STEPS FOLLWED OF PROCEDURE OF

MAKING DIE:
1. CUSTOMER DATA
2. FINALISING QUTATION
3. PURCHASE ORDER
4. FINAL DESIGN AND APPROVAL
Die shop design :A) time plan
B) step of tool design
simulation
method plan

5. PATTERN MAKING AND CASTING.

6. MACHINING AND FITING.
7. SPOTING AND POLISHING.
8. TRIALS AND CORRECTIONS.
9. QUALITY CHECKING.
10. FINAL BUY OFF.

1.CUSTOMER DATA : Customer given die build standards, GD&T, Press Specifications and material specs.
etc and special instruction if any are to be considered as Reference.
Latest 3D data given by customer should be used.

2. FINALISING QUOTATION :For finalizing quotations pre designing of tool is done from which cost is estimated. This
includes costs of standard parts, amount of material and machining required. From pre design
total C.N.C. hours are calculated and cost of which is also added.
Once the quotations are being finalized it is sent to the company for the approval of order.

3.PURCHASE ORDER :Purchase order in this company tells about its there need. In general p.o. contains
following points.

Requirements of company.

Standards to be used.

Quality and material to be used.

Tolerances needed.

4. FINAL DESIGN AND ITS APPROVAL :For design of a tool first of all operation sequence is decided according to the type of
component which also gives the number of tools required, then designing starts with the help
of CAD data given by the party. Designs are separately made for patterns and for the use for
fabrication in fitting and machine shop
After the tool has been designed the design is sent to the party for approval according to there
need.

POINT TO BE CONSIDER BEFORE LOADING:-

Part setup as final method plan

Latest cad data to be used

Max. material utilization

Previous process to be considered

Data to be used (m/p line press & trail press )

Die and part fool proofing to be considered

Part loading/unloading

Part locking/scrap ejection

Die working diagram

Dia material to be checked as per requirement

Safety of man, machine & die

Die cost/strength of die

Minimum process

Part quality as per requirement

Machining feasibility to be checked

MFG feasibility to check with existing sources

Check the material margin in die steel

DIE SHOP DESIGN :a) TIME PLAN

b) STEP OF TOOL DESIGN
SIMULATION
METHOD PLAN

a) TIME PLAN :- As Its Name Suggest It Is The Property Of Time. The

Time Plan Is a Agreement Type discussion Which is made b/w company . The
time plan shows the starting time and end time is buy off time of projector
component .This show the project co-ordinator that his team is going with time
or not.

Purpose :
The Project Plan formalizes the following:

Agreement between the Employer, Interns, and Work Experience

Advisor

Project purpose

Business and project goals and objectives

Scope and expectations

Roles and responsibilities

Assumptions and constraints

Quality Management approach

b) STEPS OF TOOL DESIGN

SIMULATION
METOD PLAN
SIMULATION :-

Simulation is the imitation of some real thing available,

state of affairs, or process. The act of simulating something generally entails

representing certain key characteristics or behaviors of a selected physical or
abstract system.
DIE:A die is a specialized tool used in manufacturing industries to cut or shape
material using a press. Like molds, dies are generally customized to the item
they are used to create. Products made with dies range from simple paper clips
to complex pieces used in advanced technology.

Die components:The main components for Die Toolsets are:

Upper die - This is the main part that all the other parts are attached to upper
portion.
Lower die - This is the main part that all the other parts are attached to lower
portion.
Die block - This is the main part that all the other parts are attached to.
Punch plate - This part holds and supports the different punches in place.
Blank punch - This part along with the Blank Die produces the blanked part.

 Pierce punch - This part along with the Pierce Die removes parts from the
blanked finished part.
Stripper plate - This is used to hold the material down on the Blank/ Pierce
Die and strip the material off the punches.
Pilot - This is used to keep the material being worked on in position.
Guide / Back gage / Finger stop - These parts are all used to make sure that
the material being worked on always goes in the same position, within the
die, as the last one.
Setting (Stop) Block - This part is used to control the depth that the punch
goes into the die.

DIE FACE FOR DRAW WITH TRIM LINE :Deciding no. of draw operation required:- h/d
where
h = inside height of shell
d = mean dia of shell
TOOL DESIGN OPERATIONS : DRAW
TRIM / PIERCING
RESTRIKE / PIERCING/ SEPERATION
CHECKING FIXTUR

DRAW DIE :The drawing operation is very similar to the forming operation except that the
drawing operation undergoes severe plastic deformation and the material of the
part extends around the sides. A metal cup with a detailed feature at the bottom
an example of the difference b/w formed and drawn . The bottom of the cup was
formed while the sides were drawn.
DRAW FORCE CALCULATION :-

L= Lenth
T= Thickness Of Sheet
S= Shear Strength Of Material

Force Calculation:L = 1872+370+305+305+275+500

L =3700
T=1.2
S =40
DRAW FORCE (Fd)= C*t*Su A
Where

C =0.5 to 2.0
A = The forming area i.e.the total area actually deformed.

BLANK HOLDER FORCE :- 20-40% OF DRAW FORCE.

TRIM / PIERCING DIE :Trimming is an operation of cutting off material to alter the shape of the strip or
blank. Automated systems require innovative designs to maintain precision trim
and efficiently remove scrap.

Single-step trim tools

Push through
Upper compound

Lower compound
Double compound

Combination tool functions

Cam or hydraulic side actions

Multiple trim stations
Drilling

Tapping
Broaching
Date code stamping

Automated tools

Integrate with Robot load / unload

Unloading trays

Scrap removal
Precision alignment

Trimming force :-

WHERE
L=Lenth to be cut in mm
T=Thickness Of Sheet in mm
S=Shear Strength Of Material

Cutting Force= L*T*S

= 3700*1.2*40
= 177600 kg
= 177.6 ton

Pad Force :- 8% Of Cutting Force

= 14 ton
SPRING CALCULATION :NO. OF SPRING

BLANK HOLDER FORCE

SPRING CONSTANT*TRAVEL

SWH 50 -70 = 20 SPRING

PIERCING DIE :The actual cutting of the opening in the stock material is done by punch
.Therefore the size of a punched opening is determined by the punch.

Piercing Punch Size = Pierced Hole Size

Piercing Die Size

= Pierced Hole Size + Clearance

CLEARANCE CALCULATION :The ideal clearance can be calculated by the following formula

Clearance = C*S*square root of (T MAX /10)

Where C is constant = 0.05 for every accurate component.

= 0.01 for normal component.

S = Sheet thickness in mm
T MAX = Shear strength of the stock material in n/mm square

T MAX for some materials:

St.steel =400n/mm square
RESTRIKE/PIERCING/SEPERATION :The restrike die operation fundamentally is a solid forming operation. The main
difference is that a restrike die is used after most of the major forming already
has been performed. The restrike die's function is to finish forming features that
could not be obtained in a previous operation. Restrike dies add details such as
sharp radii and small embosses. They also help compensate for springback that
occurred during the initial forming.
A restrike die operation often follows a drawing or trimming operation. These
dies, also referred to as qualifying dies, usually use tension to re-form the part;
however, compression also can be used.

CHECKING FIXTURE :Checking fixture is a type inspection fixture. It is used to inspect the
component. The materal of checking fixture is Ciba. The clamp are used to grip
the component on Ciba Pad. The Ciba is machined by the profile of component.
The component is lift 3mm with the help of resting Pad.

CHECKING FIXTURE FOR COMPONENT :

5. PATTERN
MAKING
INSPECTION
AND
CASTING
Patterns are made for the part of the die that is to be made by casting. Pattern
designs are generally given to an external vendor for fabrication who adds all
the types of allowances (machining allowances, shrinking allowances etc), basic
3D form is also given to the pattern according to the profile of the component
After the pattern is correctly inspected then it is sent for casting.

CASTING:
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which
contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also
known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials
are usually metals or various cold setting materials that cure after mixing two or more components
together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex
shapes that would be otherwise difficult or uneconomical to make by other methods.

MOLTEN METAL PRIOR OF CASTING

Casting images

MACHININ
G
Machining is any of various processes in which a piece of raw material is cut into a desired final shape
and size by a controlled material-removal process. The processes that have this common theme, controlled
material removal, are today collectively known as subtractive manufacturing, in distinction from
processes of controlled material addition, which are known as additive manufacturing. Exactly what the
"controlled" part of the definition implies can vary, but it almost always implies the use of machine tool.

Rough machining
Pre machining
Insert fitting
Final machining(3D machining)

ROUGH MACHINING
PLANO MILLER
HORIZONTAL BOARING

Plano milling machine

ABOUT PLANO MILLING MACHINE
Milling is the machining process of using rotary cutters to remove materials
from a work piece. Milling is a cutting process that uses a milling cutter to
remove material from the surface of a work piece. The milling cutter is a rotary
cutting tool, often with multiple cutting tips. Convention dictates that the main
axis that drives the part towards the work spindle is the Z axis with crosstraversing X axis and a vertically traversing Y axis. In this the facing is
done to make the surface straight and so that there should not be any type of
deflection and there should not be any type of blow holes in the die frame.

PICTURE OF PLANNO MILLER MACHINE

SPECIFICATIONS OF MACHINE
Axis travel(X,Y,Z)= 4900mm*1500mm*1000mm
Maximum weight of job= 18TON
Maximum R.P.M= 2000
Table size=5000*1600mm
Adopter =ISO 150 screw type
Index cutter DIA= 50,80,125,160,200,250mm
End mill DIA= 16,20,25,30,36,40,50 etc.

Cutter used

PLANNO MILLER MACHINE OPERATION

FACINGThe facing is a machining operation by which the end surface of the work
piece is made flat by removing metal from it.
Boring-

The boring operation is the process of enlarging a hole already produced by

drilling

DrillingDrilling is the operation of producing a cylindrical hole in the work piece.

JOB

ABOUT THE JOB

The job is made of CAST IRON. Carbide tip is used in cutter.

Horizontal boring machine

ABOUT THE MACHINE
The horizontal boring machine has its works spindle parallel to the ground and
work table. Typically there are three linear axes in which the tools head and part
move. Convention dictates that the main axis that drives the part towards the

work spindle is the Z axis with cross-traversing X axis and a vertically

traversing Y axis. Horizontal boring machine are often heavy-duty industrial
machine used for roughing out large components. The machine can be operated
by manually and automatically.

PICTURES OF HORIZONTAL BORING MACHINE

SPECIFICATIONS

OF

HORIZONTAL

MACHINE

Axis travel(X,Y,Z)= 1400mm*1000mm*1200mm

Maximum weight of job= 12TON
Maximum R.P.M= 1000
Table size=1800*1800mm
Adopter =ISO 150 screw type
Quill travel =750mm
Indexing=360 degree

BORING

Cutter used

FUNCTIONS OF HORIZONTAL BORING MACHINE

FacingIt is the process of making a surface smooth and to cut and remove the
unwanted parts or materials

BoringIt is the process of enlarging a hole that has already been drilled by
means of a single point cutting tool.
DrillingDrilling is the operation of producing a cylindrical hole in the work piece.

Job

Pre machining
This type of machining is done on dead buttons, places were wear plates and
inserts can be fitted. This machining is done on CNC milling using CAM data
based on design during pre CNC ejector, upper and lower are machined.

Pre machining is used before insert fitting for smooth and clean surface.

Insert fitting and assembly

Hydro Copy Milling

ABOUT THE MACHINE
Milling is the machining process of using rotary cutters to remove materials
from a work piece. Milling is a cutting process that uses a milling cutter to
remove material from the surface of a work piece. The milling cutter is a rotary
cutting tool, often with multiple cutting tips. Convention dictates that the main

axis that drives the part towards the work spindle is the Z axis with crosstraversing X axis and a vertically traversing Y axis.

PICTURES
MACHINE

OF

THE

HYDRO

COPY

SPECIFICATION OF THE MACHINE

Axis Travel (X,Y,Z)= 1600*800*600 mm

Maximum weight of Job= 3TON.
Maximum RPM=2000
Table size= 1200*1000mm
Adopter= ISO 50 screw

FUNCTIONS OF MACHINE
FacingIt is the process of making a surface smooth and to cut and remove the
unwanted parts or materials.

 Plain or slab millingMachining of a flat surface which is parallel to the axis of the rotating
cutter.
Face millingMachining of a flat surface which is at right angles to the axis of the
rotating cutter.
Angular millingMachining of a flat surface at an angle, other than a right angle, to the
axis of revolving cutter.
ABOUT THE JOB
The raw material used to make a block is D2. The block is hold on the bed
with the help of bench wise and also two blocks are used as a support which are
kept under the job. Tools used in making the job T MAX CUTTER

Surface grinder
ABOUT SURFACE GRINDER
Surface grinder is a machine tool used to provide precious ground surface,
either to a critical size or for the surface finish. The typical precision of a
surface grinder depends on the type and use age, however 0.002mm (0.0001
in) should be achievable on most surface grinders. The machine consists of a
table that travels both longitudinally and across the face of the wheel. The
longitudinal feed is usually powered by hydraulics. The grinder wheel rotates in
the spindle head and is also adjustable for height. The machine has provision for
the application of coolant as well as the extraction of metal dust (metal and
grinding particles).

PICTURES OF SURFACE GRINDING MACHINE

SPECIFICATIONS OF MACHINE

Axis travel(X,Y,Z)= 600*400*300mm

Maximum weight of job=
Maximum R.P.M= 2000
Table size=400*300mm

FUNCTIONS OF MACHINE
FACINGThe facing is a machining operation by which the end surface of the work piece
is made flat by removing metal from it.

JOB

ABOUT THE JOB

The raw material used to make a block is D2. The block is hold on the bed
with help of clamping device and angle plate is use to hold the job. There is also
magnate in-between the table which holds the job to the bed. Tool use for
grinding GRINGING WHEEL

LATHE MACHINE
ABOUT LATHE
The lathe is a machine tool which holds the work piece between two rigid and
strong supports called centers or in a chuck or face plate which revolves. The
cutting tool is rigidly held and supported in a tool post which is fed against the
revolving work. The normal cutting operations are performed with the cutting
tool fed either parallel or at right angles to the axis of the work. The cutting tool
may also be fed at an angle relative to the axis of work for machining tapers and
angles.

Picture of lathe machine

Lathe operation

Plain Turning and Step Turning

Facing
Parting
Drilling
Reaming
Boring
Knurling
Threading
Grooving
Forming

 Chamfering
Taper Turning
Filling and polishing
1. Plain Turning: Plain turning is the operation of removing excess amount of
material from the surface of a cylindrical job.
2. Step Turning: Step turning produces various steps of different diameters.
3.Facing: The facing is a machining operation by which the end surface of the
work piece is made flat by removing metal from it.
4. Parting: The parting or cutting off is the operation of cutting away a desired
length of the work piece, i.e., dividing the work piece in two or more parts.
5. Drilling: Drilling is the operation of producing a cylindrical hole in the work
piece.
6. Reaming: The holes that are produced by drilling are rarely straight and
cylindrical in form. The reaming operation finishes and sizes the hole already
drilled into the work piece.
7. Boring: The boring operation is the process of enlarging a hole already
produced by drilling.

8. Knurling: The knurling is a process of embossing (impressing) a diamondshaped or straight-line pattern into the surface of work piece. Knurling is
essentially a roughening of the surface and is done to provide a better gripping
surface.
9. Grooving: Grooving is the act of making grooves of reduced diameter in the
work piece.
10. Threading: Threading is the act of cutting of the required form of threads
on the internal or external cylindrical surfaces.

11. Forming: The forming is an operation that produces a convex, concave or

any irregular profile on the work piece.

12. Chamfering: Chamfering removes the burrs and sharp edges, and thus
makes the handling safe. Chamfering can be done by a form tool having angle
equal to chamfer which is generally kept at 45.
13. Filing and Polishing: The filing is the finishing operation that removes
burrs, sharp corners and feed marks from the work piece. After filing, the
surface quality is the work piece is improved by the polishing operation with the
help of emery cloth of fine grades.
14. Taper Turning: The taper turning is an operation of producing a conical
surface by gradual reduction in the diameter of a cylindrical work piece.

Job (after )

Before

Fitting of inserts
Pre machined inserts and punches ejectors upper and lower are assembled as per
drawing and design which is done in fitting shop.

Final CNC and polishing

Assembled ejector and die parts are loaded on CNC for final machining in this
stage profile of component is given to the tool, arrangements like pillars,
cylinders is also made again as per design.

7.Spotting and polishing :In this stage assembled on spotting press, this is done for matching the profile
of the component on upper and lower die using hit and trial method by applying
orange color on any one surface and mating them, which gives the raised parts
that are then grinded giving the perfectly mating surfaces.

Picture of die spotting

Grinding or finishing

8. Trail and correction :During fabrication and designing it is tried to keep all the points in mind
but it is impossible to make a perfect die straight away and for this mistakes
are found and in trial runs trail run is done in following steps:
Trial 1 and correction, till this stage 60% to70% mistakes are tried to be
corrected.
Trial 2 and final correction, final accuracy is supposed to get achieved by
this stage.
Trail 3, components of this trial are sent to the party for their inspection.

9. Quality check :Components of t1 and t2 and t3 components, which are sent to the party, are
first in house tested using panel checkers on CMM(coordinate measuring
machine) which uses CAD data for verification, an report of CMM is also given
along with the components.

Panel checkers