Compound Die Design: A Case Study: Sneha S. Pawar, R. S. Dalu
Compound Die Design: A Case Study: Sneha S. Pawar, R. S. Dalu
Abstract: Various components/parts used in Mechanical industry are manufactured by sheet metal. They can be produced by different
cold pressing processes. This paper presents a design of compound die by combining the blanking, piercing, drawing operation.
Compound die design is applied to dies in which two or more cutting operations, typically piercing, blanking and drawing are performed
in the same single station and completed during the single press cycle.
1. Introduction
The evolution of products, dictated by the necessity to
survive in the market, requires changing in manufacturing
processes. This requires an integrated approach of
constructive aspects, technological, organizational and
management of the development stages in order to reduce as
much as possible time and cost of the new products. Design
activity has an important role in developing a new product.
Design time being very often decisive in terms of the
marketing time of the product. Compound die design is
applied to dies in which two or more cutting operation,
typically piercing, blanking and drawing are performed in Figure 1: Housing 2D view
the same single station and completed during the single
press cycle. There are many ways to design a compound die,
but since there is no place for the finished part to go during a
compound die’s operation, the part must be pushed back into
the scrap web such that it can then be carried out of the tool
and extracted in one or another fashion later in the die
cutting operation. This necessity for a separate parts
extraction process is one downside of the compound die
system. Advantages of a compound die system, first and
foremost being the high and unsurpassed mechanical
accuracy of a single step process. A second advantage of a
compound die set up is its throughput. Because all internal
and perimeter features of the part are created in one cycle.
That means that if a strip is designed to create 10 parts, these
10 parts will be created in 10 press strokes. Figure 2: Housing 3D view
Design of compound die for downlight housing by Blanking is the operation of cutting a flat shape from the
combining the blanking, piercing and drawing operation. sheet metal. In the blanking operation required diameter are
taken from the calculation of blank size in drawing
3. Case study -Die Design Calculations operation. Blanking calculations are given below.
The case study present here includes the design and (i) Strip layout
development of the “down light housing assembly” that is Strip layout as shown in the fig 3. Economy Factor is
used for popular LED Light mounting assembly. Three depending upon the strip layout.
operations namely blanking, drawing and punching are
required to produce the component. Detailed design
procedure is given below. Figure 1 and 2 shows the view of
downlight housing.
Figure 5: Cup
T1 =25.4 + (p1 ) 0.015 =26.49mm (iv) Draw Ratio – At this component, the Draw = H/d =
T = T1 + grinding allowance = 27mm 23/133 = 0.2 < 0.7 which indicates the draw is simple &
h =10% x T=2.7mm may require only one stage for completion.
A=1.5 x T = 40.5mm
(iv) Draw & Punch radius – The Draw radius usually
Where, ranges from 4 to 10 times the Blank thickness,
P1= Perimeter therefore, Radius of Draw Die = Rd =4.5x0.8=3.6mm
T = Thickness of die block The Punch radius usually ranges from 3 to 4 times the
h = Land of die block Blank thickness, Therefore, Radius of Punch = Rp =3 x
0.8 = 2.4 mm
Angular clearance α =20 or 30 (v) Blank Holding Force=1/3 x Drawing Force = 4ton
(i) Punch design
(viii) Blanking force = π. D. t. =19ton
Checking the punch for crushing,
Where, D= blank diameter =191
h= cup height =23mm
d = punch diameter = 133mm
= shearing force =400 N/mm2
133706.18 =
(ix) Thickness of Plates
σc = 9.62N/mm2 << 750 N/mm2
Safe in crushing.
Die plate (TD)= =31.4 mm Maximum length in punch .
Top plate =1.5 X TD = 46.5 mm
Bottom plate = 1.75 X TD =82mm
Punch holder plate = 0.75 X TD=23.4 mm Lmax= 21.29 mm
Stripper plate = 0.5 X TD = 15.5 mm
Thrust plate = 8.5 mm Where, E=200 X103 N/m2
Taking the length of punch, L=25 mm
3.2 Design of die for drawing operation
3.3 Design of die for punching operation
Drawing is a process of forming a flat work piece into a
hollow shape by means of punch which causes the blank to 3.3.1 Punching operation -A (105 mm)
flow into a die cavity. Punching is a cutting operation by which 105mm hole are
made in the sheet.
(i) Clearance=10% x thickness =0.08mm
(ii) Diameter of punch =105.05mm
(iii) Diameter of die =105.1 mm
(iv) Cutting force required
Fc= π x dia of punch x t x =11ton
Lmax= 10.56 mm
Taking the length of punch, L=25 mm
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Author Profile
Sneha S. Pawar is a student of M. Tech (Production
Engineering) Mechanical Engineering, Department of
Government College of Engineering, Amravati, India