International Journal of Science and Research (IJSR)

ISSN (Online): 2319-7064

Impact Factor (2012): 3.358

Compound Die Design: A Case Study

Sneha S. Pawar1, R. S. Dalu2
1
M. Tech. student, Production Engineering, Government College of Engineering, Amravati, (M.S.) India
2
Professor, Mechanical Engineering Department, Government College of Engineering, Amravati, (M.S.) India

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.

Keywords: Compound die design, Drawing operation, Punching, Blanking, Force.

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

2. Objective 3.1 Design of die for blanking operation

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.

Volume 3 Issue 5, May 2014

Paper ID: 23041401
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Impact Factor (2012): 3.358

Figure 5: Cup

(i) Blank Diameter(D)= =191 mm.

(ii) Draw Force – Draw Force can be calculated by
Figure 3: Housing 2D view empirical relation,
P = π.d. t. s. ((D/d) – C) =12 ton
Economy factor = Where, P = Draw Force in Tons
 S =Yield strength of Metal in
= 67.66 % =427N/mm2 C= Constant (Take 0.65 to 0.7)
(ii) Clearance
 =10% x thickness = 0.08mm
(iii) Diameter of punch (dp1)=Blank dia + m =191.05mm (iii) Die clearance-
(iv) Where, m-Elastic recovery Die clearance =1.1x t =1.1 x 2= 2.2 (For single side
(v) Diameter of die=dp1 +Clearance =191.13mm clearance)
(vi) Die Block Dimension Punch diameter (dp) = (d) – 2x t =131.4mm
(vii)Perimeter (p1 ) = π x dia of die =600mm Die diameter dd =dp+ 2 x (1.1 t)=133.16mm

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

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Paper ID: 23041401
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Impact Factor (2012): 3.358
(v) Die Block Dimension

Perimeter (p1 ) = π x dia of die =330mm 

T1 =25.4 + (p1 ) 0.015 =26.49mm Lmax= 10.56 mm
T = T1 + grinding allowance = 27mm
h =10% x T=2.7mm Taking the length of punch, L=25 mm.
A=1.5 x T = 40.5mm
Press capacity –Press Tonnage can be calculated by using
Where, following formula,
P1= Perimeter Press Tonnage = Draw Force + Blanking force+ Punching
T = Thickness of die block force (A & B )+ Blank Holding Force
h = Land of die block = 12+19+11+2+4 = 48.78ton
Therefore, Press Capacity of 50 Ton shall be suitable.
Angular clearance α =20 or 30
Material for Die block should be use HCHCr 3.4 Working of compound die
Hardness – Die Block should be harden upto 60 to 62 HRC
Figure 6 depicts the die as it appears during various stages of
(vi) Punch design its cycle. The pressure plate-II is shown with metal strip
nested in position on the die block i.e. pressure plate-II hold
Checking the punch for crushing , that strip over die block. The press ram is descending. The
drawing and cutting punch just contacted with metal strip.
Cutting action is take place. The press ram continues to
105557.5 = π/4 x 1052 x σc descend drawing action is initiated and proceeds as shown.
Further descent will cause the outer edge of the draw around
σc = 12.19 N/mm2 << 750 N/mm2 the draw die radius. The pressure plate-I just hold the cup.
This pressure plate-I act as a guide for cutting punches-II.
Safe in crushing .
The drawing operation is complete. Punching of 105mm
Maximum length in punch . start as soon as the drawing operation is completed. During
the upstroke, the ejector plate will ejected the draw piece
from the die.

Lmax= 10.56 mm
Taking the length of punch, L=25 mm

3.3.2 Punching operation –B (5mm)

It is cuttings operation by which four hole of 5mm are made
in the sheet.

(i) Diameter of punch = 5+0.05=5.05 mm

(ii) Diameter of die =5.1mm
(iii) Cutting force required
Fc2 = π x dia of punch x t x =0.5ton
Total cutting force for 4 holes = 0.5 x 4
= 2 ton

(iv) Die Block Dimension

Perimeter (p1 ) = π x dia of die =330mm
T1 =25.4 + (p1 ) 0.015 =26.49mm
T = T1 + grinding allowance = 27mm
h =10% x T=2.7mm
A=1.5 x T = 40.5mm

(iv) Punch design Figure 6: 2D view of compound die

Cutting punch-I (1) ,Cutting punch-II(2), Drawing
Checking the punch for crushing
punch(3),Pressure plate-I(4), Pressure plate-II(5),Punch
plate(6),Thrust plate(7), Die(8),Ejector plate(9),Die
block(10),Die palate (11),Spring(12),pillar(13)
5026.55 = π/4 x 52 x σc
4. Conclusion
σc = 256 N/mm2 << 750 N/mm2
Safe in crushing  Successfully Design a compound dies by combing
blanking, drawing and punching operation.
Maximum length in punch.
Volume 3 Issue 5, May 2014
Paper ID: 23041401
www.ijsr.net 391
 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Impact Factor (2012): 3.358
 It is possible to get product in single die
 The developed cad design conforms the possibilities of
compound die
 The simulation also confirms the die design

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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

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Paper ID: 23041401
www.ijsr.net 392