Die automation

Action Project plan

Safety precautions

Brief study about die and its working

Study about Die Automation

Identify the area for Automation

To study the objective of die Automation

Identify the die for Automation

Study the dimension of blanks for

different variants

Design of pneumatically operate stopper

Conclusion

References

PRESENTATION CONTENTS

ACTION PLAN OF DIE AUTOMATION

S. No. Activity Description Responsibility Support required Target Date Start DateCompletion

dateStatus Remarks

1 Briefly study about die and its workingTypes of dies, its operations and product introduction

Nikunj Kumar Mr Arvind Sharma 02-02-2014 21-01-2014 05-02-2014 comp.

2 To study about die Automation details of die automation Nikunj Kumar Mr Arvind Sharma 02-12-2014 02-06-2014 16-02-2014 comp.

3 Identify the area for automationto provide the pneumatic blank stoppers in all forming dies


4 To study the objective of die automationto control the rejection in forming operation and to improve the productivity


5 Identify the dies for Automation LCV/MCV forming and HCV Forming Nikunj Kumar Mr Arvind Sharma 04-03-2014 01-03-2014 04-03-2014 comp.

6Study the dimentions of blanks for different variants

1. HCV - 410, 380 & 356 mm 2. LCV - 314 mm 3. MCV - 338 mm


7Design of pneumatically operated stoppers

1. Size of pneumatic cylinders 2. Stroke length 3. Size of different stoppers

Nikunj Kumar Mr Arvind Sharma 15/03/2014 08-03-2014 14-03-2014 comp.

8 Prepare the List of resources required

1. Nos. of pneumatic cylinders 2. Nos. of stoppers 3. Material for stoppers 4. Hose pipe and its fittings 5. fasteners

Nikunj Kumar Mr Arvind Sharma 23-03-2014 15-03-2014 Comp. Available

9 Procurement of material requiredTo list out the available materials and material to procure - and to raise the PR accordingly

Nikunj Kumar Mr Arvind Sharma 31-03-2014 23-03-2014 Comp. Available

10 Manufacturing of components Manufecturing of stoppers in Tool Room Nikunj Kumar Mr Arvind Sharma 15-04-2014 25-03-2014 Comp. Available

11 To fit the stoppers in dieTo fit the stoppers model wise with adjustable arrangement for different width blanks

Nikunj Kumar Mr Arvind Sharma 25-04-2014 30-03-2014 07-04-2014 Comp. Available

12 connection of pneumatic cylinders To connect with pneumatic line Nikunj Kumar Mr S. arumgum 30-04-2014 12-04-2014 13-04-2014 Comp.

13 Connection with PLCTo connect pneumatic cylinder of die with PLC program of press

Nikunj Kumar Mr S. Arumgum 01-05-2014 14-04-2014 04-05-2014 Comp.

14 Check as per design Make the check sheet Nikunj Kumar Mr Arvind Sharma 03-05-2014 05-05-2014 06-05-2014 comp.

15 Trial make the report of trial Nikunj Kumar Mr Arvind Sharma 05-05-2014 07-05-2014 15-05-2014 COMP.

16 Project report preperation and sumbition Detailed report preperation Nikunj Kumar Mr Arvind Sharma 10-05-2014 09-05-2014 15-05-2014 COMP.Delay due to

dept. issue

Safety precautions

Use helmet at workplace

Use glob's

Use ear plug

Use Safety shoe

Don’t touch any machine during

operation

Keep distance during press

operation

• Punch and Matrix die which are used forcutting and forming pieces in differentmethods have abundant diversity in thecases of shape, dimension and type of them,hence their designing necessitate so muchtime meanwhile their cost is very much andon the other hand various design of diesmore often are used only for one time,thereby these dies will be useless for othercases therefore because of these,warehousing them vastly get increaseswhereas the occupied space of thewarehouses turns to the big problem formanufactures which it needs so muchmoney therefore it seems necessary to use amethod to design dies consist of a few partsthat be useable in different dies or in theother word, propose a method to makeuniformity between common parts of dies.

• A die is a specialized tool used inmanufacturing industries to cut or shapematerial mostly using a press. Like molds,dies are generally customized to the itemthey are used to create. Products made withdies range from simple paper clips tocomplex pieces used in advancedtechnology

INTRODUCTION OF DIE

• Basically Die is use as a pattern that

can be change whatever require of

product

• We can also say that Die is the

replica of object

• The having lot of operations that’s

can be performed

• Working of die depend on processing

of materials

WORKING OF DIE

• Basically we have study about two

type of die

Single operation die :- Single

operation dies are designed to

perform only a single operation in

each stroke of ram.

Multi operation die :- Multi

operation dies are designed to

perform more than one operation

in each stroke of ram.

TYPE OF DIE

There are three part of die are classified

a) Progressing Dies :-These dies are able to do

progressive actions (operations) on the work-

piece like one operation followed by another

operation and so on. An operation is performed

at one point and then work-piece is shifted to

another working point in each stroke of ram.

b) Compound type Dies:-As indicated by their

names these dies are meant to do combination

of two or more operations simultaneously. This

may be cutting action followed by forming

operation. All the operations are done in a

single action of ram.

c) Combination dies:-In these dies two or

more cutting actions (operations) can be

executed in a single stroke of the ram.

CLASSIFICATION OF DIE

Blanking:- it is the material removingprocess which having camber cut will bedone. A shearing operation that creates ahole in sheet metal by separating aninterior section. The removed piece ofmetal is the desired section.

Piercing:-Another term for a punchingoperation. For various manufacturers, theterm "piercing" refers to a punchingoperation that does not produce a slug, orit is used in a more general sense.

Forming:- The plastic deformation of ametal in order to produce a useful shape.Sheet metal can be formed throughoperations that shear, stretch, bend, orcompress the metal.

PRESS OPERATIONS

• Die automation is the part of

advance working die. Here for

die automation we use pneumatic

cylinder in small size its capacity

is 100 bar

• The die perform to setup

material in require blank at right

location

• This can be handle easily

• And productivity will improved

STUDY ABOUT DIE AUTOMATION

• My aim for die automation is in our

plant all forming die with

pneumatically operate stopper

• For example we have HCV, LCV and

MCV forming die for Automation

• My project aim is minimize man

power and maximize productivity

IDENTIFY THE AREA FOR DIE AUTOMATION

Require low man power

Better finishing in product

Maintained quality as better than

requirement

Improve product cycle

It is good for produce quality

maintain

Minimize ideal time of press

It suitable for quality oriented

organization

STUDY THE OBJECTIVE OF DIE AUTOMATION

We have mainly three type of die

for automation i.e.

• HCV- Heavy commercial vehicle

• LCV- Low commercial vehicle

• MCV- medium commercial vehicle

IDENTIFY THE DIE FOR AUTOMATION

We have requirement of different size

of product as well as different process

of blanks i.e.

For HCV forming blank width size,

410mm, 380mm, 356 mm

For LCV new forming width blank

size 314mm

For old LCV or MCV forming blank

width size 338 mm

STUDY THE DIMENSIONS OF BLANKS FOR DIFFERENT VARIANTS

• We have design for every require die

with stopper pneumatic cylinder and

its stroke of length

• For HCV, MCV and LCV which are

shown in AutoCAD drawings

DESIGN OF PNEUMATIC OPERATE STOPPER

• Bending Stress/Distance From The

Neutral Axis

= Bending Moment / Moment Of

Inertia

• But to solve the problems related

to object made of c-45 steel ,the

maximum stress is taken as 140

mpa.

• Material- C45 Sut= Ultimate

tensile Strength= 630 N/mm2 Syt=

Yield tensile strength =380

N/mm2

• Safety of factor for c45 material is

1.3

BENDING, COMPRESSIVE AND SAFETY OF FACTOR

PNEUMATIC CYLINDER CONNECTIONS

Here I Have Used For Connection 8 Mm Line And Fittings Of 8mm And T Also Of 8mm

If we try to make automated of

old die than it is lot expensive

and not suitable for high

productivity and it may as

accident will be accrued due to

small mistake of worker

If we having mass production of

product for one operation than

we will try it

It is not suitable as compare new

automated die

CONCLUSIONS

SUPPORTIVE MENTOR AND REFERENCES

Mainly I would like to say thanks to my mentor Mr Arvind Sharma, Mr J. P. Yadav and

Mr Lakhan Chaudhary who help me to perform like that and both of he support for

knowledge of me

References

1. Metals HandBook (Forming), ASM, Vol. 14, 1988.

2. C.W. Wegst, Stahlshl Ussel, Verlag stahlschlussel wegst Gmbh, 1989.

3. D. Wolff, Mechanical Desktop 6.0 Quick Reference, McGraw-Hill, 2000.

4. F. W. Wilson, P. D. Harvey and C. B. Gump, Die Design Hand Book, McGraw-

Hill, 1955.

5. http://en.wikipedia.org/wiki/Pneumatic_cylinder

Engineering

Die automation