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In partial fulfillment for Master of Engineering in TOOL DESIGN


Mr. SIVAPAPACHARI.CH Under the Guidance of Mr. N S SHAH Divisional Manager CVBU – PE Pune.

ACKNOWLEDGEMENTS I am deeply gratified to Mr.A M Kare, Asst General Manager,Production Engineering Division for encouraging me and also giving his support always. I am grateful to Mr. R.P Panchbhai, HR-TATA Motors who provided his guidance to accomplish all the company formalities. I am grateful to Mrs. T.Nagaveni , my college guide for giving me this opportunity to work in such a renowned organization. I am indebted to my guide, Mr. N S Shah Divisional Manager - P.E for providing me the opportunity to work on challenging projects. I am grateful to Mr.Paranjape, Mr. Aravind, Mr Ghorpade and various other managers who have constantly supported me throughout the project. I would like to express my sincere thanks to my family for their support and encouragement.



The project includes 3-D Draw die design of sheet metal die of Head Lamp Housing, the die is produced as per Telco Standards. The die is designed using CATIA V5 as Modeling Tool. Design include Concepts such Die shut height, Cushion Pin layout, Clamping slot Position, Core design, Draw force Calculation, Blank holder force Calculation and Die Costs estimation. Total Draw force is calculated as 93.6 T.


The project also includes the manufacturing concepts such as die spotting, beading

and Grinder-less Die Manufacturing Strategies.

Concepts of Sheet Metal Properties such as n& k value, r-value are studied and experimental evaluation is done by conducting tests such as tensile test, Ericksen cupping test, Microstructure analysis of sheet metal such as EDD and Die castings Material (M-15) by Optical Microscope and the chemical composition of the materials (in wt.%) used in the present investigations was analyzed by an emission spectrometer (ARL 3460 metals analyzer).

ATOS systems were utilized to capture form information from physical models to generate a CAD model via the reverse engineering process. When the live component results are compared with Cad data, it is found that there is less than 20% deviation between the two.


TATA Motors, formerly known as Tata Engineering or Tata Engineering and Locomotive Company Ltd. (TELCO), is the flagship company of the Tata Sons Ltd. Controlled by the house of Tata; Tata Motors is India’s only fully integrated, automobile manufacturer. It is the largest commercial vehicle manufacturing company in India and is the fifth-largest manufacturer of trucks in the world.

Tata Motors is currently among one of the largest Indian companies in the private sector with an annual turnover of more than US$ 3 billion in 20010-2011. Tata Motors has the unique distinction of giving India it’s first and only indigenously built passenger car – Tata Indicia – and the premium luxury sedan – Tata Indigo.

Seven out of 10 medium and heavy commercial vehicles in India bear the trusted Tata mark. The company’s products have received wide acceptance not only in India but also in the Middle East, Asia, Africa, Australia, Latin America and Europe. Tata Motors vehicles currently sell in over 70 countries.

Apart from manufacturing light, medium and heavy commercial vehicles, Tata Motors manufactures a range of engineering products, which include passenger cars, utility vehicles, excavators, large press tools, dies and special purpose machine tools. The company has embarked on a major expansion programme at Pune and secured a license to increase its vehicle manufacturing capacity to 84,000 vehicles per annum. Nevertheless, Tata Motors has always considered it highly obligatory to increase the intrinsic value of the Tata vehicle by rigid quality control, and new improvements. The indigenous content of its vehicle has reached 99% and it can rightly be said that the imported parts of its truck can be held in the palm of one's hand.


CONTENTS Chapter No. Topics ACKNOWLEDGEMENTS ABSTRACT ORGANISATION 1 1.1 1.2 2 2.1 3 3.1 62.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.5 3.5.1 3.5.2 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.7 3.7.1 3.7.2 INTRODUCTION Sheet Metal Dies Problem Statement LITRETURE REVIEW
Objectives of the Project

Page no. i ii iii 1 1 2 3 5 6 6 7 12 13 14 15 16 16 23 24 25 27 27 28 28 30 31 35 37 37 38

THEORITICAL BACK GROUND Basic Sheet Metal Dies Components Of Sheet Metal Die Presses Single Action Mechanical Press Hydraulic Press Press/Draw Cushions Theory Of Drawing Stages of Drawing Die Manufacturing Spotting of the Draw Die Grinder-less Die Manufacturing Material Testing Sheet Metal Properties Sheet Metal Testing EDD513 Erickson Cupping Test Standard Test Method Draw Die Casting Material Testing Quality Control and Inspection Present Use: ATOS Introduction to Panel Inspection

3.8 3.9 3.9.1 3.9.2 3.1 4 4.1 4.11 4.2 4.3 4.3.1 4.4 4.5 4.5.1 4.5.2 5 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.4 5.4.5 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8

Measuring Principle Alignment of the Object 3.9.1 RPS Registration Best-Fit Registration Measuring Large Objects ANALYSIS Simulation Of Sheet Metal Forming Folding Problem Forming limit diagram concept (fld): TESTING METHOD FOR FLD Simulation Trails THINNING RESULT STRAIN RESULT Major Strain Minor Strain DESIGN PROCEDURE Die Designers Responsibilities General Design Process Method Plan Problem Description Component Drawing Input to die designer from simulation Component in draw die set up Calculations 3d Draw Die Design Procedure for 3d draw die 3D Punch Development Lower die Cushion pin layout Blank holder Upper die Tool Specification Tool weight calculation

39 39 39 40 41 42 42 42 44 46 47 48 49 49 49 50 50 50 52 54 54 54 57 58 59 60 60 61 62 62 64 65 65

5.5.9 5.6 6 6.1 6.2 6.2.1 6.2.2 6.3.3 7 8

Lifter Calculation Draw Die Cost Estimation TRYOUT AND INSPECTION OF PANEL Tryout Inspection Checking With the Inspection Fixtures Upfront Time and Expense (Draw back) Steps for Scanning CONCLUSIONS FUTURE SCOPE REFERENCE

66 67 68 68 70 70 71 72

Fig. no Fig.1.1 Fig.3.1 Fig. 3.2 Fig.6.3 Fig.3.4 Fig.3.5 Fig. 3.6 Fig.3.7 Fig.3.8 Fig.3.9 Fig.3.10 Fig.3.11 Fig.3.12 Fig.3.13 Fig.3.14 Fig.3.15 Fig.3.16 Fig.3.17 Fig. 3.18 Fig.3.19 Fig.3.20 Fig.3.21 Fig.3.22 Fig .3.23 Fig.3.24 Fig.3.25 Fig.3.26 Fig.3.27 Fig.3.28 Fig.3.29 Fig.3.30 Fig.3.31 Fig. 3.32 Fig.3.33 Fig.3.34 Fig.3.35 Fig.3.36 Fig.3.37 Fig.3.38 Fig.3.39 Title Head Lamp Housing Panel Blanking Die Single Action Draw Die Restrike Die Bending Die Flange Die Standard Die Sets Guide pin and Bushing Heel Box Screw & Dowels Shoulder Screw Retainers Spring Draw pad Bottoming Marker Die Without/ With Balancing Block Single Action Mech. Press Hydraulic Press Draw Cushion Drawing Operation Bending Operation Straightening Friction Squeezing or compression during Drawing Tension Stretch forming Verification of a Radius an Example of Unnecessary Contact an Example of Sidewall Bearing Conventional Die Manufacturing Grinder-less Die Manufacturing Grinder-less Design for Head Lamp Housing EDD Microstructure EDD Test Specimen Cupping Test Setup Cupping result Radial cracks Circumferential cracks Standard Tensile Test specimen Soft M15 Page no 2 6 6 7 7 8 8 8 9 9 10 10 11 11 12 12 14 15 15 16 17 17 18 18 19 19 24 24 24 25 25 26 29 29 30 30 30 30 31 36

Fig.3.40 Fig.3.41 Fig.3.42 Fig.3.43 Fig.3.44 Fig.3.45 Fig. 4.1 Fig. 4.2 Fig. 4.3 Fig. 4.4 Fig. 4.5 Fig. 4.6 Fig. 4.7 Fig. 4.8 Fig. 4.9 Fig. 4.10 Fig. 4.11 Fig. 4.12 Fig. 4.13 Fig. 4.14 Fig.5.1 Fig.5.2 Fig.5.3 Fig.5.4 Fig.5.5 Fig.5.6 Fig.5.7 Fig.5.8 Fig.5.9 Fig.5.10 Fig.5.11 Fig.5.12 Fig.5.13 Fig.5.14 Fig.5.15 Fig. 5.16 Fig. 6.1 Fig. 6.2 Fig. 6.3 Fig. 6.4 Fig. 6.5 Fig. 6.6

Flame hard M15 M 15 Test Specimen ThermoCole scanned data ATOS 3D scanner RPS registration Best-fit registration Rectification of folding problem by tear drops Gravity Holding Forming Process Typical FLD Curve 10% Margin for FLD Modes of Deformation Form of Die Consider in PAM-STAMP Simulation Trail 1 Simulation Trail 2 FLD Thinning Results Major Strain Minor Strain Component Drawing HEAD LAMP HOUSING Component in Car Line Component in BIW Component with Draw surface draw die set up Draw surface obtain from simulation Lower Die Blank Holder Upper Die Punch Development Clamping slot for Lower Die Cushion pin layout Blank holder Assembly Draw Bead Standard Upper die Draw Die assembly for Head Lamp Housing Cast Round Lifter Standard Trial 1 (Wrinkle) Trial 2 (Crack)
Trial 3 (OK) Inspection Fixture

Scanning Scanned Part

36 36 37 38 40 40 42 43 43 44 45 45 45 46 47 47 48 48 49 49 54 56 56 57 57 59 59 59 60 61 62 63 64 65 65 66 68 69 70 70 72 72

Fig. 6.7 Fig. 6.8 Fig. 6.9 Fig. 6.10

Meshing Part Imposing of Both Parts Imposing of Both Parts with deviation Deviation of the digitized data versus nominal data

73 73 73

Table no-1 Table no-2 Table no-3 Table no-4 Table no-5 Table no-6 Table no-7 Table no-8 Table no-9 Properties affecting the formability of the material Chemical Composition of EDD Mechanical Properties of EDD n value result for EDD-00 n value result for EDD-450 n value result for EDD-900 n value result for EDD Method Plan for Head Lamp Housing RH Cost Estimation of Draw Die 27 28 28 32 33 33 34 47 67


Graph no-1 Graph no-2 Graph no-3 Graph no-4 Graph no-5

EDD Tensile Result EDD00-Stress Vs Strain EDD450-Stress Vs Strain EDD900-Stress Vs Strain M-15 Tensile Result

28 32 33 34 35

Chart Label.1 Flow Chart for a Die 23