K.Kishore Kumar, A.Srinath. M.Naveen, R.D.

pavan kumar/ International Journal of

Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.2971-2978

DESIGN OF PROGRESSIVE DIES

K.Kishore Kumar1 , Dr. A.Srinath2 , M.Naveen3 , R.D.pavan kumar4
1,3,
Assistant Professor, Research Scholar, Dept.of Mechanical Engg, K L University
2
Professor, Department of Mechanical Engineering, , K L University,
4,
Mtech (CAD/CAM) K.L.UNIVERSITY

Abstract
Before converting raw materials to a finished product we need an accurate design of the product
and also data required for manufacturing. If the design is not accurate then defects will occur in the
manufactured product; small mistakes in designing a product makes the manufactured product useless so
more amount time is allotted for designing a new product (or) for modifying the existed design.
In this work the use of a software namely Pro/E for designing a progressive die to manufacture
washer for the M 12 bolt has been incorporated. A progressive die is a multiple station die. In this work
authors have designed a progressive die which has two stages of operation. The former operation is
piercing and is followed by blanking. In both operations a finite volume of metal is removed from the sheet
metal.
If the final product happens to be removed portion then the operation is blanking, on other hand if
pierced sheet metal is the final product then the operation is piercing. Both the operations are performed
simultaneously in a single stroke of press, thus enabling the user to obtain the final product in a single
stroke. This design procedure can also be extended for manufacturing washers for M-series bolts by
modifying the punch and die plate dimensions.
.
Key words: Progressive dies, washers, Design, forces for punching and blanking

1.DESIGN OF PROGRESSIVE DIE The operation performed in a progressive

A progressive die performs a series of die could be done individual dies as separate
fundamental sheet metal operations at two or more operations but would require individual feeding
stations during each press stroke in order to and producing .In a progressive die the part
develop a work piece as the strip stock moves remains connected to the stock strip, which is fed
through the die. The work piece on progressive through the die with automatic feeds and
dies travels from one station to another, with positioned by pilots with speed and accuracy.
separate operations being performed at each The linear travel of the strip stock at each
station. Usually the work piece is retained in the press stock is called the progression, advance or
stroke until it reaches the final station, which cuts pitch and is equal to the interaction distance.
off the finished piece .All station work The unwanted parts of the strip are cutout
simultaneously at different points along the work as it advances through the die, and one or more
strip ,which advances on station at each stroke of tabs are left connected to each partially completed
ram. Thus a complete part is produced with each part to carry it through the stations of the die.
stroke .Progressive dies generally include blanking Sometimes parts are made from individual blanks,
and piercing operations but a complicated neither a part of, nor connected to a strip in such
progressive die can do the operation of bending, cases mechanical fingers or other devices are
forming, curling and heading also .Each employed for the station to station movement of
workstation performs one or more distinct die work piece.
operation, but the scrip must move from the first The selection of any multi-operation tool,
through each succeeding station to produce a such as progressive die, is justified by the principle
complete part .One or more idle station may be that the number of operations achieved with one
incorporated in the die ,not to perform work on the handling of the stock and produced part is more
metal but to locate the strip, to facilitate inter economical than production by a series of single
station strip travel, to provide maximum size die operation dies and a number of handling for each
sections or to simplify their construction . single die.
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 K.Kishore Kumar , A.Srinath. M.Naveen, R.D.pavan kumar/ International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.
Where tool production requirements are The two shearing elements of the press
high, particularly of production rates are large, tool are the hardened punch and the die plate
totally handling cost is saved by progressive having sharp edges and a certain shearing
fabrication compared with a series of single clearance. Both the shapes of the punch and the die
operation are frequently greater than the costs of opening conform to the required shape of the
the progressive die. component. The punch is connected to the ram of
A progressive die should be heavily the power press and while descending contacts the
constructed to withstand the repeated shock and stock, exerts pressure over the stock around the
continuous runs to which it is subjected, precision cutting edges and shears it through. Exactly the
guide post and bushings should be used to maintain same phenomenon that takes place where in
accuracy .Lifters should be provided in die cavities blanking (or) in piercing (or) in any other shearing
to lift up or eject the formed parts and carrier rails operation.
or pins should be provided at the last station .When In the process of shearing four important
practical, punches should contain shudder or kicker stages are usually distinguished according to the
pins to aid in disposal of slugs. Adequate piloting observation.
should be provided to ensure proper location of the STAGE I: Plastic Deformation
strip as it advances through the die. The striper The stock material has been placed on the
plates should engage guides before contacting the die and the punch is driven towards the die. The
strip. punch contacts the stock material and exerts
The dropping of the work pieces through pressure upon it. When the elastic limit of the stock
the die is the most desirable method of part material is exceeded, plastic deformation takes
ejection, but cannot always be obtained. Cutting place.
the scrap in to small section simplifies the material STAGE II: Penetration
handling problems and produces a greater price and As the driving force of the ram continues,
return when sold as scrap metal. the punch is forced to penetrate the stock material
In the present project the progressive die and the blank or slug is displaced into the die
set is used to produce component that is washer the opening a corresponding amount. This is true
specification are as follows shearing part in of the cutting cycle, from which
the term “shearing action” is derived.
Stock strip material is mild steel. STAGE III: Fracture
Thickness of strip : 1.6mm Further continuation of the punching
Outer diameter : 26mm pressure that causes fractures to start at the cutting
Inner diameter : 12.5 mm edges of the punch and the die. Under proper
cutting conditions, the fractures extended toward
2.PRINCIPLE OF METAL CUTTING:- each other and meet. When this occurs, the fracture
The metal is brought to the plastic stage is complete and the blank or slug is separated from
by pressing the sheet between two shearing blades the original stock material. The punch then enters
so that fracture is initiated with the movement of the die opening, pushing the blank or slug slightly
the upper shear, finally result in the separation of below the die cutting edge.
the slug from the parent strip. STAGE IV:
The metal under the upper shear is As the punch completes the down stroke
subjected to both compressive and tensile stresses. up to the lower point, the component of slug is
In an ideal shearing operation. The upper shear pushed through the die opening. Strictly speaking
pushes the metal to a depth equal to about the third this action is a consequence of the dynamic
of its thickness. Because of pushing the material fracture at the stage III and only in certain case the
into the lower shear the area of cross-section of the push through takes place where the punch takes
metal between the cutting edge of the shear place where the punch travels beyond the land of
decreases and causes the initiation of the fracture. the die.
The portion of the metal which is forced into the This is the simplest approach on the
lower shear is lightly burnished and would appear shearing action. Before dealing with the details of
as a bright band around the blank lower portion. the phenomenon, the attention is drawn on the
The fractures which are initiated at both the cutting same other allied factors which calls for deeper
points would progress further with the movement deliberations on the shearing process.
of the upper shear and if the clearance is sufficient,
would meet, thus completing the shearing action.

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 K.Kishore Kumar , A.Srinath. M.Naveen, R.D.pavan kumar/ International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.
3.THE AMOUNT OF SHEARING punch. If the final product happens to the removed
CLEARANCE PER SIDE portion, then the operation is termed as blanking.
At a certain value of shearing clearance, On the other hand if the pierced sheet metal is the
which depends on the thickness, kind and its heat final product then the operation is called punching.
treated conditions of the stock, the crack line meet, Blanking
resulting in easy action, low vertical force, low It is a process in which the punch removes
horizontal force, low stripping, low wear high die a portion of material from the stock which is a strip
life but fairly distorted sheared contour. At of sheet metal of the necessary thickness and width
narrower clearance secondary cracks develop that . The removed portion called a blank and is usually
is the two cracks do not meet, resulting in further processed to be of some use.
unfavorable increase in forces but some Piercing:-
improvement is found in the quality of the cut This operation consist of simple hole
contour, due some burnishing of the shaped punching is piercing is making holes in a sheet it is
secondary cracks. identical to blanking except if the fact that the
Importance of cutting clearance punched out portion coming out through the die in
Proper cutting clearance is necessary to piercing is scrap .piercing is always accompanied
the life of the die and the quality of the piece part. by the blanking operation either before , after(or) at
Excessive cutting clearance results in objectionable the same time.
piece part characteristics, insufficient cutting Punching Force
clearance causes undue stress and wear on the The force required to be exerted by the
cutting members of the tool because of greater punch in order to shear out the blank from the
punching effort required. stock can be estimated from the actual shear area
If the amount of clearance is optimum, then the and shear strength of the material using formulae
two fracture lines meet and a clean edge is obtained P= L×T× τ
after the operation. τ→shearstrength(mm)
If the clearance is too small then the L →perimeter of cut(mm)
fracture lines miss each other and a secondary T →stock thickness(mm)
deformation taken place resulting in an unclear
edge. Shearing force (Fsh):
When the amount of clearance is too large Fsh =L×T×τ
obvious that significance amount of drawing action L=Length of cutting edge
takes place and the quality of the work piece is T=Thickness of the stock strip
again quite poor. τ =shear strength of the material Newton/sq.mm
Importance of angular clearance
Angular clearance is of vital importance Force required for piercing operation :
in any die where blanks or slugs pass through the F1=L ×T× τ
die opening. Like cutting clearance, angular
clearance is a “per side” measurement. A clearance =π×12.5×1.6×390
of ¼ per side is suggested for die work of good
quality when the stock material is less than 1.5mm =24504.4N
thick. All die-opening walls should have smoothly Force required for blanking operation:
finished surfaces throughout. Owing to the F2=L ×T×τ
lessening of the back pressure from blanks or slugs, =π×26×1.6×390
small or delicate punches will also benefit from
slightly increased angular clearance in the die =50969.199N
opening. Total shearing force :
F=F1+F2
(4)..FORCE CALCULATIONS =75473.62N
Punching and Blanking Taking factor of safety=1.5
The punching and blanking process The capacity of press required is 113.21KN
cannot strictly speaking grouped under forming
operations. In these processes a finite volume of Blank Holding Force:
sheet metal is removed by using a die and a punch. Blank holding force or stripping force is
The shape and size of the portion removed are the force,which controls the metal flow .It is the
determined by the geometry of the die and the force applied by the blank holder on the blank to

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 K.Kishore Kumar , A.Srinath. M.Naveen, R.D.pavan kumar/ International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.
control the flow of the metal in to the die
cavity.Important consideration in tooling for 5)DESIGN OF DIE ELEMENTS USING
sheet metal forming wrinkling of sheet as it is PRO/E
being formed. Hold down can best be provided by (5a)DIE BLOCK DESIGN:
hold down ring .However by using mechanical A tool-steel block which is bolted to the
spring or an auxiliary air cylinder ,hold down can bed of a punch press and into which the desired
be provided in a single action press. impressions are machined. The part of an extrusion
Stripping force required =k×L×T×τ mold die holding the forming bushing and core.
K=stripping constant The die block constitutes the female half
=0.0207(for low corbon steels above 1.5 of the two mated tools, which carry the cutting
mm thickness) edges. A vertical opening extending through the
=0.0207×π×(12.5+26)×1.6×390 block determines the size and outline of the blank.
=497.3N The exact opening is provided in the die to obtain a
=0.4973KN predetermined clearance between punch and the
Total force=shearing force+stripping force die. The amount of angular clearance and vertical
=113.21+0.4973 land in the die opening is necessary in order to
=113.70KN prevent the possibility of a blank or slug jamming
Capacity of press required for punching in the passage.
operation=113.7KN The overall dimensions should be
obtained by having minimum die wall thickness
SPRING DESIGN required for strength and by the is space needed for
Spring are used to obtain the required blank mounting screws, dowels, and stripper plate. The
holding forces : material to be used in manufacturing is HCHC and
Spring has to take up the total force and it should to be heattreated60-62HRC. Using pro/E
be designed for this load. software a new file is opened in part mode. The
Pmax=Shearing force+blank holding force sequence of commands are used.
=113700N Select the plane→front→ ok
Springs has to be designed for this force
δ/n=(8×W×D3)/(Gd4)
δ=deflection of spring
n=number of active coils
W=axial load in spring
D=mean diameter
G=modules of rigidity for
spring material
d =diameter of spring wire
In the present project
δ =10mm
D=22mm
W=113700N
10/n=(8×113700×223)/(84000×d4)--------------(1)
We also know that
Free length of spring
Lf=Solid length + maximum
compression+clearance between adjacent coils
=n|×d+C+0.15×C
| fig5a:2D OF DIE BLOCK DESIGN:
Where n =n After completion of these command a
C=max compression proper sketching plane is selected to draw the
Lf=35mm sketch as shown in the drawings and depth is given
35=nd+10+0.15×10----------------(2) to the 2-D sketch such that solid model is obtained.
Solving (1)&(2) Change PRO/E default units to user specified units
n=3turns from menu manager.
d =12.00mm Select a plane give direction of sketching
D=22mm plane a new window sketcher arises on the screen.
Toggle off the grid and refresh, draw a rectangle
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 K.Kishore Kumar , A.Srinath. M.Naveen, R.D.pavan kumar/ International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.
with given dimensions specify the depth of the die
plate (rectangle)
Select the part -> extrude -
> done
Select a proper plane and give
direction of cut specify dimensions for the cutting
portions. Give
Thru all -> done -> ok
for creating hole in die plate of specified
dimensions.
Feature->sketch->circle->ok
For standard hole set ISO standards
and select proper screw size add thread surface
click on thru all, thru thread ,select primary
reference plane select linear reference plane1 and
plane2 with given distances check the preview and
ok A signal standard hole is created. Figure:5(b)3D DESIGN OF STRIPPER PLATE
Feature->copy->mirror->dependent->done
Select a feature to be mirrored, select a 5c)DESIGN OF PUNCH PLATE
plane to mirror, the standard hole using copy
command created, four standard holes using cut Punch plate is essentially sheet metal with
command remove material up to specified depth to regularly spaced holes and is used to classify
have a step. material in applications from dredges to trommels
Feature->extrude->remove->thru all and eveything in between. Classification is
Draw rectangle on the top surface of the die plate obviously dependant on the size of the holes and
highlighted entities be aligned. Specify step depth, that is dependant on application.
die plate of 3D progressive die plate with specified Punch plates hold and support piercing,
dimensions is created. notching, and cut-off punches. They are usually
made of machine steel, but can also be made of
tool steel that has been left soft for high grade dies.
Punch plates range from small simple blocks for
holding single piercing punches to large, precision-
machined plates for holding hundreds of
perforators
The thickness of punch plate is 15mm and
the material to be used in manufacturing is EN8.
Upper part of the punch plate is provided with a
shank equal in diameter to the ram hole. The shank
is locked in position with a side screw.
This part which is dowelled together with
FIA 5A: 3DMODEL the top plate retains or holds the punches. The
The similar steps are repeated for stripper plate, center distances is picked up or transferred from
punch plate , top and bottom plates. the hardened die block to eliminate the possibility
of misalignment of punches and die openings due
5b)DESIGN OF STRIPPER PLATE to dimensional changes during heat treatment.
The primary purpose of a stripper is to Holes to receive the body of punches are provided
remove the stock from the punch after a blanking with H7 fit in order to bare a light press fitting.
or piercing operation. However the stripper serves
two other secondary function also. Firstly it guides
the strip if fixed to the die block surfaces.
Secondly, it holds the blank under pressure before
the punch descends fully if the stripper is of spring
loaded type. The thickness of stripper is 14.3mm
and the material used is EN 8.

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 K.Kishore Kumar , A.Srinath. M.Naveen, R.D.pavan kumar/ International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.
a wide shoulder to facilitate mounting and to
prevent deflection under load
In case of smaller punches the punch may
be held in a retainer which in turn is a mounted
against the punch holder. The exact length of a
punch can be found out by laying the whole
assembly drawing only as the sheet height as to be
made up from the die block, die shoe, punch ,
punch holder.
Punches of diameter less than the stock
thickness must be designed carefully because unit
compressive stress in punches rises 4 times the unit
shear stress of the material when punch diameter is
equal to stock thickness. The height for these
punches are 55mm,the material used for
figure5c):3D DESIGN OF PUNCH PLATE manufacturing in HCHC heat treated to 60-62 HRC
5d)DESIGN OF STOCK GUIDES: . Clearance between punch and die is 0.06mm is
selected from the table which is equal to 5-7%.
The size of stock guides are dependent
upon the size of strip and the size of the die block.
Two stock guides (front gage and back gage) of the
same size 2’21’83 mm are used. Both the front
back games are separate units assembled in the die
block. Both are extended and provided with strip
rest to aid in aligning the strip for starting and
feeding.

Punch 1
Punch 2

DESIGN OF TOP PLATE

Top plate (upper shoe) holds the upper
Guide pin half component of the die, clamped to the ram by
Guide bush means of the shank being screwed on its top
surface where the center of pressure is located .The
fig5d):DESIGN OF STOCK GUIDES thickness of the top plate is determined the product
of 0.9 times of the thickness of the die block which
5E)DESIGN OF PUNCHES: is equal to 19mm.The material to be used for
The exact dimensions of pitch diameter manufacturing this part is EN8.
are determined by providing clearance between
punch and die. The punch is usually designed with

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 K.Kishore Kumar , A.Srinath. M.Naveen, R.D.pavan kumar/ International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.
dimensions are based on the standard dimensions
of shank sizes. The shank is positioned where the
center of pressure is located.

DESIGN OF BOTTOM PLATE

The function of the bottom or lower
shoe primarily as a base for the complete die
assembly and in turn is bolted or clamped to the FASTENERS AND DOWELS
bolster plate over the press bed. The thickness of Fasteners and dowels are not included in
the bottom plate is 16.8mm. the design for they are available in standard form.
Openings are made with respect to the Four M 8 hexagonal socket head screw with length
die openings plus allowance, to allow stamped of 25mm each and 2 dowels of 6mm diameter with
components to fall freely. The material to be used length of 30mm,are used in the lower half
for manufacturing this part is EN8. component of the die.
Four M 8 hexagonal socket head screws with
length of 75mm,two M 8 hexagonal socket head
screw with length of 20mm,two dowels of 6mm
diameter with length of 30mm for the lower die.
GUIDE PILLERS AND GUIDE BUSHES
These elements of die are responsible for
the alignment of the lower and upper part of the
die. It should withstand deflection during
continuous production.
Standard dimensions of these parts are
used so that manufacturing would not be a problem
when these are available in the market
SHUT HEIGHT
It is the distance from the bottom bolster
to the top of the punch holder when the die is in the
closed position. The shut height will establish the
length of guidepost which must be at least 12 mm.
starter to allow for the reduced shut height due to
resharpening.
The determined shut height is 121.5mm
which is the sum of all the thickness of die
.DESIGN OF SHANK elements.
The size of shank is determined with
respect to the size of its threaded part (screw) use
in holding the top plate. The shank diameter is
31mm. Which is classified under M16 threaded
part and holding part length is 60.5mm. The
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 K.Kishore Kumar , A.Srinath. M.Naveen, R.D.pavan kumar/ International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 3, May-Jun 2012, pp.
This design procedure can also be
6.ASSEMBLY OF DIE extended for manufacturing washers for M-series
bolts by modifying the punches and die plate
dimension

REFERENCES:
.
1. Küttner, R. , A Framework for collaborative
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2. Küttner, R., Eljas, O., Teamwork in

distributed product development
environment. Annals of DAAAM for 2001,
Proceedings of 12th International DAAAM
Symposium, ed. B. Katalinic. DAAAM
International Vienna, Austria 2001.pp 269-
270

3. Dieter, G., Engineering Design, McGraw-

Hill International Editions, Mechanical
Engineering Series, ISBN0-07-366136-8,
USA 2000

4. Paquin, J.R. & Crowley, R.E., Die design

CONCLUSION fundamentals, Industrial Press Inc. Second
By the implementation of computer in edition, NY 1987, 244 pp.
design field accuracy of design is improved and
design field accuracy of design is improved and 5. Küttner, R. & Nekrassov, G. Development
design process time is reduced drastically than by of an intelligent integrated environment for
traditional method. In the process of creating the computer-aided design of work-holders.
documentation for the product design much of Proceedings NordDesign 2002, ed. Per
required data base to manufacture the product is Boelskifte & Johannes B.Sigurjonsson,
also created. August 14-16 2002, NTNU, Trondheim,
Many design problems which are Norway, pp.185-193
complicated to estimate by traditional methods are
eliminated by using CAD system.as the designs 6. Progressive Die Wizard Help, EDS 2003
have more standardization they can be imported to
any other software and also CAD provide better 7 A.C.Rao , A.Srinath -Planar linkages:
functional analysis to reduce prototype testing structural influence on mechanical
Regarding progressive die design of advantage and function generation --
progressive die is simple. Advantage of progressive Mechanism and Machine Theory 42 (2007)
die is it perform two or more operations 472–481
simultaneously by a single stroke. Progressive die
is used for high rate of production.

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