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fee (M7 Pilot —> ;Je & Progressive Ae 1 Supa ‘Daj | Dheereeeie ee There is two on more operation cov be performed in a single stroke of punches Comparison Betucer Simple & Progresso °° =~ >. than tuo O There js only one operation can be performed i a Sivgle stpdke of punch. @ Simple product can be | © Product of complex shaPe formed. is formed « G Simble die required small}@ Ts die required. for lugher humber and simple product oud complex shape adjust production . © Productivity aud efficiency In progressive die, productivity of ke oberaton ic wry. | ond eficiony i. Lugter, low.| @ The cost Is less. @ Te cost of progressive lie is wores Differerce \Bohueen Compound & Combination Die + — i Compound Dit Combiration Die Olw compowid' die two cheration!@ In tlus, Luo oberadess er of swve nature performed different nahwe con be in gingle stoke of the bund performed. in sirtgle stoke : of punch. © Here spring stipber isused.|(@) Here Here Is no need of ( iug-sh @ Less complex bart can b Bua ci form: be forwigion ng e rm ° (Compound che is uted wher} (WY) Here nu ? less cost nd ~edivuprodutiph,! Producti are cast and higher is Pequired . y aly eon be achieved. @ Here cufling die 1's wed, @ Here bending obi is used along with bloning furch. obo uh blarking bunch, ee |__Die Mousting All the component of clie and punch system ave Combindely called rowshing of / RAM 4. Purah ond die system. " | eh | \ Pilot } Bolster Plate i oe I i apstriber, When mony dies are runs th rel - | [Dowd Pi, Some press at different Hime pf eo Die shoe fire wear, occuring on see Blose Pade VLLUA bed{ oor is very bolster used. tp take wear. *Bolster blake ic cheab in cost ard easy to replace. elt ig attached to dre shoe. Pornch Plate Sat Punch Plate * Punch plate is used to locate ond, loold the punch. ar * Thus become very useful for havdlig Small punches 5 Hribber w Thuis is uses fo bold j He plote exoet post How ow the dite ov stripper oly He « lu ovoids the sheking of blade usilly punch r used. fo rome the cticked part of He plate 0 Strip wilh the punch. ° flere are two Hyper of stripper Is generally used. ji die-puncl system; Fixed Strippers]E os Pemanentty Liold Hie plate or sinb uluch Is ‘berg cub,© Spring loaded stripper. IF ts connected. with hour) cua it Lidds the plate on cinib af darough gprit Ve 2 operation. Flag Hme of cutting or ofher lanock. Outs na * Lswetwour ig a crechouuse usually connect to ram aud operate by press ram © It Is used. to freang or remove workprece- from Dit Dy Dowel Pins ~ *Dowe, Pin is used to comnect NS oe, Os Ses die with die shoe « & S Eerockweg- e TE is & Semi pemquent tybe pin to © ON? attach dre with oie cloe. _Die shoe + « Dig Ghose is provided. at ‘thie base of die | to stbport it. s[big made-up of cast Iron to supbort compressive load. elt is built-up agaiut Bolster plate utlich wear oll te food ot Fae dic oF die eloe. Pilot + [ee Ram * Pilot és Provided, sity fhe puncl to coutring tne bole in a blonks Punch, IE ensure Prat tole of blank erst KV Alot oF fhe Genres of biant . elt is not ‘on imtegral port of the bunel, but is only wed. Whey o, hole at the contre of blank 1: required. Z—Horkplece-—— cor the pressure ow edraqa= — Pi a : yen 1s alto not iwregqral component of die~ punch syshuy bub if is provided uxhren ertra operation like cuthing of extended bart of plate [strip is required « roe Misfeed. Detector 3 Smality * Misfeed detector decided, the position of A the pilot fo inc enterings fe \otector e |b provides the required aren on whycl, billot centred in the bole elt fs Hiner Han pilot ang gives actual both.UN Tale) \rugot © kg the first solid. product after solidificotiow of, : [quid Wetol + Bloom 1 lt is the first product of square cross-sectioual area, after rolling (Reducing Taickness) pf Ingots Slab‘ It is rolled product of bloom, uluch hat roctonguler cross - sectoual, area + : Plate 1 Metallicbpoduct unlvoce thickness is greaker than 5mm and bas roctongular xX - Sechoual areas \ Sheet + Metalic product whose Hrickuess jg less trom 5m aud uuidth is greater thon G00mmared it hae ractongular Cross-sechonal areas Strips It las uudt, of lecc Han 600mm and tHilckness 16 less Han Soy. Punching or Piercening _ tlk is an operation performed om sheet metal or metullicstrip. + Fonchineg or Percening is an operation for cutting a hole ih mefallic sirib or sheet by shearing achon. Clearance in punching or pleecering; \ el punch or blercertng puch or press must be same size of bole- el buncliing or pier cevung size of die must be larger Hay punch size Hot clearance ig provided on die | Sha of Die = Give of punch (hele) #2 ¢ phere, C- radial clearanceBlarkien _ *Blovkiva fs ox, operation pufermed O14 metallic sheet or Shr J * : . SI ie a shearive operotion Iv which metal cut oct from fix sleek or strip ys dssired utorkpiece- “Dice of circular shabe ig @ general product by blanking pperalion « Clearance 14 blankiivg ; elu blanking operation size of he dye mut be scune at fl sie OF blank | disk. ely blanking operahiony clearance is provided ow the puncl, or press Size of Punch = sizeof die-2e Where, C- Padial clearance For, clearance Ce) = 09-0032 tlt. where t 2 thickness of Sheet [sinp T > 6 hear strength of maternal sheet /sire'b (N/mm?) chearancé (ic) = Pore eo (P)x thickness of weg Sheet] strip Qu. Deternune the die and punch of blanking a circular dise of 20 mm diameter from Q sheet: whose thickness is [2 mm and, sheor strength of Sheet wmoterial is 294 MPa. Allso determine Hee olie ond punch size for punchy, a circulor lwole of 20 mm diameter from the above Sheet wlwse thicty ew 's 125 mmo [tool - live - 2374 Punching and Blanking’ force required, 5 Force Required (E> Lxt*T(N) i for ‘cireulay hole | blak + 2art C ol) anl} Where b = Shear lenght (mm) \ i ' t=) fluckness of sleet] strib (9) TF Shear shength of material (N/mm r= rodius of lle | blank.'| Press copatily will be = Fre Momus sire of ole Punched | pier ced) Shear force required. PW bD Compressive force on punch for minimum size 4) bole =) 62 x Ret For 4 Punclung , i ) adxt*T = & x Rat [ee SEE tn name i, ~ ~ Sr On A bole is to be pinched ina Is é) cepa mm thick plate hoving.” altimate shear strengih of wakerial Strength of 3 Nfmnm, if the allowable povjel, / press. crussing trees In the punch is 6 N/mm the diameter “of Smallest bole that con be punched will equal to? \ pC = We62 to lS Dro -live-'23 7, Qn. A tote of diameter 35mm js to be buncted “iy a Sheot metol of thickney 't' and ullimate shear Strength 400 MPa ultimate - Ghear strength 400 MPa using punchig force 4YEN, The mosuimuy value of toe t' 16 2Qu. With a bunch for whch He! ma nating vce Z Stress ig 4 times the marunuy shearing stresc = Hie plate, the smallest hole that com be pupehed it fhe plate wobld be - { O Vy 6 teietness OF plate OL x rhicbuers of plore -, Plate thichwes @ 26 Plate thickwess. ° ran h or die $= Provid blear 0” punc aa or punth or die to reduce or « Shear is provided either ie the muoimuy force oh punch or press « ° By providing shear ‘oy purch or vdie the neoruinuny force of culting decreases but evargy twodbe 'y culling remaiut conttats —— \ * Arex, = Areas = Energy inwalve Ib purehirg [blanking i \ = Constant, \ . Force (F) on Purch uth Shear; ° Et for. bunch] blanking with shear on poy mens ck | blanking i = Fran X Pat Where p — fercentoge - Shear enerqy,) = \FXS t ~ thicknes Cons tot energy for blanking | Panedvig | Freon XP xt = Fas F = Finan KP CE 5we we . Ee Que A hole of 100mm diometer is to be punched ih steel, Plate of S-6mm Huckress* The ultimate shear Stress ic BON) usith normal clearance Oh tool, cutting is complete a Hot, of penreterahon of the puncly Guve the, suttoble for the punching to bring. the cuater arith ln Hae copa- city of BOT press. [ool - live -25] Trimming Cotting Unwanted. exces: moterial from the periphery of all ready formed object, is trimintyg » Showing * & It ig process’ of, removing excess in eee of Strib to get accurate dimangion « Loncing® A. hole is bartiolby out ond. one side is bet, there ic Wo material removal, toke place Notelung + Material is removed \\ Jrom edge of Hae stribor Sheed. ferferating: Cutting Nwuber of small oles uthich ore very Close to each otter oh a sheet/ strip: Blithig? Cutting a complex, geometry on gheck|strib is cobled. slitting. Steel Rule’ Complee slabs ove cut on strib| sheet by a steel Rule. Nibbleing t Asigle punch is moved up-down rbmber of dimes fo cub small rotenial each to from complex geometry on Sheet] strip «aed Id, working forming brocess. \ \ " dimples and. brojectio a ? hy are brovided on punch aud ob oh Gheet cae . die of correspond ° fuckness of Workpiece a NO Shapes f Pemaing : Embossing * elt fs 0.0 ely pws process metal [gtrib » by plus operation elu constant 5 prrough out Hee vol : * Deformation of voluue of sheet yretal place: a. a elt requires less force than coining, + By embasng oberolion ; Produch for clecoration & releg i jous Oe perboced formed: —}\ Coining * Vi elt ts cold working pressing operation ely the coi operation troagh 7 out volwue deformation doe vot : tokes but only on surface of. Ss oe eek reiet the blank inapress aia 1s imparted , « In His operahon, large face is required than embanii operation Hard currency Wke coins ae > sheet|sttb [blank ° By coining igsrtgquia. bodge ete are formed. Curling : When Oo end ledge of a sheet] Strib Is parkally borded, Flus is called curling. Hening + Thus is Hae Complete bounding of edge of sheet/sinp-* UNIT-5 salting! “eek Drowing painedl = anaes Tobe Drawing (Seam less tube s By a moving Madr) Wire Drausing ( Ductile Moterial) A Drawing in forging (Reducing dia. of X-sechon of ove Shree - Held 8 Deeb Drauking Side of Job). Drawing rr p It is plastic deformation process in ushielj o, flate, plote or sheet (Blasi) Is formed iw “ol ev, Brdbmenetonal object of shape — like: seup -or, trodlow .cyliiaderr + | | + Drawing is performed. with the help of punch and die. Deep Drawing a If the height of cob slpbe obyect..is qreaker Hate its “diameber Thee the process’ of draiiting is called deep drawing « wee ' sited ol drawing Hickness of blank (sheet/Plale) and tickuecc of 3D cub shabe object abuost Pemaint Couatheed. Blank Dianeter For 3-D Cub Slobe Object oa d | 45) Vit By Cowervahon~mau of the Te ples makerial by blank and -cup. ta} a oust let. p. dia. of blank £ - Hhickness of blank and cup | d - daw of cup tea h - height of cup WendBy Conservation of rau (Mesdeiane = (Meweup rs AVolwme = fx Volwiue \ > toeaf = & Leal) 2) $q7. 5 < x al, apy = ad 7 idbh De 2 ED 2 + 4d - 05 uhere r= Cornen - Pockiut of die Dia of Punch = Dia. of die-2-5¢ Punch Force = Adt ac] 6 = Tensile meee \ Draw cuuing Ratio + Ratio « The ratio of blank Oe to He, 3-a ub ‘hi, is called, drawing raho. —_Linihing pe Ratio $ , A The ratio of \diameter of blank fo Hie mibuinicn diameter produced jan siagle draw is called Limit ‘diameter ratio. Limuting Duauuirg Rotio = domi In general LDR is 16 23 nfin cylinder vessel with flat bottom can .be\ deeb, drouing by double acho draure IN obiwoub mail event wiliney LDR t= ‘du first draw reducton = 501. fail eas In second draw reduchon = 307, ln Hird draw reduction = 25°/, In fourth draw reduction, = 161, Qh. For obfuining a cup of diameter 25 mm and height 15mm the size of round blank should be. Qn. A shell of 100 mm. dliouneter anol, 100 mm hetglt uth the cornen radiut 0-4, mm ts tube by cup drauing , The requireol, blaxk dix. is? Qn. The initial blank diameter required toiform a cylindnical cup of outside, ciameten dl’ aud, tohal os fea ents a corner Sodliun'P! is obtuined L@Do = Se tHdh -0-Sr (D Do zd +24 42r 200 A t+ 2L>tor ) yibede \ © Vo = @ Do = Vd® t4db-65r ak d ue \ \ Me A Cab of 50mm diameter; ord loo mm hetgut is to be drawn from, lows carbon steel sheeb neglecting the.) influaece of thickness guid ; Rodis, © Colewate the blank diameter @ Decide wheter it-car be draus jin & single draw, rf maxinwy reducton permitted re Yo. corhnenA ast of circular cross-SecHon uy I “th peace Sad. bight 60mm usilh a corner om radius gQrom is to he obtained, in Cro Steel ffm thickness © Calecate the blank size to draw M ee will +t be possible to draw the “cup iw sing : oe Ha! be an. A cy liedrical vessel wil, Aad bottom cary | deeb drain bys | _— | @ Shallow drawing ® Single acho, deeb drawing _@ Double action deeb drawing @ Tribble action deeb drei “7 ; Qn: A cub of 10e ‘height and 5 om diameter Is to be made from sheet metal of 2mm Hache The vumber of dedoctioh necetfory twill be, @® ove) uo CF three D Four: 12 Qn. The bonding force required for 'V' bonding ,'U' bording and edge bonding aull be ih rotio of Bt:2:05 @ 220-5 ©1128) O ts] Extrusion Die + i ‘Extrusion is a forming process like squeezii of toottpaste out of ee 4 ‘Iu this process ,metal is compressed. and, force to flow through suitable die to fornia a product conttoudt lorosee herl «8 et of °A solid ram drives te entire billet to ond through a stationary dig ond alto provided, with addition power ‘to Over te function. + Bodtrusion die are generally made of tight corbon oF Hss steels,ue ing Die : pomaao si au aan ee 5 es aye fo de \iuatles “Forging Is forming proces in tile’ product bar! manufactured, on formed. by compressiixg force “Betuedr| tui dléss 1 te Adele xh men oC boew a Hl? ° Malteabilitp is other essential properties of motertod, required for forging PS FOSMAN Cath AN baad ofil * Forging die consist of tuo symetrical olie called, ubber die aud lower die. | * Upber dic cdtached, with Hae ram oyu, [1 | dom lower Hes ow anil. { (Zable Die elAKHy helb of upber utluch attached oe with ~ rem Compressive force is ie Workpiece abbied. Ow the Wworkpicce to give Pre Blerdie desire shape of objects r fen Die Casting 3 ° Liquid. metal is Poured into a metal ie and then solidify -it ,This process is called die casting. +e Types of die casting 5 Je_Gurowity Die-casting _ * Liquid metol poured into metalic die by growrty force y40 it is called gravity die - cashing, * Surface finish obtained is bettar thaw othen Casting. + Application ¢ - It is used for casting of automobile bants of alunaniuny.Presses Die catia: * Liquid. -metal of smaller pressure die casting: “Kis used fen « pressure die- melting port is casted by | complex shape of Hse object is aed for casting re amaterels Tike lead (PR); none ZinO(Zn) ete-Bol fngneering Embortant fol eae —UNTT= 2 Qn. 1. Define Metal cutting utith its types--and. alto unite tybe of metal cutting tool ° Qh.2. Write the nomneclature of cutting tool. Qn. 3. Nrite down about chip formation aut, its types. Qn4. Write about mechawics of metal cutting * Tangeholor cutting force ° Feed. force ° Radial force . : Q4 5 Write about tool wear usith tyber and mechanism behind tool wean. On. 6. Explain cutting fluid with its functon and properties. Also usite +ybes of cutting fluid. UNIT-2 Qu. 1. Explain in deeb about machinability ; Qn2. Write about Toot materi utith its aide vanitien. Qn: 3. Explou'n » ¢ High carbon steel *High speed. steel 7 18-4-] Hs¢ ~ Moly bolenuin He ¢ - Suber Hs¢ ° cemented carbide © Coromics © Diomond, ; * Cubic Boron Nitride : Qu-4. Write the Nomenaclahure of drill bits . QnsS- Write about reawmen ond milling cutter ciith its tybe. Qn.6> Write about Heat treatment,