Design of Blanking Die for Stiffening Rib: A Case Study ‘Ketan Kapse', Ajinkya Jadhav”, Sagar Pawar’, Gajanan Gaikwad" M.Tech Student, Design Engineering, Walchand College of Engineering, Mabarashira, India? 1M Tech. Student, Production Engineering, Walchand College of Engineering, Maharashtra, India®* ABSTRACT: Metal cutting is used for cutting a metal of particular shape and size from metal sheet. Metal cutting operations are widely performed on press machines. The two types of operations fat are performed on press machines ae shearing and forming operations. These are namely, blanking, piecing, notching, bending, coining, drawing. deep drawing efe. The blanking and piercing is a metal shearing operation in which a pat of sheet metal is cut In blanking, the part of work piece that is removed fiom the sheet is the desired product while the remaining part is scrap. In piercing, the cut out potions scrap which gets disposed off while the remaining part isthe desired product. A die 1 a manufacturing tool used to mumufieture components of high accuracy andm large tumubers. This ppt des wi he design of Uankng de wel fr he manuitng of stifining nb. This esewch Pops focuses on designing of various components of blanking tol, two dimensional and three dimensional modelling of components. The modelling ofthe components was carried out on CATIA VS. The design and selection of blanking die is carried out by following standard die design approach. A closed die set is used forthe manufacturing of stiffening rib. The guiding rangement of plain bushing type is used for this blanking tool. The blanking tol design is governed by the material of component, thickness of component and shape and size of component. The aim is to design a blanking tool to improve the qualities of blank such as accuracy and surface ofthe cut. ‘KEYWORDS: Blanking die, CATIA, Die design, Punch Design Rib ete. 1 INTRODUCTION Sheet metal operations are widely used in the manufacturing of components of complex shape and size in the automobile and aircraft industry. Sheet metal operations are mainly of two types, metal shearing and forming operations. Sheet metal forming operations like bending, drawing, deep drawing et. are wed in the manuficturing of various components and undergo a series of operations in order to obtain the desired product, Blanking and piercing are sheet ‘metal shearing operations in which a part of sheet of predetermined shape and size is cut ffom the sheet metal In ‘blanking, the part of workpiece that is emoved from the shee isthe desired product wile the remaining pat is sarap In pierang, the cut out portion is scrap which gets disposed off while the remauning part isthe desired product. Blanking operation consists of a ceet metal tat is placed between the punch and die opening As the pmch approaches the die nd comes in coatact with the sheet metal, pressure is applied on the metal which results im the development of tensile and compressive forces in sheet metal. This results in the formation of crack near the edze of die opening and then crack propagates through the sheet metal and the part of shee is sheared.IL OBJECTIVES OF THE STUDY ‘The general objective of the research is to design a blanking tool used for the manufacturing of stiffening rib by following standard die design approach and analysis methods. ‘The factors affecting the design of blanking tool are as follows- ‘Material of sheet metal component ‘Stock thickness Bleak size Complexity of shape of blank IIL COMPONENT DETAILS ‘The dimensions of the component are shown in Figure 1 The component details are as follows: ‘Name of the componeat: Stiffening Rib Material of component: Mild steel Stock thickness: 3 mm ‘Shear streagti: 345 MPa ‘Tensile strength: 160 MPa Figure] IV.DESIGN OF COMPONENTS OF BLANKING DIE SET ‘The steps in the designing of blanking die set are as follows- Calculate clearance of punch Tonnage requirement of blank Calculate dimensions of die block Calculate thickness of lower and upper bolster plates Calculate dimensions of stripper Calculate dimensions of punch holder Selection of Bush Selection of Guide Bush‘© Calculate dimensions of punch Selection of Guide Pillar ‘© Selection of Dowels and Screws 4. CLEARANCE DETERMINATION The clearance in punch and di is the most crucial factor inthe design of sheet metal component. In blanking, clearance is provided on punch while in piercing, clearance is provided on die The cuting clearance per side is calculated by the formula- 0.0032t/% Where, C= Clearance per side 1 = Stock thickness f= Shear strength of material in MPa 10032 » 3 « V3AB 4178 mau 0.18 mm per side Angular clearance of 2° is provided on die plate so that the blank easily withdraws through the die plate. B. PRESS TONNAGE REQUIREMENT The capacity of press machine necessary to provide force required in the blanking process is to be determined. The ‘press machine must provide 30 % more force for holding the blank during operation. ‘Press tonnage = 1.3 » Blanking force Blanking force = Pt « Where, ‘Blanking force = 448 « 3 « 345 = 463,650N= 47.28 Ton ‘Press Tonnage = 1.3 » 47.28 = 61.46 Ton 602,646 Considering Factor of Safety = 1.2. Tomnage requirement = 1.2 * 61.46 73.75 Ton