Course

S.No. Name of the Course L T P C

Code
SKILL
5 ORIENTED Die Design 1 0 2 2
COURSE

Pre-Requisites :

1) Engineering Graphics / Drawing

2) Advanced 3d Modeling Tools

3) Fits & Tolerances

CAD Package:

Any one of the CAD Tool i.e. Siemens PLM software / CATIA is used to learn the
above course.

Course objectives: To impart hands-on practical exposure on Design of sheet

metal dies and mold dies.

Unit Mapped
Contents
No CO
I Introduction : CO1
Classification of presses – – Various press tool operations -
Location of clearance for regular and irregular shapes-Stock strip
terms – Layouts – Economic utilization- Classification of dies viz.
shearing, bending, drawing & forming. Design of dies –
Simple piercing/blanking – Inverted die – Compound die –
Progressive dies – Rules for developing stock – Strip layouts for
progressive dies Load centre – Necessity – Analytical and graphical
method to determine load centre (i.e. centre of pressure)
Bending dies – Blank development – Spring back effect –
Methods of correction to overcome spring back – Forces in bending
Drawing Dies -Blank development for drawing operation, Drawing
of rectangular components – Blank development
(2 Sessions)
II Sheet Metal-part1: CO2
Sheet Metal workflow
Establish basic part characteristics
Define the basic shape of the part
 Constructing base features
Sheet Metal corners
Sheet Metal cut-outs
(3 Sessions)
III Sheet Metal-part2: CO3
Sheet Metal deform features
Flat Solid and Flat Pattern
Advanced Sheet Metal commands
Analyze Formability – One step
Aerospace Sheet Metal
(3 Sessions)
IV Mold design-part1: CO4
Initializing a mold design project, Shrinkage, Mold CSYS,
Workpiece, Cavity layout, Family molds, Mold tools, Partings.
(3 Sessions)
V Mold design-part2: CO5
Mold Design Validation, Mold base, Standard Parts, Sub-insert
Library, Gates and runners, Mold Cooling Tools, Electrode design,
Creating pockets and Drawings.
(3 Sessions)

Course Outcomes: Upon successful completion of the course, the student will be
able to
Understand and Analyze various Sheet metal operations and blank
CO1:
development for various dies. {Understand level, KL2}
Use Sheet Metal tool to create base features and add more advanced
CO2:
features to them. {Apply level, KL3}
Use the Sketch Task Environment to create and edit profiles for sheet
CO3:
metal parts and Edit parametric features. {Apply level, KL3}
Use mold wizard tool to create parting surface and other elements. {Apply
CO4:
level, KL3}
Use mold wizard tool to create base features and add more advanced
CO5:
features to them. {Apply level, KL3}
Text books:
1. Fundamentals of Tool Design – ASTME, Prentice Hall, New Delhi, 1987
2. Ivana Suchy, Handbook of Die Design, 2nd Edition –Mc Graw Hills,
Newyork, 2006
3. NX 9 for Beginners - Part 5 (Sheet Metal Design) Kindle
Editionby CADFolks
Reference books:

1. Die Design Handbook – AISME, Mc Graw Hills, Newyork, 1965

2. Eary & Reed, Shear Working of Metals, Prentice Hall, New Delhi, 1969
Basic Die Making & Advance Die Making – D. Eugene Ostergaard, Mc
3.
Graw Hill
 4. Tool Design by Cyril Donaldson – Tata Mc Graw Hill, New Delhi
Machine Drawing –K.L.Narayana, P.Kannaiah & K. Venkata Reddy / New
5.
Age/ Publishers
Manuals & Tutorials on CAD/CAE packages like Pro/Engineer,
6.
Pro/Mechanica, ANSYS, etc latest available in the lab.
e- Resources & other digital material:
http://staff.uny.ac.id/sites/default/files/pendidikan/aan-ardian-mpd/1g-
1.
handbook-die-design-2nd-edition.pdf
2. https://www.scribd.com/document/403306138/Sheet-metal-design-pdf
http://www.maruf.ca/files/catiahelp/CATIA_P3_default.htm
3. https://youtu.be/tb5XBvkZql4

CO-PO mapping Table with Justification

Contribution of Course Outcomes towards achievement of Program Outcomes &
Strength of correlations (High: 3, Medium: 2, Low: 1)

Mapping P01 P02 P03 P04 P05 P06 P07 P08 P09 P010 P011 P012 PS01 PSO2

C01 2 2 1
C02 3 3 1
C03 3 3 1
C04 3 3 1
C05 3 3 1

Mapping Score Justification

CO1- Students can be able to draw blank development and able
2
PO4,PO12 to do determine the forces involved in various dies
CO2-
3 Students can be able to do simple sheet metal operation
PO4,PO12
CO3- Students can be able to design and analyze various sheet
3
PO4,PO12 metal dies using software tools.
CO4- Students can be able to create parting surface and design
3
PO4,PO12 of components of mold die
CO5- Students can be able to design and analyze the mold die
3
PO4,PO12 using software tools.
Students will be able to use the production process
CO1,2,3,4
1 techniques for various problems in their professional and
& 5-PSO1
personal career.

*****
6-6-2 Finding the Center of Pressure of a Blanking Station
Where a compound blanking die is too large, it would better be positioned on the same axis
as the ram of a press. This way the center of the press force and the center of its distribution throughout the blanking station will
coincide. To position a powerful blanking station
slightly off the center may result in greater than usual wear of die bushings, caused by the
die’s inclination in the direction of the lesser support.
In order to place a complicated shape dead on center, first the center must be located.
The method of calculating the center of pressure of an irregular shape is demonstrated on
the sample shown in Fig. 6-28.
First, the shape must be broken down into single lines without considering the geometrical entities they form. X-Y axes should be
positioned in the corner of a shape to establish
the zero position.
The length of each line is to be calculated, along with the distance of its center off the
zero point in both x and y dimension. The length of each line should be called L, and its subscript determines the sequential number of
the line.
The center of shape should then be calculated separately along each axis. The formulas
are as follows:

SCRAP AND HOLE SIZE RECOMMENDATIONS

Blanks, when positioned on a strip, certainly should not be spaced too far apart, for a large
waste of material will result. However, placing them too close to each other may create a
different kind of waste, that of a ruined strip, ruined tooling, and ruined die. The proper
spacing is very important, and its amount depends on the material thickness above everything else (Figs. 6-29 and 6-30).