CAD Modelling and Structural Anaysis of A Die PDF

CAD MODELLING AND
STRUCTURAL ANAYSIS OF A DIE

A Project Report
Waseem Shameer E18MEC012

Manikanta E18MEC009
Manufacturing Processes I
EMEC214L
Project Guide: Dr. Neelanchali Bhalla
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
P a g e 1 | 17
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.
1.2 Use of die and punch

A die and punch could be used for different sheet metal working processes like
blanking, piercing, et cetera. Here we would be focusing on punching
operation.
2. Overview of the project

2.1 Parts to manufactured
A die with the stripper plate included is to be manufactured for punching
operation for a blank size of 12 mm from scratch.
2.2 Manufacturing processes used

For this project, a lot of the manufacturing processes will be used. They
include:
i. Drilling
ii. Threading
iii. Cutting
iv. Heat Treatment
P a g e 2 | 17
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
1.2 High carbon steel (AISI 1080), Properties [1]:

1.2.1 Carbon composition: 0.8%
1.2.2 Young’s modulus: 200 GPa
1.2.3 Yield strength: 490 MPa
1.2.4 Density: 7850 kg/m3
1.2.5 Poisson’s ratio: 0.29 at 20 °C
2. Parts Used:
2.1 M10 nuts (x4)
2.2 M10 bolts (x4)
P a g e 3 | 17
Chapter 3
CAD Modelling
1. Die Shoe (2D Drawing):
2. Die Block (2D Drawing):
P a g e 4 | 17
3. Stripper Plate (2D Drawing):
4. 3D orthogonal view of the assembly:
P a g e 5 | 17
5. Assembled Die (2D Drawing):
6. M10 bolt:
P a g e 6 | 17
7. M10 Nut:
P a g e 7 | 17
Chapter 4
Manufacturing Process
1. Fabrication of the die shoe:

To begin with the fabrication, a Mild Steel (A36) plate of a cross section area close
to 200 X 150 mm and a length of 45 mm have to be procured from the market.
1.1. Cutting
The steel block procured have to be cut to a length of 34 mm using a wheel
cutting machine (fig.2). Then cut out along the other two dimensions as well
using the wheel cutting machine, so that we get a block of dimensions 200 X
150 X 34 mm (fig.1).
fig. 1 M.S Cut Block
fig. 2 Wheel Cutting Machine [2]
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
drilling (fig.4) machine to achieve this. This would give us a piece that looks
like fig.3.
P a g e 8 | 17
fig. 3 Drilled Block
fig. 4 Radial Drill Machine [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.
fig. 5 Threaded Block
fig. 6 Tap Wrench [4]
P a g e 9 | 17
2. Fabrication of the stripper plate:

We go through a very similar manufacturing process for the stripper. Its main
function is to remove the stock from the punch after the punching operation. We
use what is left of the procured M.S block.
2.1. Cutting
The steel block is to be cut to a length of 5 mm using a wheel cutting machine
(fig.2). Then cut out the along the other two dimensions as well using the wheel
cutting machine, so that we get a block of dimensions 100 X 100 X 5 mm (fig.7).
fig. 7 Cut Stripper
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.
fig. 8 Drilled Stripper
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.
P a g e 10 | 17
fig. 9 Threaded Stripper
3. Fabrication of the die block:

We must use a high Carbon steel for the fabrication of the die block. This is because
we want the die to be harder than the sheet metal for an efficient punching operation.
The problem which occurs is that a high carbon steel is not easy to work with, in
the workshop, as it will cause damages to the tools due to its hardness. We must
first perform a series of well-arranged heat treatments to manufacture the die. We
start out with a market procured high Carbon steel (0.8% Carbon) block of
dimensions close to 100 X 100 X 25 mm.
3.1. Heat treatment
3.1.1. Annealing
First, we must reduce the hardness of the given block. For this we must
use the heat treatment method annealing. This would bring down the
hardness of the material of the material to around 15 HRC [6]. Now we
would be able to easily machine our part.
Annealing is done by heating the furnace (fig.13) to a temperature of 30
°C to 60 °C above the A1 in the phase diagram (fig. 10). Then the
material is heated for a time of 2-3 hours and then cooled very slowly to
room temperature (fig.11). This cooling could be done by turning off the
heat in the furnace once the metal is heated and letting it cool inside the
furnace itself. The material will form a pearlite microstructure (fig.12).
fig. 10 Phase Diagram [7]
P a g e 11 | 17
fig. 11 Annealing and Quenching Temp. v Time [8]
fig. 12 Pearlite Microstructure [9]
fig. 13 Heat Treatment Furnace [ 10]
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].
P a g e 12 | 17
Quenching is done by heating the furnace (fig.13) to a temperature of 30

°C to 60 °C above the A1 in the phase diagram (fig. 10). Then the
material is heated for a time of 2-3 hours and then cooled rapidly to room
temperature (fig.11). This is achieved by taking the material off the heat
and then immediately dipping it in oil. The material will form a
martensite microstructure (fig.14). The workpiece after this stage would
be very hard and could be used as a die to cut mild steel blanks.
fig. 14 Martensite Microstructure [11]
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).
fig. 15 Cut Soft Block
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.
P a g e 13 | 17
fig. 16 Drilled Soft Block
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.
fig. 17 Threaded Soft Block
4. M10 Bolts and Nuts

We require 4, M10 bolts and 4, M10 nuts with a threaded pitch of 1.5 mm. These
parts would be procured from the market.
P a g e 14 | 17
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
3. Stress analysis of the die block using Autodesk Fusion 360

Autodesk Fusion 360 is a cloud-based 3D CAD/CAM tool for product development
that combines industrial and mechanical design, collaboration, and machining in a
single package. Fusion 360 enables fast and easy exploration of design ideas with
an integrated concept-to-production platform.
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.
The maximum stress which the block undergoes is 2.6 MPa

The maximum displacement the block undergoes is 0.488 μm
P a g e 15 | 17
fig. 18 Von mises stress – Die
fig. 19 Resultant displacement – Die
P a g e 16 | 17
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.
Future Scope of Improvement

Adding more stations in this die to make it a compound die is an improvement. This could
help us do more sheet metal working like lancing and nibbling with the same die.
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
P a g e 17 | 17

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CAD MODELLING AND

STRUCTURAL ANAYSIS OF A DIE

Waseem Shameer E18MEC012

1.2 Use of die and punch

2. Overview of the project

2.2 Manufacturing processes used

1.2 High carbon steel (AISI 1080), Properties [1]:

2. Die Block (2D Drawing):

3. Stripper Plate (2D Drawing):

4. 3D orthogonal view of the assembly:

5. Assembled Die (2D Drawing):

1. Fabrication of the die shoe:

fig. 1 M.S Cut Block

fig. 2 Wheel Cutting Machine [2]

fig. 3 Drilled Block

fig. 4 Radial Drill Machine [3]

fig. 5 Threaded Block

fig. 6 Tap Wrench [4]

2. Fabrication of the stripper plate:

fig. 7 Cut Stripper

fig. 8 Drilled Stripper

fig. 9 Threaded Stripper

3. Fabrication of the die block:

fig. 10 Phase Diagram [7]

fig. 11 Annealing and Quenching Temp. v Time [8]

fig. 12 Pearlite Microstructure [9]

fig. 13 Heat Treatment Furnace [ 10]

Quenching is done by heating the furnace (fig.13) to a temperature of 30

fig. 14 Martensite Microstructure [11]

fig. 15 Cut Soft Block

fig. 16 Drilled Soft Block

fig. 17 Threaded Soft Block

4. M10 Bolts and Nuts

3. Stress analysis of the die block using Autodesk Fusion 360

The maximum stress which the block undergoes is 2.6 MPa

fig. 18 Von mises stress – Die

fig. 19 Resultant displacement – Die

Future Scope of Improvement

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