper) of the die set is mounted on the upper shoe.
Back up Plate: Backup plate is placed so that the intensity of pressure does not become
excessive on the punch holder. It is also called Punch back plate and Pressure Plate.
Punch Plate: The function of the punch plate is to hold punch in its proper relative position. The
punch plate fits closely over the body of the punch. It is also called Punch Retainer.
Punch: This is the main component of die assembly, which is directly or indirectly moved by
press ram or slide. Punch and die act together to make a stamped part.
Bed: The bed is the lower part of the press frame that serves as a table to which a bolster plate is
mounted.
Bolster Plate: This is a thick plate secured to the bed which is used for supporting & locating the
die set.
Die: Die is a female part of the die block/press tool for producing the given job work in a press.
Die and punch work together to make the desired shape product.
Stripper: A stripper is used to strip the metal strip from a punch or die.
Guidepost & Guide post bushing: This two-component of the press tool guide the die set to
maintain the alignment during the operation. Properly lubricated, and positioned, they improve
tool operation and contribute to producing quality products. This is also called a pillar die set.
Shut Height: The distance between the top of the bed and bottom of the slide, with its stroke
down and adjustment up.
Stroke: The distance of Ram movement from its up position to its down position. It is generally
constant for mechanical presses but variable for hydraulic presses.
METAL STAMPING PRESS TOOLS COMPONENTS:
Press Tool components may be divided into the following categories:
 Structural Components
 Working Components
 Guiding or Locating Components
 Stripping Components
 Fastening Components
 Feeding Components
1. Structural Components:
Press tool Components holding working components to one another and the press. Like Upper
shoe, Lower shoe, shank.
2. Working Components:
Components which actually participate in forming the desired shape stamped part. Like Punch &
Die.
3. Guiding or Locating Components:
Guiding Components maintain accurate alignment of the upper shoe with the lower shoe during
the operation. Guidepost sets and dowel pins are examples of guiding components.
4. Stripping Components:
components that remove or strip blanks and scrap from the punch or die when the operation is
over. Like Stripper, push off pins, Ejectors, Knockouts.
5. Fastening Components:
Fastening Components hold together all parts of the press tool as a unit. Like Punch Plate, Die
block, All Fasteners.
6. Feeding Components:
Feeding Components feed the blank or metal sheet to the stamping station. These components
help to increase the rate of production.
THE REQUIREMENT OF PRESS TOOL DESIGN:
While designing a press tool and selecting the press for a given job, the following factors must be
considered :
1. Thickness of component
2. Power requirement
3. Kind of operation to be performed
4. No. of operations to be performed
5. Overall work size
6. Speed of operation.
Press tool design should suit the type of production i.e mass production, small-batch, or Huge
batch.
Press tools should meet the following requirements:
 The press tools should ensure the demanded output, safe operation & easy maintenance.
 Press tools should be designed in such a way that possible standard components are used for
the manufacturing of products.
 Press tools should be designed for maximum utilization of material as well as manpower.
 Working Parts of the press tools must be strong and durable and replaceable when worn out.
 Dimensional accuracy and surface finish must be within tolerances.
DESIGN OF PRESS TOOLS:
The sheet metal stamping process is a very fast and precise manufacturing process. But what if,
press tool is not working efficiently or it takes many more operations to produce stamped parts.
So it is very important to design an economy friendly and time-saving press tools.
Steps to design any Sheet metal stamping press tool or die:
 The computing of the required force ( Press tonnage)
 Selection of press
 Determination of shut height of the tool
 computing die thickness and margins ( Minimum cross-section)
 Drawing strip layout and comparing material utilization
 Design of locating elements
 Selection of Hardware
 Drawing die plan ( Pillar sets, Punch height, and mounting)
 Identify the center of pressure and checking scrap disposal
 Drawing Details
THEORY OF PRESS TOOL STAMPING PROCESS:
Sheet metal cutting operations in a stamping work is a shearing process. As the punch touches
the sheet metal and travels downwards, it pushes the material into the die opening. The material
is subjected to both compressive and tensile stresses. These stresses will be highest at the edges
of the die and punch and material will stressing beyond its elastic limit and start cracking there.
3 Steps of shearing or fracture in sheet metal cutting operations:
 Stressing the material beyond its elastic limit.
 Plastic deformation due to reduction in area
 fracturing starts in a reduced area.

Forces Disposition:
The forces developed in the shearing operation is represented by a triangle as shown in the
below-given figure. The vertical shearing force and horizontal lateral force are represented
by V and H respectively. The resultant force is represented by R.

1. Vertical Force: The value of Vertical Component V depends upon the area to be sheared and
the shear strength of the material to be cut. Shear Area is a multiple of the length of cut and sheet
thickness.
2. Horizontal Force: The value of horizontal or lateral force H depends upon the die clearance.
The horizontal force can be stated in terms of vertical force percentage. This percentage is the
same as the die clearance percentage.
For perfect shearing/cutting of sheet metal, clearance must be in the proper amount.
PRESS TOOL CLEARANCE:

The amount of space between punch cutting edge and the die-cutting edge is known as clearance.
For better understanding, ―Clearance is the amount of extra space required in the hole of
the die to allow the punch to pass through to punch a hole in the material‖.
Importance of Proper press tool Clearance:
Clearance has a significant role in all cutting operations and forming operations. The die
clearance depends upon the work material, it ranges from two to ten percent of the thickness of
the worksheet. Ductile material should have lesser die clearance otherwise soft material would be
drawn into the gap and harder material needs more die clearance for good shearing action.
Excessive clearance causes more burr on the sheared sheet while less clearance reduces the burr
but it also damages the edges of the die and punch. This results in frequent resharpening of the
die and the punch and decreases the press tool life.
The range of die clearances for various materials for stamping work:
Note that the die clearances are specified in the percentage of Sheet thickness. For a close cutting
profile, there would be a die clearance between the die and punch all around in profile.
DIE CLEARANCE FOR VARIOUS MATERIALS:

Material M.S Aluminum Brass

Clearance % Sheet Thickness 2.5% – 5% 1.5% – 3% 1.5% – 3%

Note: It is not possible to get tolerances than die clearance on components so it is necessary to
perform an additional shaving operation for high precision work.
Die clearance for punching press tool:
The hole pierced in the sheet is a tapered one, with minimum opening equal to punch size. The
maximum size of the hole at the bottom of the sheet depends upon the width of the die opening
. As the minimum size is important in piercing/punching, the punch is made equal to the hole
size. The Die clearance on the die cut out is bigger than the size stated on the component
drawing.
For Example:
Piercing a hole of ∅ 20 mm out of 2 mm thick MS sheet.
The punch diameter will be the same as the hole size i.e 20 mm.
Die clearance at 2.5% of sheet thickness = 2.0 x 0.025
⇒ 0.05 each side
⇒ Die bore = 20 + 2 x 0.05 = ∅ 20.10 mm
Die Clearance for Blanking press tool:
The blanked profile sheet is also tapered one, with minimum size at the bottom and maximum at
the top. The maximum size of the hole at the bottom of the sheet depends upon the die opening.
As the minimum size is important in piercing/punching, The punch is made equal to the hole
size.
The maximum dimensions of the blanks should not exceed the sizes stated in components
drawing. So in blanking the die cutout is made equal to the die profile hole and the punch must
be lesser on every side by the clearance size.
For example:
Blanking an of ∅ 20 mm blanked sheet out of 2 mm thick MS sheet.
Die diameter will be same as hole size i.e 20 mm.
clearance at 2.5% of sheet thickness = 2.0 x 0.025
⇒ 0.05 each side
⇒ Punch Size = 20 – 2 x 0.05 = ∅ 19.90 mm
FORGING DIE DESIGN PRINCIPLES:
Forging die design principles revolve around ensuring the die's ability to withstand high forging
loads, maintain dimensional accuracy, and facilitate efficient metal flow for the desired shape,
while also considering factors like material selection and cooling.
Here's a more detailed breakdown of key principles:
1. Material Selection:
High Mechanical Properties: Dies must possess high strength, hardness, toughness, and wear
resistance to withstand the intense forces and repeated cycles of forging.
Thermal Properties: Good thermal conductivity, heat resistance, fatigue resistance, thermal
stability, and oxidation resistance are crucial for maintaining die integrity during the hot
forging process.
Considerations: The choice of material depends on the forging technique, metal component
size/shape, and projected die service life.
2. Die Shape and Geometry:
Accurate Shape: The die shape directly determines the final shape of the forged part, so it
must be designed to accurately produce the desired geometry.
Metal Flow: Die design must facilitate smooth and controlled metal flow during forging,
minimizing defects and ensuring proper grain structure.
Flash Control: In impression die forging, the design should control the "flash" (excess metal
that flows outside the dies) to ensure efficient material usage and proper part dimensions.
Cavity Design: Cavity design should consider factors like draft angles, undercuts, and radii to
ensure easy die opening and part ejection.
3. Cooling:
Controlled Cooling: Coordinated cooling can enhance the strength of the final product by
optimizing grain flow and controlling microstructure.
Die and Part Temperatures: Maintaining the correct temperature balance between the die and
the metal during the forging process is crucial for successful forging.
4. Heating:
Preheating: Metal ingots are heated to a state where they retain their shape but can be easily
reshaped through the application of force.
Die Heating: Dies are heated to specific temperatures, typically ranging from 300 to 600
degrees Celsius, depending on the metal being forged.
5. Other Important Factors:
Production Volume: The design should consider the production volume and choose the
appropriate die material and construction methods.
Forging Technique: The chosen forging technique (e.g., open-die, closed-die, extrusion
forging) will influence the die design requirements.
Safety: Die design should prioritize safety, considering factors like ease of operation,
accessibility for maintenance, and potential hazards during the forging process.