DESIGN & MANUFACTURING OF

NUT PIERCING DIE

MAJOR PROJECT REPORT

Submitted in partial fulfilment of the requirements for the award of the degree

of

BACHELOR OF TECHNOLOGY
in

TOOL ENGINEERING
by

Group 5
BATCH – 2018-2022

Guided by

Dr. GAURAV ARORA DR. KANWARJEET SINGH

(Assistant Professor) (H.O.D, B.Tech-T.E.)
(CO-Guide) (Guide)

DEPARTMENT OF TOOL ENGINEERING

DELHI SKILL AND ENTREPRENEURSHIP UNIVERSITY ,

OKHLA – II , CAMPUS
 CANDIDATE’S DECLARATION
It is hereby certified that the work which is being presented in the B.Tech major
project titled “ DESIGN & MANUFACTURING OF NUT PIERCING DIE ” in
partial fulfilment of the requirement for the award of the degree of Bachelor Of
Technology and submitted in the department of Tool Engineering of “DELHI
SKILL AND ENTREPRENEURSHIP UNIVERSITY , OKHLA – II , CAMPUS”,
Delhi is an Authentic record of our own work carried out during a period from
March to June 2022 under the guidance of Dr. Gaurav Arora, Dr. Kanwarjeet
Singh.

The matter presented in B.tech major project has not been submitted by us for the
award of any other degree of this or any other Institute.
STUDENT NAME ENROLLMENT SIGNATURE
NUMBER

Mohd.Wajahat 01370208618
(Group Leader)
Md. Sadiq Saifi 01270208618

Rohit Sharma 42970208618

Manas Tandon 01170208618

Amaan Khan 40370208618

Harsh Arora 00870208618

Adarsh Kumar Shukla 40270208617

Shweta 42170208618

Ayush Singh 00670208618

Prashant Kumar Singh 40870208618

Raunaq Singh 41970208618

i
 CERTIFICATE
This is to certify that major project titled “DESIGN & MANUFACTURING OF
NUT PIERCING DIE” is the bonafide work of student of group 05(Batch 2018-
2022), who carried out the research under our supervision. Certified further, that to
the best of our knowledge the work reported here in does not form part of any other
project or dissertation on the basis of which a degree outward was conferred on an
earlier occasion on this or any other candidate.
STUDENT NAME ENROLLMENT NUMBER
Mohd.Wajahat(Group Leader) 01370208618
Md. Sadiq Saifi 01270208618
Rohit Sharma 42970208618
Manas Tandon 01170208618
Amaan Khan 40370208618
Harsh Arora 00870208618
Adarsh Kumar Shukla 40270208617
Shweta 42170208618
Ayush Singh 00670208618
Prashant Kumar Singh 40870208618
Raunaq Singh 41970208618

Dr. Kanwarjeet Singh Dr. Gaurav Arora

(HOD Tool Engg) (Assistant Professor)
(Guide) (Co-Guide)

ii
 ACKNOWLEDGEMENT

This project is a golden opportunity for us to learn Tool Engineering and get
development towards actual working conditions of industries. We considered ourself
honored and privileged to have so many wonderful people who lead us.

We would like to stand our sincere thanks to Professor S. Maji, worthy Director-
Cum Principal. For providing us the facilities to carry out our project work. We
express our deep gratitude to Dr. Kanwarjeet Singh H.O.D-B.Tech(T.E.), for his
valuable Guidance and suggestion throughout project work. He provided an
academic environment of logical enrichment, advice and stimulation to excel and
provided us his valuable suggestion and precious time in accomplishing our project
report. We are thankful to Dr. Gaurav Arora Co-Mentor, Asst. Professor for giving
his time and suggestion to complete our project work, and providing us an
opportunity to undergo this project and learn and design something innovative and
productive.

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 ABSTRACT
The project includes Designing and Manufacturing of Nut Piercing Die for
Stamping operation titled as “DESIGN & MANUFACTURING OF NUT
PIERCING DIE”. The project aims to explore the techniques involved press
tool design and manufacturing sheet metal product with the complete up
gradation of market. The main objective of project is to develop a die which
can attach a nut to the sheet with the help of piercing and forming operation.
This project will help in creating an alternate option of welding operation for
joining nut and sheet metal.

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 TABLE OF CONTENT

S.No. Description Page No.

Candidate’s declaration i

Certificate ii

Acknowledgement iii

Abstract iv

1. Chapter1-Introduction 1
1.1.Piercing Operation 1
1.2.Forming operation 2
1.3.Formability 2
1.4.Nut Piercing 3

2. What is Piercing Nut 4-5

3. Applications of Nut Piercing 6-7

4. Advantages of Nut Piercing over 8-9

5. Chapter2-Mechanical Press 10

2.1How Does Mechanical Press Work 11

2.2Why Use a Mechanical Press 11-13

6. Chapter3-Design considerations for Nut Piercing Die 14-23

7. Chapter4-Calculations 24-25

8. Chapter5-Design of Nut Piercing Die

5.1 Design of Die Set 26

5.2 Design of Die Block 27

5.3 Design of Punch 28

5.4 Design of Punch Plate 29

5.5 D Model of Nut Piercing Die 30

5.6 Assembly Drafting 31

5.7 Design Of Final Product 32

9. Chapter6-Manufacturing Process

6.1 Turning Operation 33

6.2 Drilling Operation 33

6.3 Tapping Operation 34
6.4 Threading Operation 35
6.5 Shapping Operation 35
6.6 Facing Operation 36
6.7 Boring Operation 37

10. Chapter7-Process Planning

7.1Die Block 38

7.2Punch 39
 7.3Punch Plate 40

7.4Guide Pillar 41

7.5Upper and Lower Plate 42

7.6Nut 43

7.7Knob 44

7.8Shack 45

7.9 Different Parts 46

11. List of components 47

12. Final Die Set 48

13. Costing 50-52

14. References 53
 Chapter1
Introduction
There are number of operations like piercing, blanking, forming trimming, bending
that can be performed using a press tool to get a desired part from sheet metal. These
operations are performed with the help of pneumatic, hydraulic, or mechanical
presses.

In this project nut is attached with the sheet metal through piercing and forming
operation.

1.1 Piercing Operation

In piercing operation, a clean cut hole is produced in your sheet using a press tool.
Part which contains hole is our piece part and the one which is being blanked out is
considered as slug.

Piercing operation is performed wherever we need a hole of cut out on sheet.

Fig. 1 Sheet metal after piercing operation

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1.2 Forming Operation

Forming is an operation bending a sheet of metal along a curved axis. The material
is confined between the punch and die and is stressed in compression and tension
beyond the elastic limit.

The shape of component is governed by shape of die and punch.

Fig. 2 Sequence Drawing Operation

1.3 Formability
Formability is the ability of a given metal to undergo plastic deformation without
being damaged. The plastic deformation capacity of metallic material however is
limited to a certain extent beyond which material could face fracture or shearing.

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1.4 Nut piercing

It is an operation of attaching a piercing nut with the unit stock of sheet metal by
placing it between die and the punch (which holds the nut) and die.

Nut is fixed with the stock through piercing and forming operations performed at the
same time.

Fig. 3 Sequence of application of the self-piercing nut

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 What is Piercing Nut?

These nuts are internally threaded, precision, work-hardened steel with external
undercuts on two sides or on outer side in case of circular nut. Used in sheet-metal
panels and installed by automatic machinery, they can be attached in open or blind
locations. Self-piercing nuts have high resistance to torque, vibration, tension, and
shear loads, and particularly to a combination of such forces.

Self-piercing nuts can either pierce and be clinched simultaneously or be clinched

into pre-pierced holes. Nut installation may proceed simultaneously with other
forming, blanking, and piercing operations at high speed in both single and
progressive die setups. The nut can be installed individually, in strip or coil stock, or
as multiples in one panel.

Standard self-piercing nuts may be installed in metal panels up to 0.145 in. thick.
The work-hardened steel nut has a pilot-head hardness greater than Rockwell B 85.
Proper malleability is retained in threaded areas.

Self-piercing nuts for flush mountings are available for thin metals at high stresses.
Application of the high-stress nut is generally limited to metal thicknesses of 0.03 to
0.09 in. A locknut feature can be produced by projections on the driver (nut plunger).
Controlled distortion of the last threads in the nut provides a locking action that can
be made to torque requirements.

Self-piercing nuts can be installed in unplated, plated, or painted panels. Installation

in a painted panel has little or no effect on the painted surfaces.

For proper torque resistance, a self-piercing nut should have an asymmetrical shape.
A pilot should protrude a minimum of 0.005 in. through sheet metal to ensure proper

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slug removal. When piercing two metal thicknesses, the pilot should protrude a
minimum of 10% of the total maximum thickness of both metals.

Self-piercing nuts can be located on 1.5-in. centers with standard tools, or closer
with special tooling. Rotation of the nut on the panel allows some deviation in the
center distances.

Fig. 4.1 Section of Piercing Nut Incorporated in metal sheet

Fig. 4.2 Section of Piercing Nut Incorporated in metal sheet

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 Applications of Nut Piercing
Punch nuts are mounted in different metal parts of cars:
• functional supports,
• holders,
• complete side panel frames,
• wheel houses,
• roof rails,
• antenna plates and many others.
Other than cars nut piercing operation find application in sheet metal wherever we
need to attach nut with the sheet.
Example-Nuts can be attached with the help of nut piercing operation in following
parts.

Fig. 5 Piercing Nut used in a sheet metal frame of automobile part

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Fig. 6 Pierced Nut in slider bracket of car seat

Fig. 7 Pierced nut used in

Door panel

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 Advantages of Nut Piercing

• Using nut piercing over the welded nut is more beneficious because it is more

cost effective to produce individual parts as finished part. Welding is no

longer required.

• Saves electricity

• No smoke

• No weld splatter, which eliminates re-tapping of the nut

• Avoids intermediary steps between the pressing and welding stations

• Reduces lead times

• Avoids difficulties with coated sheet metal

• More secure orientation of the nut against sheet metal and a more exact right-

angle, thus avoiding misassembly such as positioning.

• Easier feeding and less risk of the nut getting stuck in the feeding system

• More even distribution of pressure between nut and sheet metal

• No stress concentrations due to sharp corners

• Reduced risk of stress cracks in the sheet metal

• They provide strong threads in very thin material.

• May be installed using any standard Arbor press.

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 • Provide high push-out and torque-out resistance.

• Do not require special hole preparation, such as chamfering and deburring.

• Reverse side of material remains flush.

• No re-tapping necessary after application.

• Low installed costs, fewer parts to handle, fewer assembly steps and less

assembly time.

• Controlled setting force

• Optimal torsional resistance

• Optimal pull through force

• Optimal push out force

• Allows generous stamping process window compensation

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 Chapter 2
Mechanical Press

A mechanical press is a machine press that is primarily used for forming sheet metal
and metal extrusion. Press machines are the classic and common machine tools that
can be basically divided into a hydraulic press and mechanical press. The press
working is an essential modern metal fabrication process across industries. The
mechanical press is not only used for sheet metals but also used for manufacturing
plastic products and a variety of machining operations such as broaching. Machine
presses including mechanical press and hydraulic press all require a great amount of
output force to complete the metalwork, for example, to deform a considerable piece
of metal. The type of energy source, the manner, and nature where the machine press
will transfer the energy vary, define the efficiency as well as the output the machine
tool can provide.

In a vertical mechanical press machine, the force vector works upward and
downward relative to gravity. In other cases, the same machine type is mounted
horizontally where the working force is applied to the path perpendicular to the
direction of the gravity. The working principle of the mechanical press is however
the same no matter that the force is exerted vertically, horizontally, or at the
intermediate angle.

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 2.1 How Does Mechanical Press Work?
In short, the working principle of the mechanical press is to convert the rotational
force from the electric motor to a translational force which drives the mechanism of
pressing work. The energy source of the mechanical press machine is typically a
motor. Using a mechanical press machine, there are 3 main steps to complete the
metal forming process. The production cycle begins with the material placed on the
dies where the metal sheet or other raw materials should stay in place for machining.
The operators should then manipulate the mechanical press to apply appropriate
pressure in order to force and shape or alter the raw materials as they need.
Subsequently, the finished products will be ejected and collected from the
mechanical-machines.

All components in a mechanical press require to be lubricated through the internal

system, in general, which supplies a stable flow of lubricants to ensure smooth
movement during the pressing process. In general, mechanical presses are large
machine tools that might be dangerous to some degree. The operations require
workers with proper training and safety procedures. The proper range of the stroke
is also vital when performing metalworking using a mechanical press machine.

2.2 Why Use a Mechanical Press?

The mechanical press has numerous benefits when performing metal shaping. For
starters, the metal forming cycles performed in a mechanical press are typically more
rapid than one in a hydraulic press. Unlike other types of machine press, the
application of force in a mechanical press can vary from speed and magnitude
throughout the stroke length.

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Among different styles and sizes of machine presses, the mechanical press is widely
chosen to use in metal forging production as well as sheet metal forming. On top of
that, a mechanical press is also ideal for impact extrusion applications where the
rapid and consistent application of force can be fully utilized over a preset distance.
The most effective and powerful mechanical press machine nowadays perhaps is the
one having the capacity of approximately 12,000 tons.

Following are some subtypes of mechanical press that can provide a wide range of
metal machining jobs for specific applications. The subtypes of the mechanical press
include but are not limited to the stamping press, the screw press, the punch press,
the press brake, and more. The mechanical punch press is primarily used to form
holes repeatedly under a great amount of pressure. The mechanical screw press is
also called the fly press, utilizing the ram which is driven upward and downward by
the screw to shape the metal pieces through the dies. The mechanical stamping press
is also a classic press which consists of a press frame, a ram, and a bolster plate.

The stamping press also employs the die to deform and cut the metal parts. As for
the mechanical press brake, it is a special style of press machine that can be used to
bend the metal parts into desired profiles. In a press brake, the bending force can be
up to 3000 tons. Some common applications of this mechanical press include the
production of the back-plate of a computer case, the frame pieces, and the electronic
enclosures. Some of the CNC mechanical press brakes can even perform the metal
forming work with excellent accuracy to a fraction of 1 mm.

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 Fig. 8 The J23 Manual Punching Press Machine

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 Chapter 3
DESIGN CONSIDERATIONS FOR NUT PIERCING DIE
Design Considerations

• Minimum hole diameter should be at least 20 % greater than stock thickness.

In the case of stainless steels, it should be 2 times the material thickness.

• Minimum wall thickness (distance from hole to edge or hole to hole) should
be at least 2 times stock thickness.

• For non-round slots, the minimum wall thickness should be 2 times thickness
for short slots < 10 thicknesses long; and 4 times thickness for long slots > 10
thicknesses long.

• Minimum hole (and short slot) to bend distance should be 2.5 × the stock
thickness + bend radius.

• For long slots, the distance should be 4 × the stock thickness + bend radius.

3.1 Design of piercing punches

Piercing punches are usually the weakest link in any die design. Therefore, the
following factors must always be taken into consideration:

1. Make the punches strong enough so that repeated shock in operation will not
cause fracture.

2. Slender punches must be sufficiently guided and supported to insure

alignment between punch and die members and also to prevent buckling.

3. Make provision for easy removal and replacement of punches in the event of
breakage.

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3.2 Design of Punch Plates

Punch plates hold and support piercing, 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. Important design considerations include:

1. Adequate thickness for proper punch support.

2. Good doweling practice to insure accurate location.

3. Sufficient screws to overcome stripping load.

3.3 Design Conception

a Punch Plates for Single Punches

A punch plate for holding a single punch (Figure 10.1) is made square and with
sufficient thickness for good punch support. Two socket cap screws, applied at the
corners, resist stripping pressure, while dowels at the other two corners provide
accurate location. Minimum distance from plate edges to screw centers A is 1 1/2
times screw diameter B.

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Fig. 9 Punch plate for a single punch.

Stripping force. When center distances are small, a single punch plate can hold a
number of piercing punches. When a large number of punches are retained, the
stripping force should be calculated to insure that sufficient screws are used to fasten
the punch plate to the die.

3.4 Design of Pilots

Pilots play a vital role in the operation of multiple-station dies. Many press-line
troubles can be traced to pilot faulty design. When applying pilots, the following
factors should always be considered:

1. Pilots must be strong enough so that repeated shock will not cause fracture.
Severe shock is applied to the pilot point more often than is realized. Consider
that the pilot moves a heavy material strip almost instantly into register. Pilot
breakage increases cost of the stamping because hundreds of inaccurate parts
may be produced before failures are discovered. Also, there is the danger of

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 costly jams resulting from a broken pilot falling between the cutting edges or
forming members of the die.

2. Slender pilots must be sufficiently guided and supported to prevent bending,

which can cause faulty strip-positioning. They should be made of a good grade
of tool steel, heat-treated to 57-to-60 Rockwell C for maximum toughness and
hardness.

3. Provision should be made for quick and easy removal of the pilots for punch
sharpening.

There are two methods of piloting in progressive dies:

• Direct piloting consists of piloting in holes pierced in that area of the strip that
will become the blank.

• Indirect piloting consists of piercing holes in the scrap area of the strip, then
locating in these holes at subsequent operations.

Direct piloting is the preferred method, but certain blank conditions require indirect
piloting. Figure 10 shows examples of direct piloting (1) and indirect piloting (2).

Figure 10: Examples of direct piloting (1)

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3.5 Design of Gages

Gages must be considered in the design of press tools because these components
position the strip longitudinally in its travel through the die. In second-operation
dies, gages locate the previously blanked or formed part for further processing
operations. Design considerations include:

1. Material choice. Commercial gage stock or an equivalent finished tool steel

is used for gages in first class dies. Cold-rolled steel should be used only when
low production requirements exist.

2. Adequate thickness. The back gage and front spacer must be thick enough to
avoid binding the strip between the stripper plate and the die block because of
possible camber in the strip. Camber, or curvature, is more pronounced in
coiled stock that has not passed through a straightener.

3. Good doweling practice. Because gages locate the strip or part, they should
always be doweled in position.

4. Accuracy of location. Dimensions from the die hole to the locating surfaces
of gages are always given decimally on the drawing.

5. Accuracy of locating surfaces. The gaging surfaces that actually bear against
the strip (or part) should be ground, and so marked on the die drawing.

3.6 Design of Strippers

Stripper plates remove the material strip from around blanking and piercing punches.
Severe adhesion of strip to punches is characteristic of the die cutting process.
Because of their low cost, solid strippers are the most frequently used type,

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particularly when running strip stock. Spring strippers, though more complex,
should be used when the following conditions are present:

1. When perfectly flat, accurate blanks are required, spring strippers flatten the
sheet before cutting begins.

2. When very thin material is to be blanked or pierced, to prevent uneven fracture

and rounded blank edges.

3. When parts are to be pressed from waste strip left over from other operations,
spring strippers provide good visibility to the operator for gaging purposes.

4. When stripping occurs immediately, small punches are not as subject to

breakage.

5. When conducting secondary operations, such as in piercing dies, increased

visibility provided by spring strippers allows faster loading of work and
increased production.

Stripper plates may be made of cold-rolled steel if they are not to be machined except
for holes. When machining must be applied to clear gages, the plates should be made
of machine steel, which is not as subject to distortion. This chapter describes
numerous methods of applying stripper plates and their components.

3.7 How to Select a Die Set:

3.7.1 INTRODUCTION

After all die details have been designed, a die set of the proper size and style is
selected from a manufacturer's catalog and drawn in position. Between 5 and 10
percent of total design time is spent selecting and drawing the views of the die set.
This allowance may be increased considerably if the designer does not thoroughly
understand the principles underlying die set selection and representation.
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Die sets are manufactured in a bewildering variety of sizes and shapes. This chapter
will acquaint you with the various styles as well as indicate proper methods of
selection and placement.

Advantages realized when die components are retained in a properly selected die set
are:

1. Members are kept in proper alignment during the cutting process, even though
some looseness may exist in the press ram. Thus, uniform clearances are
maintained around cutting edges for producing blanks free of burrs.

2. Die life is increased.

3. Dies can be installed in the press in a minimum amount of time because they
are self-contained units.

4. Storage is facilitated. There is no possibility of loss of loose parts.

5. Properly designed dies can be sharpened without removal of cutting members.

Standard die sets range from 3 by 3 inches (76-by-76 mm) to 45-by-60 inches
(1,143- by-1,524 mm). Die holder and punch holder thicknesses range from 1
to 3 1/2 inches (25.4 to 89 mm).

3.7.2 PRINCIPLES OF SELECTING THE DIE SET

Ten elements of die set information must be decided before a die set can be ordered:

1. Make or manufacturer

2. Type

3. Size

4. Material

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 5. Thickness of die holder

6. Thickness of punch holder

7. Type and lengths of bushings

8. Lengths of guide posts

9. Shank diameter

10.Grade of precision.

In selecting a die set from a catalog, first consider the dimensions from front to posts
and from side to side. This is the die set area, or usable space, to which die details
can be fastened. Next in importance is the thickness of the die holder and of the
punch holder.

Materials

Selecting the material from which the die set is to be made will depend upon strength
requirements. There are three choices:

1. Semi-steel

2. All steel

3. Combination in which the punch holder is semi-steel and the die holder is all
steel.

3.8 How to Design Blanking Punches

3.8.1 INTRODUCTION

Blanking punches range from tiny components for producing watch and instrument
parts to large, multi-unit members for blanking such parts as automobile fenders,

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doors, and tops. The size of the blank to be produced determines the type of punch
to use. Design considerations include:

• Stability, to prevent deflection.

• Adequate screws, to overcome stripping load.

• Good doweling practice, for accurate location.

• Sectioning, if required, for proper heat treatment.

Illustrations that follow show numerous methods of applying blanking punches to

small, medium, and large cutting dies. Several considerations are covered, such as
keying the punch in order to keep it from turning, use of inserts for ease and economy
of replacement, use of sectioning to facilitate heat-treating and minimize distortion,
use of shedders to prevent clinging of blanks to punch faces, and proper proportions
of and construction of blanking punches. These methods further explain Step 3 in
Chapter 5 Fourteen Steps to Design a Die.

3.8.2 APPLYING BLANKING PUNCHES

Small Blanking Punches

Figure 11 shows the method of applying a blanking punch

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Fig. 11 design of punch plate

Body diameter A is made considerably larger than blanking diameter B;

radius C provides supporting material to give rigidity and prevent deflection of the
punch upon contact with the material strip. Section view a shows the punch, punch
plate, and punch holder as they would appear in the lower left section view of the
complete die drawing. Plan.

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 Chapter 4 CALCULATIONS
a. Nut

✓ Size =M10*1.5

✓ Panel range = 0.8-1.5

b. PUNCH

✓ Fit= H7g6 (Slide Fit)- Fit between nut and punch

✓ Clearance = 0.007-0.041 mm

✓ Punch opening for fixing nut (Nut) = 18.8 + 0.008 = 18.808 mm or 19 + 0.008 =
19.008 mm

✓ Punch Head Thickness= 10mm

✓ Punch Height=76.2mm

✓ Diameter= 26mm

(Punch dimensions are according to ASTME standard from BASIC DIE MAKING)

c. DIE Block

✓ Piercing nut dia for piercing(∅K) = 11.92±0.8

✓ DIE CAVITY = 11.92 + 2% of sheet thickness (for cold rolled steel = 2% *1.5) = 11.92
+ 0.03= 11.95 mm

✓ Dimensions of Die Block= 100X100mm (For sheet thickness 1.5mm according to DIE
DESIGN FUNDAMENTAL-J.R. Paquin)

✓ Die Block Thickness= 23.81mm for sheet thickness 1.5mm

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✓ Angular Relief= 1/4degree

(Standard Die Block size- From “Fundamentals of Die Design by J.R.Paquin”)

d. Punch Plate

✓ Dimension (length x Breadth) =50.8mm x 50.8mm

✓ Thickness- 1.5 X Punch diameter = 1.5 x 26= 39

(Plate standards are from “Die Design Fundamentals” by J.R.Paquin)

e. Die Set

✓ Dimensions of upper plate and lower plate (Length x Breadth) =250mmx175mm

✓ Upper Plate Thickness= 35mm

✓ Lower plate Thickness= 45mm

✓ Guide Pillar Diameter= 30mm

✓ Distance between Guide Pillars=255mm

(Die set is according to TRTC Standards)

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 Chapter 5
Designing of Nut Piercing Die

5.1 Design of Die Set

Fig. 12.1 Different views of Die Set are shown

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5.2 Design of DIE BLOCK

Fig. 12.2 Different views of Die Block

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 5.3 Design of PUNCH

Fig 12.3 Different views of Punch

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 5.4 Design of PUNCH PLATE

Fig 12.4 Different views of Punch Plate

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 5.5 3-D MODEL OF NUT PIERCING DIE

Fig. 12.5 Isometric view of complete Nut Piercing Die

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 5.6 ASSEMBLY DRAFTING

Fig. 12.6 Different view of Assembly are shown

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 5.7 Design of Final Product

Fig. 12.7 Different Views of Final Product (Nut attached to sheet metal)

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 CHAPTER 6
MANUFACTURING PROCESS
Various Operations

6.1 Turning –

Turning is a machining process in which a cutting tool, typically a non-rotary tool bit,
describes a helix toolpath by moving more or less linearly while the workpiece rotates.

The turning processes are typically carried out on a lathe, considered to be the oldest of
machine tools, and can be of different types such as straight turning, taper turning,
profiling or external grooving. Those types of turning processes can produce various
shapes of materials such as straight, conical, curved, or grooved workpieces. In general,
turning uses simple single-point cutting tools. Each group of workpiece materials has an
optimum set of tool angles that have been developed through the years.
The bits of waste metal from turning operations are known as chips.

Fig. 13.1 Rough Turning Fig. 13.2 Finish Turning

The general process of turning involves rotating a part while a single-point cutting tool is
moved parallel to the axis of rotation. Turning can be done on the external surface of the
part as well as the internal surface (the process known as boring).

6.2 Drilling–

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in
solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is
pressed against the work-piece and rotated at rates from hundreds to thousands of
revolutions per minute. This forces the cutting edge against the work-piece, cutting off
chips (swarf) from the hole as it is drilled.

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 Fig. 14.1 Vibration Drilling Fig. 14.2 Magnetic Drilling Machine

6.3 Tapping–

Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be
threaded into the hole. Also, it is used to make thread on nuts.
Tapping can be done on the lathe by power feed or by hand. Regardless of the method,
the hole must be drilled with the proper size tap drill and chamferred at the end.

Fig 15.1 Tapping Operation

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 Fig. 15.2 Tapping Steps

6.4 Threading –

Thread cutting on the lathe is a process that produces a helical ridge of uniform section
on the workpiece. This is performed by taking successive cuts with a threading toolbit the
same shape as the thread form required.

Fig. 16.1 External Threads Fig. 16.2 Threading Operation

6.5 Shaping –

Shaping is performed on a machine tool called a shaper. The major components of a

shaper are the ram, which has the toolpost with cutting tool mounted on its face, and
a worktable, which holds the part and accomplishes the feed motion.

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 Fig. 17 Components of a Shaper

6.6. Facing–

Facing is the process of removing metal from the end of a workpiece to produce a flat
surface. Most often, the workpiece is cylindrical, but using a 4-jaw chuck you can face
rectangular or odd-shaped work to form cubes and other non-cylindrical shapes.

When a lathe cutting tool removes metal it applies considerable tangential (i.e. lateral or
sideways) force to the workpiece. To safely perform a facing operation the end of the
workpiece must be positioned close to the jaws of the chuck. The workpiece should not
extend more than 2-3 times its diameter from the chuck jaws unless a steady rest is used
to support the free end.

Fig. 18 Finishing of the tool

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6.7 Boring–

Boring is the process of enlarging a hole that has already been drilled (or cast) by means
of a single-point cutting tool (or of a boring head containing several such tools), such as
in boring a gun barrel or an engine cylinder. Boring is used to achieve greater accuracy of
the diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed as the
internal-diameter counterpart to turning, which cuts external diameters.

Fig 19.1 Boring Fig. 19.2 On lathe machine

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 Chapter 7
Process Planning

7.1 Die Block

Fig 20. Die Block with 5 holes

Operation Performed:
• Shapping Operation
• Drilling Operation
• Turning Operation

Material used: EN31

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 7.2 Punch

Fig 21.1 Top view of Punch Fig. 21.2 Side view of Punch

Operations Performed:

• Turning operation
• Facing operation

Material used : Mild Steel

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 7.3 Punch Plate

Fig 22.1 Top view of Punch Plate

Fig 22.2 Side view of Punch Plate

Operations Performed:
• Drilling operation
• Turning operation

Material Used : Mild Steel

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 7.4 Guide Pillar

Fig. 23 Guide Pillars

Operations Performed:
• Turning Operation
• Thread Cutting

Material Used: Mild Steel

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 7.5 Upper & Lower Plate

Fig. 24 Upper plate

Operations Performed:
• Drilling Operation
• Shapping Operation

Material Used: Mild Steel

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 7.6 Nut

Fig. 25 Nut

Operation Performed:
• Undercut is given Using Lathe Machine

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 7.7 Knob

Fig. 26 Knob

Operation Performed:
• Turning Operation

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 7.8 Shank

Fig. 27 Shank present in Upper Plate

Operation Performed:
• Turning Operation

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 7.9 Un-assembled Die

Fig. 28 Different Parts

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 List of Components
1. Die Set
2. Punch Plate
3. Die Block
4. Gage Pin
5. Punch
6. Piercing Nut
7. Nut holding Assembly
7.1.Pin housing
7.2.Holding Pin
7.3.Spring

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 FINAL DIE SET

Fig. 29 Different Views of Die

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 COMPARISON OF NUT PIERCING WITH WELDING
OPERATIONS

NUT PIERCING WELDING OPERTION

Nut piercing is smokeless Welding creates smoke
It saves electricity It requires high amount of electricity
No spatter in thread, no Generates weld splatter, hence re-
contamination of the surface tapping of the nut required
Avoid difficulties with coated sheet Difficult to perform welding on coated
metal sheet metal.
More even distribution of pressure Odd distribution of pressure between nut
between nut and sheet metal and sheet metal
They provide strong threads in very Provides weak threads in very thin
thin material material
Low installed costs, fewer parts to It is not cost effective as it requires high
handle, fewer assembly steps and less energy to operate, pre-hole operations,
assembly time hence cost effective increased transportation and logistics
costs and finished welded nut requires
extra work and part handling, i.e.,
separate welding equipment
Less Environmental damage, i.e., no High environmental damage
vapors, gases and noise Vapors, gases and noise generates
Improved working conditions, no Tough working conditions, mandatory to
troublesome protective clothing to wear protective clothing and carry
wear shields to protect specifically eyes
High processing speed Less processing speed
The metal is not exposed to thermal The metal is exposed to thermal stress
stress that could change the structure that could change the structure of the
of the material. High strength material. Risk of burning of thin sheet
properties are maintained also metal. Negative effect on the surface
directly at the joint finish (coil coated sheet, galvanized
sheet)

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 Costing

Raw Material Cost:

Part Material Size (mm) Weight Price Cost

Used

Top MS 250x175x35 2.5 kg Rs Rs

Plate 90/kg 225

Bottom MS 250x15x45 2.5 kg Rs Rs 225

Plate 90/kg

Punch MS 76.2x26x10 0.5 kg Rs Rs 45

90/kg

Punch MS 50.8x26x1.5 2 kg Rs Rs 180

Plate 90/kg

Die EN31 100x100x1.5 2 kg Rs Rs 260

Block 130/kg
Guide MS 250x175x30 1 kg Rs Rs 90
Pillar 90/kg

Clip MS 10x5x2 0.2 kg Rs Rs 18

90/kg

Total : Rs 1043

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 MACHINE HOUR RATE
The process plan for each component is sketched out to know various process involved in
manufacturing. The time required for different machining operation are calculated
approximately. The manufacturing time multiplied by corresponding machine hour rate
gives the total machining cost.
Machining cost = machining time x machine hour rate
Some of approximate cost of machining is given below: -

MACHINE COST FOR EACH OPERATION

MACHINING OPERATION MACHINING RATE PER

HOUR (in Rs)
Turning 900
Drilling 850
Tapping 725
Shaping 1050
Milling 1000
Boring 800

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S.no. Description Turning Drilling Tapping Shaping Milling Boring Press
trial
1. Top plate - 45 - - 60 - -
2. Bottom plate - 40 - - 60 - -
3. Punch 60 35 -
4. Die block - 40 20 45 60 - -
5. Punch plate - 30 - 40 60 - -
6. Guide pillar 30 - 20 - 30 - -
7 Nut 60 - - - - - -
8. Knob 30 - - - - - -
9. Shank 30 - - - - - -
Total time 210 155 40 85 270 35 30
(min.)
Total cost 3,150 2,195 483 1,487 4,500 466 500
(Rs)

Total time: - 825 min = 13hr 75 min

Total cost: - Rs 12,781

Raw material cost: - Rs 1,043

Machining cost: - Rs 12,781
Total manufacturing cost: - Rs 13,824

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 References

• Die design fundamentals by Vukota Boljanovic J. R. Paquin

• Basic die making by D. Eugene Ostergaard
• Advanced Die making by D. Eugene Ostergaard
• https://images.app.goo.gl/4toQ1e549VLzK1F27
• https://images.app.goo.gl/TvW1tBbzJfC5nhu3A
• https://www.machinedesign.com/fasteningjoining/article/21812630/selfpierc
ing-nuts

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