MDP375

Die Design
Tutorial 6

Eng. Eslam Elsaid

eslam.bahgat@eng.asu.edu.eg
1. The following products will be made from sheet from St60; the
sheet is 2000 mm length and 1000 mm wide and 1 mm thickness.
a)Calculate number of products per unit sheet
for each product.
b)Make a sequence lay out for each product.
c)Calculate the required force for each
product.
d)Estimate the center of pressure for each
product.
e)Find the clearance between punch and die
for each product.

2
 0
R3
a)Calculate number of products per unit sheet
for each product.
t=1 mm
2000

100
a1
2

996

1000
1996
b12

3
 Wide / Longitudinal

0
R3
a)Calculate number of products per unit sheet
1.2
a

1.2
for each product. 1.2
a

b
t=1 mm

100
996

1b.2
1996

4
 1.2 1.2

1.2
a)Calculate number of products per unit sheet
for each product.

162.4
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒= 𝐿+ 2𝑏
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=160+2 ×1 . 2=162 . 4 𝑚𝑚

1.2
𝑠𝑡𝑟𝑖𝑝 𝑙𝑒𝑛𝑔𝑡 h −𝑎
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=
( 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑤𝑖𝑑 𝑡 h+𝑏𝑟𝑖𝑑𝑔𝑒 )
1996−1.2
𝑁𝑜.𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝= =32.5≈32𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠/𝑆𝑡𝑟𝑖𝑝.
( 60+1.2 )
𝑠h 𝑒𝑒𝑡 𝑤𝑖𝑑𝑡 h 996
𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h 𝑒𝑒𝑡=
𝑠𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒 ¿ =6.13≈6𝑆𝑡𝑟𝑖𝑝𝑠/𝑆h𝑒𝑒𝑡.
162.4 5
 1.2 1.2

1.2
a)Calculate number of products per unit sheet
for each product.
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=162. 4 𝑚𝑚
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=32 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠 ∕ 𝑆𝑡𝑟𝑖𝑝

1.2
𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h𝑒𝑒𝑡=6𝑆𝑡𝑟𝑖𝑝𝑠 ∕ 𝑆h𝑒𝑒𝑡
𝑠𝑡𝑟𝑖𝑝 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h 𝑒𝑒𝑡= × =
𝑠 h 𝑒𝑒𝑡 𝑠𝑡𝑟𝑖𝑝 𝑠h 𝑒𝑒𝑡
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h𝑒𝑒𝑡=6× 32=192 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 ∕ 𝑆h𝑒𝑒𝑡

6
 Wide / Traverse

1.2
a)Calculate number of products per unit sheet
for each product.
t=1 mm

1.2
1.2

996
1.2

1996

7
 1.2
a)Calculate number of products per unit sheet
for each product.

1.2
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒= 𝐿+ 2𝑏
1.2 1.2
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=160+2 ×1 . 2=162 . 4 𝑚𝑚
𝑠𝑡𝑟𝑖𝑝 𝑙𝑒𝑛𝑔𝑡 h −𝑎
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=
( 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑤𝑖𝑑 𝑡 h+𝑏𝑟𝑖𝑑𝑔𝑒 )
996−1.2
𝑁𝑜.𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝= =16 .24 ≈16 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠/𝑆𝑡𝑟𝑖𝑝.
( 60+1.2 )
𝑠h 𝑒𝑒𝑡 𝑙𝑒𝑛𝑔𝑡 h 1996
𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h 𝑒𝑒𝑡=
𝑠𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒 ¿ =12.29≈12𝑆𝑡𝑟𝑖𝑝𝑠/𝑆 h𝑒𝑒𝑡.
162.4 8
 1.2
a)Calculate number of products per unit sheet
for each product.

1.2
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=162. 4 𝑚𝑚
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=16 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠
1.2∕ 𝑆𝑡𝑟𝑖𝑝 1.2
𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h𝑒𝑒𝑡=12𝑆𝑡𝑟𝑖𝑝𝑠 ∕ 𝑆 h𝑒𝑒𝑡
𝑠𝑡𝑟𝑖𝑝 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h 𝑒𝑒𝑡= × =
𝑠 h 𝑒𝑒𝑡 𝑠𝑡𝑟𝑖𝑝 𝑠h 𝑒𝑒𝑡
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h𝑒𝑒𝑡=12×16=192𝑃𝑟𝑜𝑑𝑢𝑐𝑡 ∕ 𝑆h𝑒𝑒𝑡

9
 Narrow / Longitudinal
a)Calculate number of products per unit sheet
for each product.

1.2
t=1 mm 1.2 1.2

996

1.2
1996

10
a)Calculate number of products per unit sheet

1.2
for each product. 1.2 1.2

𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=𝑊 +2 𝑎
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=60+2 ×1 . 2=62. 4 𝑚𝑚

1.2
𝑠𝑡𝑟𝑖𝑝 𝑙𝑒𝑛𝑔𝑡 h −𝑎
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=
( 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑙𝑒𝑛𝑔𝑡 h+𝑏𝑟𝑖𝑑𝑔𝑒 )
1996−1.2
𝑁𝑜.𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝= =12.36≈12 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠/𝑆𝑡𝑟𝑖𝑝.
( 160+1.2 )
𝑠h 𝑒𝑒𝑡 𝑤𝑖𝑑𝑡 h 996
𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h 𝑒𝑒𝑡=
𝑠𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒 ¿ =15.96≈15𝑆𝑡𝑟𝑖𝑝𝑠/𝑆h𝑒𝑒𝑡 .
62.4 11
a)Calculate number of products per unit sheet

1.2
for each product. 1.2 1.2

𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=62 . 4 𝑚𝑚
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=12 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠 ∕ 𝑆𝑡𝑟𝑖𝑝

1.2
𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h𝑒𝑒𝑡=15𝑆𝑡𝑟𝑖𝑝𝑠 ∕ 𝑆h𝑒𝑒𝑡
𝑠𝑡𝑟𝑖𝑝 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h 𝑒𝑒𝑡= × =
𝑠 h 𝑒𝑒𝑡 𝑠𝑡𝑟𝑖𝑝 𝑠h 𝑒𝑒𝑡
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h𝑒𝑒𝑡=12×15=180 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 ∕ 𝑆h𝑒𝑒𝑡

12
 Narrow / Traverse

0
R3
a)Calculate number of products per unit sheet

1.2
for each product.
t=1 mm
1.2 1.2

100
996

1.2
1996

13
 1.2
a)Calculate number of products per unit sheet 1.2 1.2
for each product.

𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=𝑊 +2 𝑎

1.2
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=60+2 ×1 . 2=62. 4 𝑚𝑚
𝑠𝑡𝑟𝑖𝑝 𝑙𝑒𝑛𝑔𝑡 h −𝑎
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=
( 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑙𝑒𝑛𝑔𝑡 h+𝑏𝑟𝑖𝑑𝑔𝑒 )

𝑠h 𝑒𝑒𝑡 𝑙𝑒𝑛𝑔𝑡 h 1996

𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h 𝑒𝑒𝑡=
𝑠𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒 ¿ =31.98 ≈31𝑆𝑡𝑟𝑖𝑝𝑠/𝑆h𝑒𝑒𝑡.
62.4 14
 1.2
a)Calculate number of products per unit sheet 1.2 1.2
for each product.
𝑆𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒=62 . 4 𝑚𝑚
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝=6 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠 ∕ 𝑆𝑡𝑟𝑖𝑝

1.2
𝑆𝑡𝑟𝑖𝑝𝑠 𝑝𝑒𝑟 𝑠 h𝑒𝑒𝑡=31𝑆𝑡𝑟𝑖𝑝𝑠 ∕ 𝑆h𝑒𝑒𝑡
𝑠𝑡𝑟𝑖𝑝 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h 𝑒𝑒𝑡= × =
𝑠 h 𝑒𝑒𝑡 𝑠𝑡𝑟𝑖𝑝 𝑠h 𝑒𝑒𝑡
𝑁𝑜 .𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 𝑝𝑒𝑟 𝑠h𝑒𝑒𝑡=6× 31=186 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 ∕ 𝑆h𝑒𝑒𝑡

15
Narrow/ Narrow/ Wide/ Wide/ Orientation
Traverse Longitudinal Traverse Longitudinal

No. of
Products per
Sheet

16
 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑎𝑟𝑒𝑎 ∗𝑛𝑜 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠
𝑈𝑡𝑖𝑙𝑖𝑠𝑎𝑡𝑖𝑜𝑛 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛 (𝐼𝑓 𝑎𝑠𝑘𝑒𝑑 𝑡𝑜)= × 100
𝑠 h 𝑒𝑒𝑡 𝑎𝑟𝑒𝑎
2 2
𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝑎𝑟𝑒𝑎=1 00 ×60+𝜋 ×30 =8827 . 43 𝑚 𝑚

2
𝑆 h 𝑒𝑒𝑡 𝑎𝑟𝑒𝑎=2 000 ×1000=2000000 𝑚 𝑚
8827 . 43 × 192
𝑈𝑡𝑖𝑙𝑖𝑠𝑎𝑡𝑖𝑜𝑛 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛= × 100 %=85 . 25 %
2000000

Scrap Calculation (If asked to) = (1 - )

Scrap Calculation = (1 -0.8525)

17
b)Make a sequence lay out for each product.

Stage 0 Stage 1 Stage 2 Stage 3 Stage 4

----

18
b)Make a sequence lay out for each product.
Stage 0 Stage 1 Stage 2 Stage 3 Stage 4

----

Stage 0: Insertion of the strip

Stage 1: Punching the two holes – The dashed rectangles are next to cut.

Stage 2: Punching the three rectangles – The next is two dashed rectangles.
Stage 3 : Punching the two dashed rectangles.
Stage 4: Punching the whole shape(Blanking).
19
 . ( mm²)
t: Sheet thickness.
a) Required Force : L: Circumference of
shearing area.
Required
force (N).
𝑭 =𝑺∗ 𝑨
Shear strength for sheet material(MPa).
S ≈ 0 . 6 𝜎 𝑈𝑇𝑆

St 60
𝜎 𝑈𝑇𝑆=600 𝑀𝑃𝑎.

S=0. 6 ∗600=360𝑀𝑃𝑎.
20
 Shearing
a) Required Force :

Piercing Blanking

21
a) Required Force :
𝑭 =𝑺 ∗ 𝒕 ∗ 𝑳
S=0 . 6 ∗ 600=360 𝑀𝑃𝑎.
t =1 𝑚𝑚 .
0
1) Required Force for piercing circular Ø1
holes :

𝑭 𝟏 =𝑺 ∗𝒕 ∗ 𝝅 ∗ 𝑫
𝑭 𝟏 =𝟑𝟔𝟎 ∗𝟏 ∗ 𝝅 ∗ 𝟏𝟎
𝑭 𝟏 =𝟏𝟏𝟑𝟎𝟗. 𝟕 𝑵 .

22
a) Required Force :
𝑭 =𝑺 ∗ 𝒕 ∗ 𝑳
S=0 . 6 ∗ 600=360 𝑀𝑃𝑎.
2
t =1 𝑚𝑚 .
2) Required Force for piercing rectangular

5
holes :

𝑭 𝟐 =𝑺 ∗𝒕 ∗ 𝑳
𝑭 𝟐 =𝟑𝟔𝟎 ∗𝟏 ∗ 𝟐(𝟓+𝟐)
𝑭 𝟐 =𝟏𝟎𝟎𝟖𝟎 𝑵 .

23
a) Required Force :
𝑭 =𝑺 ∗ 𝒕 ∗ 𝑳
S=0 . 6 ∗ 600=360 𝑀𝑃𝑎.
t =1 𝑚𝑚 .
5

3) Required Force for piercing rectangular

5
holes :

𝑭 𝟑 =𝑺 ∗𝒕 ∗ 𝑳
𝑭 𝟑 =𝟑𝟔𝟎 ∗𝟏 ∗ 𝟐(𝟓+𝟓)
𝑭 𝟑 =𝟕𝟐𝟎𝟎 𝑵 .

24
a) Required Force :
𝑭 =𝑺 ∗ 𝒕 ∗ 𝑳
S=0 . 6 ∗ 600=360 𝑀𝑃𝑎.
t =1 𝑚𝑚 . 5

4) Required Force for piercing rectangular

10
hole :

𝑭 𝟒= 𝑺 ∗ 𝒕 ∗ 𝑳
𝑭 𝟒=𝟑𝟔𝟎 ∗ 𝟏 ∗𝟐(𝟏𝟎 +𝟓)
𝑭 𝟒=𝟏𝟎𝟖𝟎𝟎 𝑵 .

25
c) Required Force :
𝑭 =𝑺 ∗ 𝒕 ∗ 𝑳
S=0 . 6 ∗ 600=360 𝑀𝑃𝑎.
t =1 𝑚𝑚 .

0
R3
5) Required Force for blanking:

100
𝑭 𝟓 =𝑺 ∗𝒕 ∗ 𝑳
𝑭 𝟓 =𝟑𝟔𝟎 ∗𝟏 ∗ [ 𝟐 (𝟏𝟎𝟎 ) +𝟐 ( 𝝅 ∗ 𝟑𝟎) ]
𝑭 𝟓 =𝟏𝟑𝟗𝟖𝟓𝟖 .𝟒 𝑵 .

26
c) Required Force :
𝑭 =𝑺 ∗ 𝒕 ∗ 𝑳
𝑭 𝟏 =𝟏𝟏𝟑𝟎𝟗. 𝟕 𝑵 . Ø1
0

𝑭 𝟐 =𝟏𝟎𝟎𝟖𝟎 𝑵 .

5
5

𝑭 𝟑 =𝟕𝟐𝟎𝟎 𝑵 . 5

𝑭 𝟒=𝟏𝟎𝟖𝟎𝟎 𝑵 .
10

𝑭 𝟓 =𝟏𝟑𝟗𝟖𝟓𝟖 .𝟒 𝑵 .
27
d)Estimate the center of pressure for each product.

158.7
----
131.2

91.2

81.2

81.2
71.2
31.2
Y

30

3.7
63.7
118.7
X
152.4
213.6

28
d)Estimate the center of pressure for each product.

158.7
----
131.2

91.2

81.2

81.2
71.2
31.2
Y

30

3.7
𝑛
63.7
𝐹𝑋= ∑ 𝑓 𝑛 𝑥𝑛 118.7
𝑛=1
X
𝑛 152.4

𝐹 𝑌 = ∑ 𝑓 𝑛 𝑦𝑛 213.6

𝑛=1 29
 d)Estimate the center of pressure for each product.
𝑛

∑ 𝑓 𝑛 𝑥𝑛
𝑛=1
𝑋= 𝑛

∑ 𝑓 𝑛
𝑛 =1

11309. 7 ×30 × 2+10080 ×63 . 7 × 2+7200 ×118. 7 +10800 ×152 . 4 × 2+139858 . 4 × 213 . 6
𝑋=
11309 .7 × 2+10080 ×2+ 7200+10800 × 2+139858 . 4

𝑋 = …𝑚𝑚
𝑛

∑ 𝑓 𝑛 𝑦𝑛
𝑛=1
𝑌= 𝑛

∑ 𝑓 𝑛
𝑛=1

11309 . 7( 31. 2+131 . 2)+ 10080(71 . 2+91 . 2)+7200 × 81 .2+ 10800(3 . 7+ 158 .7)+ 139858 . 4 × 81. 2
𝑌=
11309 . 7 ×2+ 10080 ×2+7200+ 10800 ×2+139858 . 4

….. mm
30
e)Find the clearance between punch and die for each product.
Shearing

Piercing Blanking
Punch size = Hole size - 2 C
Punch size = Blank size
Die size = Hole size
Die size = Blank size + 2 C
C = Clearance.
𝑪=𝒂 ∗ 𝒕 Stock thickness
0.045 for Al
Allowance
0.075 for St 31
b) Punch and Die Size:
𝑪=𝒂 ∗ 𝒕
𝑪=𝟎.𝟎𝟕𝟓∗𝟏=𝟎.𝟎𝟕𝟓𝒎𝒎
1) Punch and die for piercing circular holes :
Punch size: 0
Ø1
𝒅 𝒑 = 𝒅𝒉
𝒅 𝒑 =𝟏𝟎𝒎𝒎
Die size:
+2C
+2*0.075

𝒅 𝒅=𝟏𝟎. 𝟏𝟓𝒎𝒎 32
b) Punch and Die Size:
𝑪=𝒂 ∗ 𝒕
𝑪=𝟎.𝟎𝟕𝟓∗𝟏=𝟎.𝟎𝟕𝟓𝒎𝒎
2) Punch and die for piercing rectangular holes : 2
Punch size:

5
𝒍 𝒑 = 𝒍𝒉𝒃 𝒑 = 𝒃𝒉
𝒍 𝒑=𝟓 𝒎𝒎 𝒃 𝒑=𝟐 𝒎𝒎
Die size:
+2C 𝒃 𝒅=𝒃𝒉 +𝟐 𝑪
b

+2*.075 𝒃 𝒅=𝟐+𝟐∗ . 𝟎𝟕𝟓

l

𝒍 𝒅=𝟓.𝟏𝟓𝒎𝒎 𝒃 𝒅=𝟐.𝟏𝟓𝒎𝒎 33
b) Punch and Die Size:
𝑪=𝒂 ∗ 𝒕
𝑪=𝟎.𝟎𝟕𝟓∗𝟏=𝟎.𝟎𝟕𝟓𝒎𝒎
3) Punch and die for piercing rectangular holes5:
Punch size:

5
𝒍 𝒑 = 𝒍𝒉𝒃 𝒑 = 𝒃𝒉
𝒍 𝒑=𝟓 𝒎𝒎 𝒃 𝒑=𝟓 𝒎𝒎
Die size:
𝒍 𝒅=𝒍𝒉 + 𝟐 𝑪 𝒃 𝒅=𝒃𝒉 +𝟐 𝑪
𝒃 𝒅=𝟓+𝟐∗ 𝟎. 𝟎𝟕𝟓
𝒍 𝒅=𝟓+𝟐∗ 𝟎 . 𝟎𝟕𝟓 b

𝒍 𝒅=𝟓.𝟏𝟓𝒎𝒎 𝒃 𝒅=𝟓.𝟏𝟓𝒎𝒎 l
34
b) Punch and Die Size:
𝑪=𝒂 ∗ 𝒕
𝑪=𝟎.𝟎𝟕𝟓∗𝟏=𝟎.𝟎𝟕𝟓𝒎𝒎 5

4) Punch and die for piercing rectangular hole :

Punch size:

10
𝒍 𝒑= 𝒍𝒉 𝒃 𝒑 = 𝒃𝒉
𝒍 𝒑=𝟏𝟎𝒎𝒎 𝒃 𝒑=𝟓 𝒎𝒎
Die size:
𝒍 𝒅=𝒍𝒉 + 𝟐 𝑪 𝒃 𝒅=𝒃𝒉 +𝟐 𝑪
𝒍 𝒅=𝟏𝟎+𝟐∗𝟎. 𝟎𝟕𝟓𝒃 𝒅=𝟓+𝟐∗ 𝟎. 𝟎𝟕𝟓
b

𝒍 𝒅=𝟏𝟎 .𝟏𝟓𝒎𝒎 𝒃 𝒅=𝟓.𝟏𝟓𝒎𝒎 l 35

b) Punch and Die Size:
𝑪=𝒂 ∗ 𝒕
𝑪=𝟎.𝟎𝟕𝟓∗𝟏=𝟎.𝟎𝟕𝟓𝒎𝒎

0
R3
5) Punch and die for piercing blank:

100
Punch size:
For rectangular portion:

𝒍 𝒑=𝟏𝟎𝟎 −𝟎 . 𝟏
Round Straight Round Total
𝒍 𝒑=𝟗𝟗 .𝟗 𝒎𝒎 end 1 portion End 2 length
30 100 30 160
For round ends:
0.025 0.1 0.025 0.15
𝑹 𝒑=𝟑𝟎− 𝟎.𝟎𝟐𝟓
𝑹 𝒑=𝟐𝟗.𝟗𝟕𝟓𝒎𝒎 36
b) Punch and Die Size:
𝑪=𝒂 ∗ 𝒕
𝑪=𝟎.𝟎𝟕𝟓∗𝟏=𝟎.𝟎𝟕𝟓𝒎𝒎

0
R3
5) Punch and die for piercing blanking:

100
Die size:
For rectangular portion:

𝒍 𝒑= 𝒍 𝒃
𝒍 𝒑=𝟏𝟎𝟎 𝒎𝒎
For round ends:
𝑹 𝒑= 𝑹 𝒃
𝑹 𝒑=𝟑𝟎𝒎𝒎 37
 Systematic Solution

1. You have to cut the sheet edges to clean it using a table shear.

2000
a1

1000
b1

2. Strip layout and number of strips calculation

38
 Systematic Solution

3. Calculate number of products per strip

4. Calculate number of products per sheet:

5. Utilisation Calculation (If asked to) =

6. Scrap Calculation (If asked to) = (1 - )

7-Shearing Force Calculation.

8-Sequence layout.

9-Estimation the center of pressure.

39
References:

1-Lecture notes for Dr: Ramadan ElGamasy

2-Handbook of Die Design 2nd Edition

42