Paper Key : IRJ************748
Author: Pawan Kumar Singh,Dr. Pawan Kumar,Dr. Shyam Singh
Date Published: 01 Nov 2024
Abstract
The compound die is utilized in the industry for manufacturing various sheet metal components. This study focuses on the design and development of a compound die specifically for producing plain washers used in different types of bolts. Previously, Plain washers were made using a conventional die, which involved two separate processes requiring two dies, two mechanical power presses and more than one workers. This method was time-consuming, longer production times, quality issues, and higher energy consumption which leading to increased per unit costs. The introduction of the compound die addresses these challenges by allowing blanking and piercing operations to be completed in a single stroke of the mechanical power press. As a result of developing the new die tooling costs and the per-unit cost of Plain washers have decreased, while production rates have increased. The compound die has led to a 75.6% reduction in tooling costs due to significant savings in raw materials. Additionally, production rates have surged by 300%, maintenance costs have dropped by 66.6%, and labor costs have decreased by 75%, all of which positively impact the per-unit cost of the product. Overall, the unit cost has been reduced by 36%. Thanks to the compound die, which has shortened both the cycle time and material handling time and we can produce plain washer from sheet metal scrap which leads raw material cost reduction. The newly designed system allows the operator to easily use the dies with the assistance of a mechanical power press. The main goal is to maintain a straightforward mechanism while ensuring that all necessary requirements are met. The new tool can be used in large-scale manufacturing to create uniform parts with precise geometrical tolerances. The advantages of using a compound die include time efficiency, reduced movement of the part which minimizes operator fatigue, and lower labor and production costs. A one-time investment in the necessary equipment will guarantee a consistent supply of high-quality products, leading to significant profits for manufacturers.Dies are essential in modern manufacturing, enabling the efficient shaping and forming of sheet metal into various products used in sectors like automotive, aerospace, electronics, fasteners, and more. The design and analysis of press tools are crucial for ensuring precision, cost-effectiveness, and production efficiency. A die tool is the material that reshapes sheet metal into different sizes and shapes and sheet metal dies are employed in numerous industrial and commercial production processes. Many everyday products are created using sheet metal press dies, leading manufacturers to innovate and explore new trends. Dies are often tailored to the specific item being produced. They play a key role in industrial manufacturing, as nearly all products with multiple components will include at least one part shaped by a press tool through stamping tool design. This widespread application is primarily due to the low cost of sheet metal and the quick and efficient nature of forming operations.1Categories of DiesSimple dies: These dies are made to carry out a single operation, such as blanking, piercing, notching, trimming or drawing using one stroke of a power press.Multi-operation dies: These dies are designed to perform multiple operations simultaneously in a single stroke of a power press.Progressive die: A progressive die features a series of operations with each station executing a specific task on a workpiece during one stroke of a power press. Each step contributes to the final product, which is completed only after the last operation. This type of die is commonly used in metalworking to efficiently produce a high volume of complex-shaped finished items.2Compound Die: A compound die is used to create basic flat components, such as washers and other flat sheet metal products. In this method, a metal strip is fed through the compound die, which performs multiple cuts and punches in one stroke, unlike progressive or transfer die stamping that requires several strokes. A compound die can carry out two or more operations at one station and is mainly considered a cutting tool, focusing on cutting tasks.1Combination Die: A combination die is akin to a compound die, but its main difference is that it can perform multiple cuts, punches, and bends in a single stroke rather than needing multiple strokes. In combination die operations, cutting is combined with non-cutting processes. These dies can switch between progressive and compound operations based on the specific requirements of the final product. This flexibility allows manufacturers to improve their production processes for various part designs and quantities. Combination dies offer a versatile and efficient tooling solution for producing sheet metal parts with different shapes and production volumes, merging the benefits of both progressive and compound dies to streamline production and lower the overall cost of the finished product.3Power Press Machine :- A Power Press Machine is utilized for shaping metal into specific forms. It features a controlled system designed for processing different types of sheet metal. This versatile machine can both shape and cut simultaneously, making it primarily used in sheet metal fabrication. It is one of the most flexible machines available for sheet metal work and is widely used in various heavy industrial settings. In the past, manually shaping metal sheets required significant labor and effort. However, with a Power Press Machine, cutting, bending, pressing, and forming metal sheets into various shapes and sizes becomes much easier by applying substantial pressure.4Washer :- Washers are small circular rings that are placed on the shafts of threaded fasteners like screws and bolts. They enhance strength by evenly distributing the weight load across the fasteners, positioned between the surface and the head of the fastener. Made from mild steel or plastic, washers offer corrosion resistance, which boosts the strength and longevity of the fastener.Purposes of using washer:Load Distribution : One of the primary reasons for using washers is to spread the load over a larger area. While threaded fasteners are useful, they can put significant stress on the material around them. For instance, when constructing a shed with wood, driving a fastener into the timber could lead to splintering and compromise the structural integrity of the surrounding area. A washer helps to distribute the weight, reducing potential damage to the material. Although washers may not be necessary for all materials, they are recommended for softer ones like wood.Spacing : It may seem unusual to use a spacer when inserting a fastener, but it can be beneficial if the fastener is particularly long. Sometimes, the bolt or screw may exceed the depth of the material. In such cases, a spacer washer is needed to create a gap between the surface of the material and the head of the fastener, ensuring a secure hold without protruding through the other side.Vibration Dampening : Washers can also be utilized to absorb the impact or shock from vibrating machinery.Previously, plain washers were made using basic dies separately, which involved two different operations to produce each washer. This approach negatively impacted production rates and the cost per unit. By transforming these simple dies into a compound die while taking design complexity into account, we can overcome many of the previous drawbacks.The objective is to create a compound die for manufacturing plain washers used in various bolts and automotive components. Previously, the plain washer was made using a traditional die, which involved two separate processes requiring two die sets, two mechanical power presses for a single output, and multiple workers. This method was time-consuming, leading to increased costs, longer production times, quality issues, and higher energy consumption. The solution lies in utilizing a compound die that can perform both blanking and piercing operations in a single stroke of a mechanical power press. Additionally, we need a die that is adaptable to different raw materials, allowing us to produce plain washers from sheet metal scrap, which is abundantly available in various thickness in Raipur.
DOI LINK : 10.56726/IRJMETS62039 https://www.doi.org/10.56726/IRJMETS62039