sae. } senna, ater 4 oie mamas 33 Chapter. 1 DIE PLANNING 1.1 Process Planning 1.1.1 Property, Thickness, Shape and Size of Material Tt is necessary to know the following itens about the property, thickness, shape and sie of material, and to be able to determine the manufacturing proc procedure and provide Ate design planning (2) Property of material Te 4s necessary 0 know the Following itens about material @ o © (a) Elongation + Appendix 2) (e) revalue (Strain nardening exponent) (©) rvalve (Lankéord value) (@) Brichsen depeh index (2) conical cup value (3) Material directionality (2) Thickness of product The thickness of formed parte often chaages after forming. Tt is necessary to know the designing method against it, (@) Method of creasing the strength of product by adding beads (&) Method of 1g the eteength of (©) Method of increasing the strength of product by flangi (@) Method of increasing the strength of product by heaningme (@) Method of decreasing che thickness by burring (3) Shape and size of netertal Tr ie necessary to know the following items about the shape and size of ma tale. (@) Serip sheet and standard dimensions (b) coft strip (Ribbon) (e) Sketch Blank 1.1.2 Application, Shape, Dimensional and Shape Accuracy of Product: Te ie a essary to know che owing Stems about the application, shape, dimensional and shape accuracy of products, snd to be able to determine the manufacturing process procedure and provide die design planning. (1) application of product Tt Ge necessary to know the working process procedure and dle structure suited to the product application (a) ovter parts Fla, wrinkles, distortion, hair line direction, and burr (b) Hand-touched pares Barr, bi wsking direction, and corners (©) Parts of high dimensional accuracy Sheared edge shape, dimensional accuracy, shape accuracy, (@ Reinforcing parts Beads, Flanges, bulging, and ribs (@) ter parts of equipment (2) shape of product, te necessary to know the relation of product shape to 2s) working operations and éie structure (@) Dovble-row layout (8) Scrapless (c) Working Linit én pressworking Peripheral width and hole diameter ) Guide hole to the next step, and forming (e) Bend xeliet cutout (2) shape: (3) Dimensional snd shape accursey of product Te 48 necessary to know the effects of working proc ie structure on the dimensional and shape accuracy of product (a) Distortion due to blankiog Conpound blanking, dropping-through, cut-o! and notching (b) Warping and wisting due to blanking (e) Bare height (2) sheared edge shape , Fine blanking and finish blanking (Die with round corners) (©) Hole positional accuracy and dénensional accuracy (2) Bend width accuracy Die type and ate materiel (p) Accuracy of minéauz disonsion to be bent (i) Rend angle accuracy (4) Dimensional accuracy of drawing diameter ) G) Dimensional accuracy of drawing depeh 1.1.3 Production Quaneity de necessary co know the oliowing tens sbout production | 1 3 quantity, and to be able to provide the planing for working ¢ and die design> TRBIER hurter + ote russ 39 (CL) Bigh-productson-requirement die Te 4s necessary to know about high-production-requ dses. (2) Die for Large production Progressive die and transfer die (8) Die for mediua production Single die and progressive dic (c) Dée for snail production Continental die and aingle die (2) Die for prototype 1.1.4 Date of Delivery and Trial Operation of Die y to be able to determine the die structure to be used in each vorktng proc and the nusber of proces om the following items. () Machining capacity (2) Available tine of die material (3) Type of pressworking 7 6 of ale 1.1.5. Specification of Avatlable Press Machine 6 necessary to know the specification of avaslable press Imachine, and to be able to determine the manufacturing process » Procedure asd the style of die construction, (Cf, Append: (2) Pressure cap (2) Stroke tengeh5 (3) Maaber of otroke (4) Die height (5) Shut esght (6) stide area | (7) Bolster area 1.1.6 Type and Characteristics of Press Machines of press machines. (CE, Appendix 1) (2) Ctype single action single crenk prese (2) Ctype single action double crank press (3) Straight side single action single crank press (4) Straight side single action double crank press (5) Link press ) (6) KouckLe joint prose (1) Petetion serew-press (8) shearing machine (9) Press brake 1.7 Type and Characteristics of Pressworking Tt is necessary co have a deep kno age of the type and characteristics of pressworking, snd to be able to determine the manufacturing process procedure and the atyle of die construction. (2) type and characteristics of shearing vork (Fi asa ss6ary to know the type and characteristics of 2m2T8otk r hater 1 of Pn 43 shearing work, and to be able to deter he working process procedure and the style of die construction, (@) cuteing (o) Farting (e) Banking (@ Hereing © ( Lancing aig (g) Wotching (hy Hale blanking (2) Horton cutting (3) shaving (1) Fine blanking, (2) Fintan blanking (2) Type and characteristics of bending work (Pig. 1.2) Tt ds necessary to know the type and characteristics of bending vork, and to able to determine the working proces (a) Vebending () Uobending (e) Tebending (2) z-bending (e) Gylindrseal bending (© Twist by rotating (3) Type and characteristics of deep drawing (Fig. 1.3) characteristics of ie is necessary to know the type an: deop-deaving by presavorking, and to be able to det ate ing process procedure and the atyle constructionter} DIE Pamune 48 ) Cupping (b) Rectangular shel. drawing (e) Irregular shape draving (4) ‘type and characteristics 2th. Te te necessary to know the type and charas shoot forning by pressworking, and bbe able to determine the manufacturing process procedure and the style of die construction. (a) Stretch Flanging (b) shrine #langing (@) Curing (e) Batgieg | | | (£) Necking (g) Stretch foraing (i) Beading > (5) Type and characterietice of cold forging (Pig.1.5) ress, TB Tt 4a necessary to know the type and characteristics of cold forging by pressvorking, end to be able to determine the manufacturing process procedure end the style of aie construction. (a) Bxteueion (b) coining (©) Upectting (a) suaging (e) sizing (2) PiatteningBates weer) ox rum 47 1.1.8 Number of 0} Pressworking rations and Operation Sequence in Te is necessary to be able to provide actual process planning fron the following ‘tens. (2) Combination of presevorking operations (2) Sequence of operations () Part location (4) date of detivery (5) Press machine avatlable (6) Die structure {culation of Blanking Force for Process Planning is necessary to know the calculation mt od of blanking for process planning, (2) caleulatfon formula for blanking Force 2) shear se ength of various materials (3) Relation between blanking force and 1.1.10 Calculation of Blank Developeent Length under Bending for Process Planning It is necessary to know the calewlation sethod of blank development length under bending for process planning @ bending (Fg.1.6) culation formula for blank development length under (2) Position of neutral axis under bendingaac ois pane 49 1.1.11 development of Drawn Products for Process Planning Tt is necessary to know about the development of drawn products for process planning (2) Csleulation method of surface area of cupping products (Cf. bppenate 4) @ as lation method of surface area of rectangular shell ng products 1.1.12 Calculation of Drawing Rate (Drawing Ratio) for Process Pranoing Ie ds necessary to know the calculation method of deauing rate (drawing ratio) for process planning. (2) Celewatéon method of drawing rate (2) Caleulation method of drawing ratio Drawing ) Selection of drawing rate for each process (&) Drevebitity for each material (5) Lintting drawing rate 1.1.13 Operations after Pressworking It fe necessary co know the following items about processes after pressworking.ATI “ating Holes for suspending for plating (2) Welding Dowels for projection, and positioning holes (3) staking Mole diameter and strength at the bend (4) Levering No convex parts (5) putting Surface favs and wrinkles (6) Tapping (7) deburring 1.2. Die Estimating 2.1 Type and Structure of Dies (CF. Appendix) It 48 necessary to know the type and structure of dies, snd tobe able to determine the style of die construction and estimate the approxieate number of operations. Blanking die (Fig.2.7.(1) thru (6), Plg.2.8 #ig.2.9.(1) thew (5)) )enew (5), (2) Bending ate ( 10.(2) ekew (10)) ©) Deep draving die (Pig.2.12.(2) thew (8)) (®) Sheet forming die (3) compound dis, combination of (1), (2),(3),0r (4)Daten) Oe RMI 53 5 (6) Progressive die, combination of (1) ,(2).(3) or (4) (Fig.2.17.() thea (3)) 2), (2)4 (3) oF (4) o Ate, coabination of 1.2.2 Type and Characteristics of Machine Tools f Die-pa smBRD © As necessary to know the type and characteristics of machine tools for die-parts. (Detailed deseription will be nade in chapter 3) 1.2.3. Working Method and Wunber of Operations for 0 is necessary to be able to estinate the nachiny eeelbe ng method and che number of operations for die-parts. (2) capacity of machine tool (2) Machining time of machine toot (3) Setup eine of machine tool (4) s8¢8 and tools for ining 1.2.4 Type, Characteristics and Cost of Die Material G) type and characteriatics of die material (2) cost and available tine of die material Te 4e-neci ary to know the cost and a (a) catalogs of die material asnufecturers Q sation of die material sellers 2.5 Type, Heat Treatment Method and Cost of Too! Te 4s necessary to know the type, heat tr sent method and cost of tool steels.ter 1 OIE PME 5S 1.2.6 Surface Treatment Method and Cost of Die-parts Te is necessary to know the gurface treatment method and 1.2.7 Type and Cost of Purchased Units to know the type end cost of the following parte. a (2) Plates (3) Punch (A) Bie bushing 1.2.8 Die Life It jen sary to be able to estimate the die 1ife fron the following stems. (4) vie satertal and heat treataent hardness @) die structure (2) Machining acthod of die cutting edge (Surface roughness) (&) Acuce angle part of products (5) Property of watertal (6) Accuracy of the press machine u 1.2.9 Approximate Estimate of Die Cost Te 46 necessary £0 aske an approximste estinate of die costs. [Die eostg-(vesign costs)+(Machining costs)+ (ta 121 costs) (2) Approximate estinate from similar productsese super 1 ote rosa 7 Te ds necessary to aske an approxinate ¢stinate from sinilar products, considering the following items. (a) size of product () shape of prods (©) Property of material (2) Dimensional and form accuracy of product (@) Die structure (2) Past performance of experience (2) Approxinate estinate of standard cost per unit Te 4b neces ry to estimate the sta ost per unie (iasRiBing costa] = (seandara cost per unit) xyApproninate number *) Teandard coats} (Maintenance) (oper: per anit )"(ee ) (labor) #(ovenensy (a) Maintenance costs Cores ee) +(ietianed Cet) (b) Operating co (Comsnabis) Toon) + costs) +eoses + (6) tabor costs (Wage) + (dettare costs) (@) overhead burden (Plane overhead)+(Goneral control costs end selling costs) @) Approximate estinate of number of design processes Xe is necessary to make an approximate estimate of the nunborcopter 1 oie ams 59 of design processes from the following itens. (2) Approxinate number of de: In processes estinat (b) Number of operations in a dic (Prosre transfer die) | similar products | (©) mse struccure (@ Size of product (©) Complexity of product shape (2) Relation to peripheral egufprentoer 1 OLE PLONE 6S ‘cation working = a } £ fection and the | OPS or half nade products Bach burr 4s at sane di shape is free. “[Blaaiing the whole cizcunfarence of co Closed shape.” Blenked sidan’ (passed = sides of dies) form products. a £ [Freeing [Blanking the vote chrcunference oF g closed shape. Sides to be blanked 28 el (residual sides) form products. = E [resuming [cutting off crime after forming or deep 3 craves, = & [Lancing Linearly sliteing materials by the S |[ettetiog | tnctined pnche Ean J [notching | Blanking products with partially open |[™= =] 3 Wetting of0)| ohare = Gale binning Making the projection by «trying on thel [© ] Balivay of plereings = = . Blanking. che blanks (or holes) wien | {EHIDL Snell altovance ry Fine blanking] Blanking for the fine sheared surtace | : as By pplying the blank, holder on the Finish | anking for Fine sheaved surface of blanking [ote antertaie by applying dies with Fig. L1 Type and chersctaristios of shear by press workingFig. 1.2. Type of bending workFie. L411 814 memomm fof sheet and tube forming8 mie acne Eemroanhotee 1 ie Rae 6 rag tel Reaty ih eate of #002 \ rf tRsaey B16 abr S eR SetIESt Fig. 1.6 Calculation of development leash of sheet inder bending