You should have to write the problem first then write what is given and

required with schematic diagram to make clear for your reader.in addition to
that you need to explain for which part of the process you are making design
analysis.

DESIGN OF COMPONENTS OF COMBINATION PRESS TOOL

Reciver cover model s Model Description

I) For piercing die and punch of central line

A) Die Clearance C

 C= .0032 × 𝑡 × √𝜏 2.1

Where C = 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒

t= 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙,mm
𝜏 =material shear stress ,M Pa
Inserting the value on equation 1 above t=1.5mm,𝜏 =460 N/mm2 will
become
 C= .0032 × 1.5 × √460
C= .1 mm
Hence clearance for die is 0.1mm.
 For ф5mm punched hole die clearance = 5𝑚𝑚 + 2 × .1𝑚𝑚
= 5.2𝑚𝑚
 For ф12mm punched hole die clearance= 12𝑚𝑚 + 2 × .1𝑚𝑚
= 12.2𝑚𝑚
 For rectangular hole length die clearance L= 68mm +2 × .1𝑚𝑚
L= 68.2𝑚𝑚
  For rectangular hole height die clearance H= 21.35𝑚𝑚 + 2 × .1𝑚𝑚
H= 21.55𝑚𝑚
B) Length of the punch for ф5 piercing punch using buckling formula

nπ2 𝐸I
l=√ Eq.2.2
𝑝

Where n= 2 𝑤𝑖𝑡ℎ 𝑠𝑡𝑟𝑖𝑝𝑝𝑒𝑟 𝑔𝑢𝑖𝑑𝑒

𝑁 𝑁
E= 𝑌𝑜𝑢𝑛𝑔′ 𝑠 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 , 2.1 × 105
𝑚𝑚2 𝑚𝑚2
𝜋𝑑 4
I= 𝑚𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 𝑓𝑜𝑟 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑏𝑜𝑑𝑦 = , Eq.2.3
64

𝑤ℎ𝑒𝑟𝑒 𝑑 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑢𝑛𝑐ℎ , 𝑑 = 5

P= 𝑝𝑢𝑛𝑐ℎ𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 = 𝜋𝑑𝑡𝜏, Eq.2.4

Where 𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 , 𝜏 = 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ , 𝑑 = 𝑑𝑖𝑎𝑚𝑡𝑒𝑟

I = 𝜋54
64
= 30.7𝑚𝑚4

𝑝 = 𝜋 × 5 × 1.5 × 460

𝑁
= 10838.5
𝑚𝑚2

2𝜋2 2.1×105 ×30.64

𝐿=√
10838.4946

𝑙 = 108.3𝑚𝑚
If the safety factor is 3,then

𝐿 = 108.3/3

𝐿 = 36.1mm

Similarly

𝜋 × 124
I=
64

I= 1017.9 𝑚𝑚4

𝑝 = 𝜋 × 12 × 1.5 × 460

𝑁
𝑝 =26012.4
𝑚𝑚2

2×𝜋2 ×2.1×105 ×1017.9

L= √
26012.4

L= 402.8𝑚𝑚

Taking Safety factor 3 for L

402.8
𝐿= 𝑚𝑚
3

𝐿 = 134.3 𝑚𝑚

The length of the rectangular punch similarly calculated using the buckling
equation

𝑏ℎ3
𝑚𝑜𝑚𝑒𝑛𝑡𝑜𝑓 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 𝑓𝑜𝑟 𝑟𝑒𝑐𝑡𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑏𝑜𝑑𝑦 𝑜𝑓 = I = Eq.2.5
12

𝑤ℎ𝑒𝑟𝑒 𝑏 = 𝑏𝑟𝑒𝑎𝑑𝑡ℎ/𝑙𝑒𝑛𝑔𝑡ℎ, ℎ = ℎ𝑒𝑖𝑔ℎ𝑡 of the rectangle.

 68×21.353
𝐼=
12

= 55146.9 𝑚𝑚4

𝑝 = 2(68 + 21.35) × 1.5 × 460

𝑁
= 123303
𝑚𝑚2

𝑛𝜋 2 𝐸𝐼
𝐿=√
𝑝

1×𝜋2 ×2.1×105 ×55146.9

𝐿=√
123303

𝐿 =962.8 mm

Taking the safety factor 5 to length L of

962.8
𝐿=
5
𝐿 = 192.56 𝑚𝑚
C) Thickness of the die by considering over all force on the die

𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑡𝑜𝑡𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 = 𝑉 = 8 × 10838.49 + 26012.38 + 123,303

 𝑁
𝑉 = 236023.3
𝑚𝑚2

𝐵 2
3𝑉 (( 𝐴) )
𝑇𝑟 = √ 𝑓𝑡 [ 𝐵 ] Eq.2.6
1+( )2
𝐴

Where Tr= 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑖𝑒(𝑚𝑚)

𝑉 = 𝑉𝑒𝑟𝑡𝑖𝑐𝑎l force (N)

𝑁
𝑓𝑡 = 𝑃𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 ( )
𝑚𝑚2
𝑁
= 160
𝑚𝑚2

𝐵 = 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑆𝑙𝑜𝑡/𝑏𝑙𝑎𝑛𝑘 (𝑚𝑚)

𝐴 = 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠𝑙𝑜𝑡/𝑏𝑙𝑎𝑛𝑘 (𝑚𝑚)

Taking the approximate to square for circular hole the summation of the slot will
become

𝐵 = 8 × 5 + 12 + 21.35

= 73.35 𝑚𝑚

Similarly 𝐴 = 8 × 5 + 12 + 68

= 120 𝑚𝑚

Inserting the above value in Eq.2.6 we will get

73.35 2
3×236023.23 ( )
120
𝑇𝑟 = √ [ 73.35 2 ]
160 1+( )
120
 = 61.6 𝑚𝑚

Hence Tr approximately 62mm

Tacking 3mm for grinding it becomes 65mm.

D) tacking the above thickness to get margin M

𝑀 = 2𝑇𝑟 (Max.) Eq.2.7

Taking the above value 𝑀 = 2 × 62

= 124 𝑚𝑚

E) Length of the die is calculated L

𝐿 = 𝐴 + 2𝑀 (Min.) Eq.2.8
= 120 + 2 × 124

𝐿 = 368 𝑚𝑚

F) Width of the die is calculated W

𝑊 = 𝐵 + 2𝑀 + 3𝑑 Eq.2.9
Where d is screw diameter to fasten the die it is depend on
vertical shearing force .
𝑊 = 73.35 + 2 × 62 + 3 × 16
𝑊 = 245 𝑚𝑚
G) Taking the length 400 mm and the width 250mm from table diagonal pillar
die set Fig.N5a. a1Xb1=400𝑚𝑚 × 250𝑚𝑚
 Length of lower bolster a2= 670𝑚𝑚
 Thickness lower bolster c1= 63 𝑚𝑚
 Width of lower bolster b2= 310 𝑚𝑚
 Upper bolster thickness c3= 100 𝑚𝑚
  Guide pillar diameter d1= 38 𝑚𝑚
 Distance between two guide pillar e= 510 𝑚𝑚
H) Screw and dowels
𝑁
Vertical force = 236,023.23
𝑚𝑚2

Stripping force= 10% × 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 Eq.2.10

𝑁
= 23602.3
𝑚𝑚2

Taking the formula root area A is given by

𝐴 = .7854(𝐷 − 1.227𝑝)2 Eq.2.11
Where D –diameter of screw .
p-pitch of the screw.
Taking M12 screw into Eq.2.8

𝐴 = .7854(12 − 1.227 × 2)2

𝐴 = 71.57 𝑚𝑚2

Load capacity L for the screw

𝐿 =𝐴×𝜎 Eq.2.12

𝑁
Where 𝜎 − 𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤 80
𝑚𝑚2

𝑁
𝐿 = 71.57𝑚𝑚2 × 80
𝑚𝑚2

= 5725.6 𝑁

Number of screws to take 23602.3 N the stripping force

𝑠𝑡𝑟𝑖𝑝𝑝𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
No_of screws= Eq.2.13
𝐿
 23602.3 N
=
5725.6 𝑁

= 4.1212

=4

Hence for M12 number of screw needed is 4.

Tacking M 16× 1.75 screw and using Eq.2.11 and Eq.2.13

𝐴 = .7854(16 − 1.227 × 1.75)2

= 150.7 𝑚𝑚2

23602.23
No of screw =
150.7×80

= 1.9577

Hence the number of screw M16 is 2.

To take the horizontal force dowels are used

Horizontal force= 𝐷𝑖𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑐𝑒 × 𝑉 Eq.2.14

= .1 × 236,023.23

= 23602.3 𝑁

If two dowels are used

23602.3
Load/dowel=
2

𝑁
= 11801.2
𝑑𝑜𝑤𝑒𝑙
 𝑙𝑜𝑎𝑑/𝑑𝑜𝑤𝑒𝑙
Area= Eq.2.15
𝜎𝑑

𝑁
Permissible stress of dowel - 𝜎𝑑 = 50 𝑚𝑚2

11801.2
Area=
50

= 236.023 𝑚𝑚2

236.022
Dowel ∅ = √
.7854

= 17 𝑚𝑚

Hence two dwells ∅ 17 are required to take the horizontal force.

 Length of standard punch for round pierced hoe ∅5 𝑎𝑛𝑑∅12 from standard
table 70m (For type punch d,Fig. M3)
 M6.00 STANDARD PILLARs (Fig.M4) for d1= 38 𝑚𝑚 length
90,200,220,240,260,280,300,350 Type A.
 Type B length for Standard pillar 70,90,110.125 Type.
II) Side profile and rectangular die pierced hole die and punch.
A. Die Clearance C
From Eq.2.1 ,calculated as C= .1 mm
Hence clearance for die is 0.1mm
 For rectangular punched hole 12.8 mm× 10.38 𝑚𝑚 with die clearance
= [(12.8 𝑚𝑚 + 2 × .1 𝑚𝑚)(10.38 𝑚𝑚 + 2 × .1 𝑚𝑚)]
= 13 𝑚𝑚 × 10.58 𝑚𝑚
 For rectangular punched hole 13.99 mm× 25 𝑚𝑚 with die clearance
= [(13.99 𝑚𝑚 + 2 × .1 𝑚𝑚)(25 𝑚𝑚 + 2 × .1 𝑚𝑚)]
= 14.2 𝑚𝑚 × 25.2 𝑚𝑚
  For rectangular punched hole 90.46 mm× 13.3 𝑚𝑚 with die clearance
= [(90.46 𝑚𝑚 + 2 × .1 𝑚𝑚)(13.3 𝑚𝑚 + 2 × .1 𝑚𝑚)]
= 90.66 𝑚𝑚 × 13.5 𝑚𝑚

B) Length of the punch for piercing rectangular punch 12. 8mm × 10.38𝑚𝑚
using buckling formula

Using Eq.2.2
1×𝜋2 ×2.1×105 ×1192.9
𝐿=√
31988.4

= 278.01 𝑚𝑚

Taking safety factor 3 we get

278.01𝑚𝑚
𝐿=
3

= 92.67 𝑚𝑚
𝑏ℎ3
𝐼= ,
12
12.8×10.383
𝐼=
12

= 1192.9 𝑚𝑚4

𝑝 = 2(12.8 + 10.38) × 1.5 × 460

𝑁
= 31988.4
𝑚𝑚2

Similarly for rectangular punch 25 × 13.99 the punch length calculated as

25×13.993
𝐼=
12

= 5704.4 𝑚𝑚4
 𝑝 = 2(25 + 13.99) × 1.5 × 460

𝑁
=53806.2
𝑚𝑚2

𝜋2 ×2.1×5704.4×100000
Hence 𝐿 = √
53806.2

𝐿 = 468.76

Again tacking the safety factor 5

468.76
𝐿=
5

= 93.75 𝑚𝑚

Similarly for rectangular punch 90.46 × 13.3 the punch length calculated as

90.46×13.33
𝐼=
12

= 17734.96 𝑚𝑚4

p= 2(90.46 + 13.3) × 1.5 × 460

𝑁
= 143,188.8
𝑚𝑚2

𝜋2 ×2.1×17734.96×100000
𝐿=√
143,188.8

𝑁
= 506.66
𝑚𝑚2

Tacking safety factor 5 L becomes

506.66
𝐿=
5
 𝐿 =101.3 mm

𝑉𝑒𝑟𝑖𝑐𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑡𝑜𝑡𝑎𝑙 = 31988.4 + 53806.2 + 143,188.8

= 228983.4 𝑁

𝐵
3𝑣 ( )2
𝐴
Thickness of die= √ 𝐵
𝑓𝑡[1+ ( )2 ]
𝐴

3×228983.4×.9915]
𝑇𝑟 = √
160×1.9915

= 46.2 𝑚𝑚
Allowance for grinding 3mm hence Tr 49mm
Margin ,𝑀 = 2𝑇𝑟
= 1.6 × 46𝑚𝑚
= 73.6 𝑚𝑚

Length of the die L,

𝐿 = 346 + 2𝑀
= 346 + 2 × 73.6
= 493.2 𝑚𝑚
Width of the die, W
𝑊 = 𝐵 + 2𝑀 + 3𝑑
= 154.577 + 2 × 73.6 + 3 × 16
= 349.777 𝑚𝑚

Taking the length 500 mm and the width 400mm from table diagonal pillar die set
Fig.N5a. a1Xb1=500𝑚𝑚 × 400𝑚𝑚

 Length of lower bolster a2= 798𝑚𝑚

 Thickness lower bolster c1= 75 𝑚𝑚
 Width of lower bolster b2= 460 𝑚𝑚
  Upper bolster thickness c3= 110 𝑚𝑚
 Guide pillar diameter d1= 48 𝑚𝑚
 Distance between two guide pillar e= 624 𝑚𝑚

Screw and dowels

𝑁
Vertical force = 228,983.4 𝑚𝑚2

Stripping force= 10% × 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 Eq.2.10

𝑁
= 22,898.34
𝑚𝑚2

Taking the formula root area A is given by

𝐴 = .7854(𝐷 − 1.227𝑝)2 Eq.2.11

Where D –diameter of screw .
p-pitch of the screw.
Taking M12 screw into Eq.2.8

𝐴 = .7854(12 − 1.227 × 2)2

𝐴 = 71.57 𝑚𝑚2

Load capacity L for the screw

𝐿 =𝐴×𝜎

Eq.2.12

𝑁
Where 𝜎 − 𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤 80
𝑚𝑚2

𝑁
𝐿 = 71.57𝑚𝑚2 × 80
𝑚𝑚2

= 5725.6 𝑁
 𝑁
Number of screws to take 22,898.34 N the stripping force
𝑚𝑚2

𝑠𝑡𝑟𝑖𝑝𝑝𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
No_of screws= Eq.2.13
𝐿

22,898.34 N
=
5725.6 𝑁

= 4.1212

= 3.99

Hence for M12 number of screw needed is 4.

Tacking M 16× 1.75 screw and using Eq.2.11 and Eq.2.13

𝐴 = .7854(16 − 1.227 × 1.75)2

= 150.7 𝑚𝑚2

22,898.34
No of screw =
150.7×80

= 1.89

Hence the number of screw M16 is 2.

To take the horizontal force dowels are used

Horizontal force= 𝐷𝑖𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑐𝑒 × 𝑉 Eq.2.14

= .1 × 228,983.4

= 22,898.3 𝑁

If two dowels are used

22,898.3
Load/dowel=
2
 𝑁
= 11449.15
𝑑𝑜𝑤𝑒𝑙

𝑙𝑜𝑎𝑑/𝑑𝑜𝑤𝑒𝑙
Area= Eq.2.15
𝜎𝑑

𝑁
Permissible stress of dowel - 𝜎𝑑 = 50 𝑚𝑚2

11449.15
Area=
50

= 228.983𝑚𝑚2

2228.983
Dowel ∅ = √
.7854

= 17 𝑚𝑚

Hence two dwells ∅ 17 are required to take the horizontal force.

III) Blanking die and punch

a) the force required to blank the component calculated as
𝑝 = 943.71 × 1.5 × 460
= 651159.9 𝑁
b) thickness of the die evaluated as Tr

𝐵
3𝑣 ( )2
𝐴
𝑇𝑟 = √ 𝐵
𝑓𝑡[1+ ( )2 ]
𝐴

154.577 2
3×651159.9 ( )
346
=√ 154.577 2
160[1+ ( ) ]
346

= 45.1 𝑚𝑚 𝑚𝑚
 = 45 𝑚𝑚

With grinding allowance of 3mm total thickness becomes

𝑇𝑟 = 45𝑚𝑚 + 3𝑚𝑚
= 48 𝑚𝑚
Margin ,M
𝑀 = 1.6 × 45𝑚𝑚
= 72 𝑚𝑚
Length of the die ,L
𝐿 = 𝐴 + 2𝑀

= 346 𝑚𝑚 + 2 × 72 𝑚𝑚

= 490 𝑚𝑚

Width of the die ,W

𝑊 = 𝐵 + 2𝑀 + 3𝑑

= (154.577 + 2 × 72 + 3 × 16) 𝑚𝑚

=346.577 mm

Approximated to the above length and width 500 𝑚𝑚 × 400 𝑚𝑚

Taking the length 500 mm and the width 400mm from table diagonal pillar die set
Fig.N5a. a1Xb1=500𝑚𝑚 × 400𝑚𝑚

 Length of lower bolster a2= 798𝑚𝑚

 Thickness lower bolster c1= 75 𝑚𝑚
 Width of lower bolster b2= 460 𝑚𝑚
 Upper bolster thickness c3= 110 𝑚𝑚
 Guide pillar diameter d1= 48 𝑚𝑚
 Distance between two guide pillar e= 624 𝑚𝑚

Stripping force= 10% × 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑓𝑜𝑟𝑐𝑒

 = 10% × 651,159.9

= 65,115.99 𝑁

Taking the formula root area A is given by

𝐴 = .7854(𝐷 − 1.227𝑝)2 Eq.2.11

Where D –diameter of screw .
p-pitch of the screw.
Taking M12 screw into Eq.2.8

𝐴 = .7854(12 − 1.227 × 2)2

𝐴 = 71.57 𝑚𝑚2

Load capacity L for the screw

𝐿 =𝐴×𝜎

𝑁
Where 𝜎 − 𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤 80
𝑚𝑚2

𝑁
𝐿 = 71.57𝑚𝑚2 × 80
𝑚𝑚2

= 5725.6 𝑁

𝑠𝑡𝑟𝑖𝑝𝑝𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
No_of screws= Eq.2.13
𝐿

65,115.99 N
=
5725.6 𝑁

= 11.37

= 11
Tacking M 16× 1.75 screw and using Eq.2.11 and Eq.2.13

𝐴 = .7854(16 − 1.227 × 1.75)2

= 150.7 𝑚𝑚2

65,115.99
No of screw =
150.7×80

= 5.4

Hence the number of screw M16 is 6

To take the horizontal force dowels are used

Horizontal force= 𝐷𝑖𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑐𝑒 × 𝑉 Eq.2.14

= .1 × 651,159.9

= 65,115.99𝑁

If two dowels are used

65,115.99
Load/dowel=
2

𝑁
= 32,557.995
𝑑𝑜𝑤𝑒𝑙

𝑙𝑜𝑎𝑑/𝑑𝑜𝑤𝑒𝑙
Area= Eq.2.15
𝜎𝑑

𝑁
Permissible stress of dowel - 𝜎𝑑 = 50 𝑚𝑚2

32557.995
Area=
50

= 651.16 𝑚𝑚2
 651.16
Dowel ∅ = √
.7854

= 28.79 𝑚𝑚

Two ∅29 𝑚𝑚 dowels are needed

Hence two dwells ∅29 are required to take the horizontal force

𝜋𝑑 𝐸𝑑
L= √ 2.2
8 𝑆𝑡
 L= 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑢𝑛𝑐ℎ
d= 𝑝𝑢𝑛𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑝𝑢𝑛𝑐ℎ𝑒𝑑 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
E= 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑒𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦
S= 𝑠ℎ𝑒𝑎𝑟 𝑆𝑡𝑟𝑒𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
Inserting the numerical value d=5mm,E=2.1× 100,000 N/mm2 , S=460
N/mm2,t=1.5mm.

𝜋×5 2.1×100000×5
L= √
8 460×1.5

𝐿 = 76.567 𝑚𝑚

Hence length of the punch for 5mm piercing hole becomes 76.567 mm
Similarly for ф8 mm punch length piercing tool
𝜋×12 12× 2.1×100000
L= √
8 460×1.5
L=284.77 mm
The length of 12mm punch is 284.77 mm