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STRUCTURAL ANAYSIS OF A
DIE
A Project Report
Mechanical Engineering
Bennett University
CAD modelling and Structural Analysis of a Die
Contents
Introduction 2
Relevance of die and punch
Overview of the project
Materials and parts used 3
Materials used
Parts used
CAD modelling 4
Manufacturing process 8
Fabrication of die shoe
Fabrication of stripper plate
Fabrication of die block
Stress analysis 15
Blank size, die diameter, and clearance
Cutting force
Stress analysis of the die block using Autodesk Fusion 360
Conclusion 17
Future scope of improvement
References
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CAD modelling and Structural Analysis of a Die
Chapter 1
Introduction
1. Relevance of Die and Punch
1.1 Impact on the industry
In the manufacturing sector, the more expensive casted parts are now being
replaced with sheet metal parts. As a result of this advancement, the weight
and price of these parts have reduced significantly. The production rate could
easily be increased with minor customizations.
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CAD modelling and Structural Analysis of a Die
Chapter 2
Materials and Parts used
1. Materials Used:
1.1 Mild steel (A36), Properties [1]:
1.1.1 Carbon composition: 0.3%
1.1.2 Young’s modulus: 200 GPa
1.1.3 Yield strength: 240 MPa
1.1.4 Density: 7850 kg/m3
1.1.5 Poisson’s ratio: 0.29 at 20 °C
2. Parts Used:
2.1 M10 nuts (x4)
2.2 M10 bolts (x4)
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CAD modelling and Structural Analysis of a Die
Chapter 3
CAD Modelling
1. Die Shoe (2D Drawing):
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CAD modelling and Structural Analysis of a Die
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CAD modelling and Structural Analysis of a Die
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CAD modelling and Structural Analysis of a Die
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CAD modelling and Structural Analysis of a Die
6. M10 bolt:
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CAD modelling and Structural Analysis of a Die
7. M10 Nut:
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CAD modelling and Structural Analysis of a Die
Chapter 4
Manufacturing Process
1.2. Drilling
The next step would be to drill holes of 10 mm diameter at the locations as per
the drawing up to a depth of 25 mm. Also, a hole of diameter 12.5 mm needs
to be drilled at the centre for the blank to pass through. We would use a radial
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CAD modelling and Structural Analysis of a Die
drilling (fig.4) machine to achieve this. This would give us a piece that looks
like fig.3.
1.3. Threading
Now, we have to thread the fresh 10mm holes created after the drilling
operation with the M10 ISO standard. This could be easily done with the help
of a tap wrench (fig.6). After this, our die shoe is ready, which would look like
fig.5.
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CAD modelling and Structural Analysis of a Die
2.2. Drilling
The next step would be to drill holes of 10 mm diameter at the locations as per
the drawing up to full depth. Also, a hole of diameter 12.5 mm needs to be
drilled at the centre for the stock to pass through. We would use a radial
drilling (fig.4) machine to achieve this. This would give us a piece that looks
like fig.8.
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CAD modelling and Structural Analysis of a Die
2.3. Threading
Now, we have to thread the fresh 10mm holes created after the drilling
operation with the M10 ISO standard [5]. This could be easily done with the
help of a tap wrench (fig.6). After this, our stripper plate is ready, which
would look like fig.9.
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CAD modelling and Structural Analysis of a Die
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CAD modelling and Structural Analysis of a Die
3.1.2. Quenching
After the machining of the soft material produced by annealing, we
must make the material hard again. For this we use the heat treatment
method quenching. This would bring the hardness of the material to
about 60 HRC [6].
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CAD modelling and Structural Analysis of a Die
3.2. Machining
3.2.1. Cutting
The soft steel block after annealing have to be cut to a length of 25 mm
using a wheel cutting machine (fig.2). Then cut along the other two
dimensions as well using the wheel cutting machine, so that we get a
block of dimensions 100 X 100 X 25 mm (fig.1).
3.2.2. Drilling
The next step would be to drill holes of 10 mm diameter at the
locations as per the drawing up to full depth. Also, a hole of diameter
12.5 mm needs to be drilled at the centre for the stock to pass through.
We would use a radial drilling (fig.4) machine to achieve this. This
would give us a piece that looks like fig.16.
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CAD modelling and Structural Analysis of a Die
3.2.3. Threading
Now, we have to thread the fresh 10mm holes created after the drilling
operation with the M10 ISO standard. This could be easily done with
the help of a tap wrench (fig.6). Now the soft die block is ready to be
quenched, it would look like fig. 17.
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CAD modelling and Structural Analysis of a Die
Chapter 5
Stress Analysis
1. Blank size, die diameter, and clearance
Given,
Blank diameter = 12 mm
Sheet metal thickness = 1mm
For a mild sheet metal, the clearance should be recommended as 25% of the sheet
metal thickness for thickness less than 5 mm[r].
Clearance = 25% of 1mm
= 0.25mm
Die diameter = Blank diameter + 2 * clearance
= 12.5 mm
Sheet metal width = 35 mm
2. Cutting Force
Cutting strength of the sheet in N/mm², f = 240
Cutting length in mm, l = π * Blank diameter
= 37.7 mm
Thickness in mm, t = 1
Cutting force = f * l * t
= 9.048 KN
The punch force will directly be applied on the surface of the die which is in
contact with the sheet metal. It is clearly visible from the analysis that the die will
not fail under this force application.
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CAD modelling and Structural Analysis of a Die
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CAD modelling and Structural Analysis of a Die
Chapter 6
Conclusion
This is a detailed report on how to go about manufacturing a die for a punching operation.
A lot of the manufacturing processes have been used in the fabrication of this die like
cutting, drilling, and threading. Heat treatment and how it to could change a material’s
properties have been explained. Following this procedure and adjusting some materials
according to what is available in the market, this manufacturing process is very possible.
References
1. https://matmatch.com/learn/material/carbon-steel
2. https://www.bosch-professional.com/om/en/products/gco-240-0601B380P0
3. https://www.hmpdrills.com/product/drilling-machine/mini-radial-drilling-machine/
4. https://www.fine-tools.com/windeisen.html
5. Design of Machine Elements
V. B. Bhandari
6. Heat Treatment, Selection, and Application of Tool Steels
William E. Bryson
7. DeGarmo’s Materials and Processes in Manufacturing
8. Possibilities of MgB2/Cu Wires Fabricated by the in-situ Reaction Technique
E. Martínez and R. Navarro
9. Fatigue limit evaluation considering crack initiation for lamellar pearlitic steel
Shigeru Hamada and Daisuke Sasaki
10. https://www.wisoven.com/products/batch-ovens/heat-treat-ovensdraw-temper-
furnaces
11. Effects of quenching and tempering on the microstructure and bake hardening
behaviour of ferrite and dual phase steels
C.F. Kuang, J. Li, S.G. Zhang, J. Wang, H.F. Liu, and A.A. Volinsky
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