Papers by Keyword: Punch

Abstract: The technology repair and restoration dies for hot punching is considered. During the overhaul the hammer die, a layer of metal is removed from the side the mirror to the entire depth the cavity of the stream, then the figure the new stream is marked, and then the stream is milled as in a new punch. Sometimes such methods restoring punches as electric arc surfacing welding or deformation with a special punch in the form of a stream are used. When installing inserts in a punch, it is necessary to compensate for the removed metal layer with special linings. Welding electrodes must be selected depending on the requirements for the base metal and service properties the deposited layer – hardness, heat resistance, allowable specific pressures, machinability, heat treatment acceptance, etc.

Abstract: This research aimed to reduce die and punch wear and improved the quality of the production process with the application of the Lean Six Sigma methodology. Die and punch had limited capability in cutting material edges in the case study company. The root-cause analysis showed a correlation between the hard coating and the lubricant effect on wear reduction using the design of experiments and DMAIC based on the Six Sigma approach. The results indicated that a combination of AICrN-PVD coating and aloe vera oil provided the most outstanding results in terms of wear reduction. Moreover, it had the potential to minimize the cost of product defects or repairs significantly. These findings showed the effect of the Lean Six-Sigma approach at the die production process, which increased operational efficiency and consistency to enhance business performance and meet customer requirements.

Abstract: This article explained the tolerance analysis method in the micro-manufacture area on the keychain cranioplasty plate product dimensions. This research aimed to compare the simulations of keychain cranioplasty plate product dimensions using the ISO 286 tolerance standard. The manufacturing process to produce the keychain cranioplasty plate used the blanking process. The dimensions analysis aimed to observe the effect of punching speed and tool punch material on the product’s quality. The ISO 286 tolerance on blanking product used IT Grade of 10 for the punching process. The keychain cranioplasty plate dimensions from the blanking process simulation had an excellent quality if the sizes were close to the actual product’s dimensions. The keychain cranioplasty plate product had to have a high precision level between 10–100 μm so that the medical field could use it.

Abstract: The paper deals with numerical simulation and its verification when designing production the gutter corner for the rainwater systems. The deep drawing process has been simulated in Pam Stamp 2G software by ESI Group and the part and blank geometry, friction and process parameters have been optimized. Then, those parameters and the die geometry were verified by experiment when lamination tooling concept has been adapted. The metal laminated tooling technology was used for production of the punch by applying the laser cutting, assembling and joining. The experiments were done using hot deep galvanized steel sheet DX54D+Z with thickness 0.6 mm.

Abstract: The paper presents a methodology developed by the author for reconstructing surfaces of shaping the punch which is an element of the stamping die. It describes the entire process of the punch reconstruction i.e. 3D scanning, modeling, FEM analysis and processing. This process was implemented by the stamping press cooperating with the authors. Conclusions have been formulated.

Abstract: The fine blanking product cost can be increased, however, while the precise fine blanking tool and high cost fine blanking press are required. Therefore it is very important to design the fine blanking tool in view of life expectancy of punch. In this paper the fatigue simulation of fine blanking tool punch for recreation vehicle seat recliner sector tooth was conducted with using the commercial FEA software ANSYS in order to evaluate the life expectancy of the fine blanking tool punch. Initially, the material properties were tested, the fine blanking tool was designed for production experiments. The modelling of tool elements and the fatigue simulation according to repeated loads was conducted. As a result of fatigue simulation, the fine blanking tool punch for seat recliner sector tooth had been fractured with 11,121 strokes. In the fine blanking production experiments, the fine blanking tool punch had to be regrinded, after it was used with 10,160 strokes. It would be found that the fatigue simulation of the fine blanking tool punch was conducted with an error of 8.6% .

Abstract: Fine blanking is a press-working process that permits the production of precise, finished components which are cleanly sheared through the whole cutting surface. The manufacturing cost can be reduced because the secondary operations such as milling and broaching can be eliminated and the multistage combined stamping process can be added. The product cost can increase, however, while the precise fine blanking tool and high cost fine blanking press are required. Therefore it is important to design the fine blanking tool in view of the life expectancy of the punch. In this paper the fatigue simulation of fine blanking tool punch for automobile start motor flange was conducted using the commercial FEA software ANSYS. Initially, the material properties were tested and the fine blanking tool was designed for production experiments. The modelling of tool elements and the fatigue simulation according to repeated loads were conducted. As a result of fatigue simulation, the fine blanking tool punch for start motor flange had been fractured with 3,981 strokes. In the fine blanking production experiments, the fine blanking tool punch had to be regrinded after it was used with 3,425 strokes. It was also found that the fatigue simulation of fine blanking tool punch was conducted with an error of 14%.

Abstract: The analysis of the composition of cold extrusion die, extrusion die working part, backward extrusion die parts design, at the same time the plunger design, analyzed the packed dimension and tolerances of convex die and concave die manufacturing.

Abstract: The design for a plate of cold stamping die design, Analysis of the technology of first part, determine the mould structure scheme, design choose zero, components, mainly to the punch, concave die, die and punch, design, drawing mould assembly drawing.

Abstract: The premise of the flexible multi-point die stamping processing is that each punch can be adjusted to required position. Using numerical control technique, punches can be adjusted by stepping motors through driving screw rods. But each punch requires a stepping motor in this equipment. This kind of equipment is much expensive. In addition, the distance between adjacent punches is much big. Thus, this kind of equipments is not suitable for processing some small and medium-sized sheet metal parts. A new kind of equipment for press forming sheet metal parts is presented. Only two DC motors are needed to adjust punches of male and female moulds in this kind of equipment. Punches can be arranged more closely. This kind of equipments can be used to process small and medium-sized sheet metal parts.