Simulation and structural analysis of a Punch and Die used in

Industries
J.BOOPATHI 1, P.SAKTHIVEL2 , M.RANJITHKUMAR 3, S.PUNITHAN4
1 , Assistant Professor / Department of Mechanical Engineering, Annapoorana Engineering College, salem.
2 , Assistant Professor / Department of Mechanical Engineering, Annapoorana Engineering College, salem.
3 , Assistant Professor / Department of Mechanical Engineering, Annapoorana Engineering College, salem.
4, Assistant Professor / Department of Mechanical Engineering, Annapoorana Engineering College, salem.

boopathimech2014@gmail.com ,sakthivel141289@gmail.com, ranjithmach209@gmail.com &punithan2005@gmail.com

ABSTRACT

This project is detail with the material optimization of trust plate, punch and dies block used in
blanking tool where mild steel is considered. Here the Trust plate is optimized by OHNS Steel and The
punch and dies block by Hc HCr material. The existing and optimized material will be analyzed using ansys
workbench 14.0 under the same load conditions. The design is modeled by using Pro-E software and is
imported to ansys. The basic boundary conditions are applied in ansys and the solutions like total
deformation, strain and stress are obtained.

Keywords- OHNS Steel and The punch and dies block by Hc HCr material.

Introduction
Press tools are commonly used in Hydraulic press, Pneumatic press and mechanical presses to
produce components at a high productivity rate. The types of operations conducted using the tool, such as blanking,
punching, bending, shaping, welding, trimming, etc. are typically classified by press instruments. Also defined is the
press tool as a blanking tool, punching tool, bending tool, etc. C type presses have a bed plate which is used to lock
the die bottom bolster. T-bolts are used to lock the die, so this plate contains ' T-slots where t-bolts are slid into it.
These slots are diagonally placed and are generally used on the long side of the plate with a horizontal slot. The top of
the tool faced a vertical sliding ram with a clamping mechanism that only accommodates a limited diameter of a
cylindrical threaded component called the tool's "shank."

The bottom portion of the tool is locked to the bottom bed plate and the top portion of the tool is locked to the
sliding ram. The tool's top and bottom portions are normally driven by appropriate pillar and bush assemblies (one or
two pairs), which offer the tool's punching elements protection. The tool is generally placed slightly above the bottom
bed plate by providing exactly the same size for two parallel blocks. This is a necessary action since many tools; scrap
(cut pieces that are a waste) is discharged through the tool's bottom element, not necessarily in the tool's center. The
scrap or the blank (the portion required) comes out of the die at various locations. These must be separated
horizontally from the comparisons placed between them. Otherwise, they accumulate within the tool itself, causing
the tool to suffer serious harm. Turret style punch presses are fitted with a table or bed with brushes or rollers to
allow low friction to pass through the working part of the sheet metal. Brushes are used to minimize scratches on the
work piece, such as brushed aluminum or highly polished materials.
 Turret style Punch presses are computer-controlled numerically (CNC) capable of running in an automatic mode to
perform material processing according to a pre-built system

Blanking Tool:

When a component is produced with one single punch and die where the entire outer profile is cut in single stoke is
called Blanking.
 Blanking is the cutting of flat sheet metal shapes. The hole and metal remained after blanking operation is discarded
as a waste.
 The width of the blank or material is the size of the die.
 It is a metal cutting operation.
 It is fast process and generally used for medium and mass production volumes.
 It is cheapest process in manufacturing.

LITERATURE REVIEW
A critical literature review within a specific field or interest of research is One of the most essential
activities in the process of research. In order to produce a more productive review of literature, it is recommended
to include the entire process of selecting resources, reading and writing on previous research studies selected which
includes the discussion of drawing methods or techniques applied to the modal to achieve maximum efficiency: and
save time.. In addition, this section also includes argument of the designs of die to find out which design
provides the best performance. Besides that, the manufacturing process and Parameters are also discussed.
Vital information is .transferred from external source into this section such as the itemed, reference book,
and scientific journals edited by well known professors around the world. Hence, this section acts as a
platform for the whole research to support and define each action performed during analysis and
experiment.

Modeling Compounds of PRO-E

 Sheet Metal Processes
 Sheet Metal Characteristics
 Engineering Design
 Conceptual Design
 Finite Element Analysis

Modeling Compounds of Pro-E Basic Commands to create the model section

• Sketch
• Circle
• Ellipse
• Line Create the hexagon
• Rectangle
• Dimension
• Extrude
• Revolve
 • Arc
• Create the hexagon
• Rectangle
• Dimension
• Extrude
• Revolve

Fig-1

Nodes and Elements

Fig-2
 Red dots represent the element's nodes.
 Elements can have straight or curved edges.
 Each node has three unknowns, namely the three-way translations. The subdivision process of the part into
small pieces (elements) is called meshing. Smaller elements generally yield more accurate results but require
more resources and time from the computer .Ansys suggests the size and sensitivity of a global component for
meshing.

The default meshing settings are recommended for the initial run. Use a smaller size of the element for a more
accurate solution.

Analysis procedure analyzing – step by step procedure

 The 3D model of the ball bearing is designed by using pro-e software and it is converted as IGES
format.
 The IGES (Initial Graphic Exchange Specification) format can be imported into the ANSYS Workbench to
evaluate ANSYS Workbench Open
 Create new geometry
 File – import external geometry file – generate
 Fig-3

 Project – new mesh

 Defaults – physical preference – mechanical
 Advanced – relevance center – fine
 Right click the mesh in tree view – generate mesh

Fig-4

 Project – convert to simulation – yes

 Select the all solid in geometry tree
 Definition – material – new material
 New material – right click – rename – MILD STEEL
  Enter the value of the young’s modulus, poisons ratio, density and etc.
 New analysis – Static structural
 Static structural – right click – insert – fixed support
 Select the bottom face
 Geometry – apply
 Static structural – right click - insert – FORCE – select the face to define the direction
 Geometry – apply
 Provide the value to 98100 N
 Solution – right click - insert the total deformation, equivalent elastic strain, and equivalent stress.

 Right click the solution icon in the tree – solve

a. To capture the figure use the option new figure in tool bar.
b. The all results are taken in a picture – and save it to the required folder in the system
c. The all readings are tabulated.

For material optimization, just change the material properties of required soild under geometry and right
click the solution and click solve. And to get the results, repeat the same procedure.

Loading Conditions :

Results of Mild Steel OHNS

 FIG-4

Results of Mild Steel HcHCr

Fig-5

Conclusion

From the above results under same loading conditions, the tool with mild steel has low values of
deformation. So the mild steel tool can be considered as best among the two models. In the industrial sector,
the project carried out by us will make an impressive mark. While carrying out this project, we are able to study
3Dmodeling Software (PRO-E) and Analysis Software Study (ansys) in order to develop our basic knowledge of
design.

Reference
1. KopanathiGowtham, K.V.N.S. Srikanth& K.L.N. Murty, Simulation of the effect of DIE Radius
on Deep Drawing Process.

2. Numerical Simulation And Analysis On The Deep Drawing, R.PADMANABHANA,

M.C.OLIVEIRAA, J.L. ALVESB, L.F. MENEZESA, Journal Of Materials.

3. Recessing Technology 200(2008)416–423.

4. Numerical Damage Prediction In Deep-Drawing Of Sheet Metals, M. KHELIFAA, M. OUDJENEB,
Journal Of Materials Processing Technology 200(2008)71–76.