MATERIALS AND FOUNDATIONS OF DESIGN PUNCH MACHINE

Anyelo J. Caro Quintero, Miguel A. Sanabria Suarez, Danneth Alejandra Rincn Hernndez
DOC. JOS LUIS RUBIANO

ABSTRACT
In this project describes the design process of a punch, which was made using the
materials that best fit it, starting from previous knowledge taught in the areas of
physics, materials and design fundamentals. This machine has the objective of
drilling an aluminum foil with a diameter of 5 mm.

INTRODUCTION
This report shows how a prototype of a punching machine is made, which will be used
to drill aluminum. With this report we want to illustrate the step by step for the
construction of the same, in addition to showing a series of tables and graphs where
the machine was tested in operation. The machine is electrical because of the
teacher's requirements and perforations of approximately 5 mm in diameter, the
materials used to make the machine were wood and balso. The report will calculate
the stresses of the machine, and the engine used for the work of the machine.

GENERAL OBJECTIVE
Build a prototype punching machine that is capable of drilling a sheet of
aluminum.
SPECIFIC OBJECTIVES
Calculate the stresses and moments that present machine.
Define the drilling mechanism.
Define the support structure.
Design the prototype power, build and tune the prototype.

THEORETICAL FRAMEWORK

PUNCH MACHINE

It is a type of machine that is used to perforate and to form plates of different materials using
a punch and a matrix like a press, two tools are involved, one that is placed in the inferior part
of the piece to punch or matrix, and another one Which is placed on the top or punch.

AWL

A punch is a tool that ends in tip and is used to generate dies, holes or holes on a surface.
According to their characteristics and materials, the punches can be used to perform different
kinds of work.

To use a punch is very simple: only its tip must be pressed on the surface that is meant to be
bored. Care must be taken, of course, with the tip of the instrument as it may cause an accident
in the work area. There are punches used for the engraving of medals, coins and other objects.
There are also punches used by jewelers to decorate their creations. In some cases, the
punches have tips that can be changed according to the need for specific use. In this way, the
same punch can be used to drill metals, leather, wood, etc.

MATRIX

It is the base of the punch where it contains the hole through which the punch passes to make
the cut commonly called the cutting die; Which serves to potentiate the area determined to cut
and thus facilitates the work of the punch reducing the effort required to cut.

HOW IS IT WORKING?

The compression of the material generates a deformation, as the penetration of the punch
advances in the material, cracks start at the contact edges between the punch and the part
and the die and the part, and as these cracks progress, a rupture occurs Or fracture causing
the sheet to separate from the cutting material, the two cracks coincide and the punch
continues to penetrate until the cut material is ejected.

Fuente: http://procesosdecorte.weebly.com
INDUSTRIAL USE
Actually the other applications are numerous. There are more than 40 standard dies to perform
different jobs can punch any type of profile: Flat plate, plate, hollow tube, angle, UPN, T profile,
U profile, IPN, etc ... Different matrices can be attached to flare tube, Or debunking sheet,
manufacture of arrowheads in sheet and in tube, round corners of sheet metal. All types of
matrices manufactured by the same customer or purchased from other manufacturers can be
coupled.
CUTTING TOLERANCE
To make a hole of a specific dimension in a sheet of a certain thickness the punch must have
the same dimension as the desired hole and the matrix should have a slightly larger dimension.
That difference in dimensions is known as the die cut tolerance. It is very important that the
cutting tolerance of the die is evenly distributed around the punch measure even at the corners.
For example, if a punch is 10 mm in diameter and the die is 10.2 mm the total tolerance of 0.2
mm must be evenly distributed so that between the punch wall and die wall a tolerance of 0 ,
1 mm. Around the perimeter.
CUTTING FORCES
This is called the effort required to separate a portion of material from a piece by its shearing.
The force required to cut a piece depends on the material to be cut, the dimensions of this cut
and the thickness:

Where:
=
=
=

EXTRACTION FORCE
This is called the effort required to return the punch of the die piece once the cut has
been made. The pulling force depends on the nature of the material to be cut, its
thickness, the shape of the figure and the material surrounding its cutting perimeter.
The extraction force can be approximated to 10% of the cutting force:

TORQUE
In engineering, torsion is the solicitation that occurs when a moment is applied on the
longitudinal axis of a mechanical element or prism, such as axes or, in general, elements where
one dimension prevails over the other two, although it is possible to find it In different situations.
The torsion is characterized geometrically because any curve parallel to the axis of the piece
is no longer contained in the plane initially formed by the two curves. Instead a curve parallel
to the axis is twisted around it
CUTTING EFFORT
The cutting shear or shear shear is the internal or resulting stress of the stresses parallel to
the cross-section of a mechanical prism such as a beam or a pillar.
In the machine is the shear force at the time of the perforation of the aluminum can, this effort
is calculated with the formula:

=

Where:
= , () ()
= (2 )
= ( ) (4)
=
TORQUE
It is when a force is applied at some point of a rigid body, the body tends to make a rotational
movement around some axis. The application of a force perpendicular to a distance (arm) of
the fixed axis of rotation produces a torque. Is manifested in the rotation of the object.
The torque of a force depends on the magnitude and direction of f and its point of application
with respect to an origin or.
Torque is the product of the magnitude of the force perpendicular to the line connecting the
axis of rotation with the point of application of the force by the distance (d) between the axis of
rotation and the point of application of the force.
ANALYSIS OF TORQUES IN THE MACHINE.
In the punching machine there do not exist directly torques since its mechanism directly
contains the force of the motor transmitted by means of circular movement on a screw that
also transmits to the support that contains the punch, although in the efforts in some points to
exert a force Where torque could be applied

MOMENT OF ENGINE INERTIA

Represents the equivalent of mass in rotating motion: it is the ratio (I) between the applied
torque (C) to a rotating system and the angular acceleration.

There is a well-defined relationship between the mass (m) of the rotating body, its distance
from the axis of rotation and the moment of inertia; Therefore, the same mass creates
completely different moments of inertia by varying the distance to the axis of rotation.

All the rotating organs present in a car are characterized by a moment of inertia, such as: the
steering wheel, the transmission organs and the wheels. Depending on the cases, it will be
interesting that the moments of inertia are large or small.
1
= 2
2
ENGINE TORQUE
It is the moment of force exerted by a motor on the axis of power transmission or, in
other words, the tendency of a force to rotate an object about an axis, point of support,
or pivot. The power developed by the torque is proportional to the angular velocity of
the transmission axis where it is represented by means of the following formula
=
ENGINE POWER
It is the work that the motor is able to perform in the unit of time at a certain speed of rotation.
It is normally measured in steam horses (CV), being 1 CV equal to 736 watts
P= Ty
The power is mechanical work that incorporates in its value the time parameter. That
is, the power is expressed with a number that quantifies the work done over a period
of time. The faster the work is performed, the more power is developed.
DESIGN PROCESS
DEFINITION OF THE PROBLEM
The problem question is: How can a hole be made in an aluminum can using an electric
mechanism and that performs a hole of minimum 5 mm in diameter?
We propose that in order to realize the hole of a form and dimension already
mentioned; The punch, the womb, and * the stepping stone * must have the same
shape. The can should be in the middle of the punch and die, then the motor will turn
a crank to the base in which it exerts a force allowing the punch to go down and make
a perfect hole in the can.

SELECTION CRITERIA

Que la maquina funcione por medio de un motor elctrico.

El espesor de la lmina de aluminio para la potencia del motor.
El costo de la mquina parte por parte.
Funcionamiento de la mquina cumpla con el objetivo para el cual fue construida.
Que la mquina no sea manual.
Precisin a la hora de hacer el orificio.
Presentacin o apariencia.
Ajuste y buena proporcin de la mquina.

SELECCIN DE ALTERNATIVA
Criterios Mquina con Mquina con una Mquina tipo
tornillo madre manivela troqueladora
Motor elctrico x
La potencia del x
motor.
El costo de la $80.000 aprox $150.000 aprox $200.000 aprox
mquina.
Cumple el objetivo
La mquina es X X
manual
Escogimos la mquina con una manivela y por este se desplaza el mecanismo que
perfora porque tena un costo promedio al resto de las mquinas.

ESQUEMA DETALLADO
A continuacin, se muestra un esquema del prototipo de maquina escogido por el
grupo de trabajo:
Diagrama de fuerzas

Vista isomtrica.

Vista rende-rizada.
 DESCRIPCIN DEL PROCESO DE CONSTRUCCIN DE LA ALTERNATIVA (editar
despus de las medidas)
El proceso de construccin de esta mquina comienza por una tabla de madera de
20x20cm, la cual tomamos como base, de manera central y ortogonal a la base
pusimos dos tablas de las mismas dimensiones (10x16cm) y separadas a una
distancia de 8.8cm, estas tablas sirven como base para sostener la matriz; al lado de
esta se ubica otra tabla de igual dimensin (10.4x8.8cm) que cubren lateralmente a el
motor. Luego se hace separadamente el ensamble de una biela que lleva un soporte
que impacta con perforadora y finalmente se ubica de manera que el conjunto quede
fijo y ortogonal a la base.

PUESTA A PUNTO: PROBLEMAS ENCONTRADOS

La perforadora que tena inicialmente estaba muy mal estticamente y al cambiarla ya
no cumpla con el objetivo y despus de varios intentos se termin dejando la misma
perforadora que estaba partida en dos, se realizaron varios cambios de apariencia
para dar un mejor acabado.

RELACIONES MATEMTICAS
En principio se tuvo que hallar la fuerza mnima para hacer trabajar la mquina, le
pusimos el peso necesario para que el punzn perforara, de este modo se hall la
fuerza mnima.
El peso necesario fue de 200 g, para trabajar la fuerza en Newton fue necesaria la
conversin a kg.
1
200 = 0.2
1000
Para hallar la fuerza utilizamos la segunda ley de Newton donde F=m*a, entonces
= 0.2 9.8/^2
= 1.96
Es decir, la fuerza mnima para el trabajo de la maquina es de 1.96 N.

Para hallar la potencia del motor se tuvieron que realizar los siguientes clculos:

60 1 2 10.15
= = = 6.28 1
60

1 1
= 2 = 0.07 0.0081 2 = 2.76 102
2 2

= = (2.76 102 2 ) (6.28 2 ) = 1.73 101 2


= = (1.73 101 2 ) (6.28 ) = 1.08

,
= .
 = .
= .
= .

ESFUERZO CORTANTE
Entonces, se tiene que el esfuerzo cortante para la maquina es de:
1.96
= = 7.98103
2
( 4 0.025 ) 0.05
,
= , () ()
= (2 )
= ( ) (4 )
=

ESFUERZO POR TORSIN

En la maquina el esfuerzo por torsin ocurre en el momento que la plataforma que
sostiene el punzn se desliza por el tornillo madre, y se calcula con la siguiente
formula:

(2.8 101 )
= = = 7.74 103
1.085 106

Anlisis del mecanismo

A partir de la Ley de Hooke puede calcularse la deformacin total que sufrir un
elemento. Segn la Ley de Hooke:
E

=

PL
=

Con esta expresin puede calcularse la deformacin conociendo la carga P la
longitud de la barra L, la seccin transversal A y el mdulo de elasticidad E (en la
zona elstica).
Entonces, se reemplazan los valores y nos da:
|1.96 N 13.5 cm|
= Kg
|0.28 0.2 106 cm2

= |4.725 x 10^ 4|
El momento flector es de 4.721 x 10^-4, es decir la deformacin del aluminio antes de
ser perforado. A continuacin, se ve una grfica de cmo es la deformacin de este
tipo de materiales:

CONCLUSIONES
Al poner a prueba la mquina y realizar todos los clculos, se llega a la
conclusin que la potencia del motor utilizado es la suficiente para realizar la
perforacin en la lmina de aluminio
Es importante determinar las fuerzas en cada punto de un sistema mecnico
para as hallar los puntos de seguridad y as ofrecer mayor calidad.
It was verified that, having a lower thickness, the shear force is higher.
If the material to be broken is of a very great thickness unlike the tinplate of
aluminum, the machine could not break it.

CYBERGRAFIA
Seleccin Y Aplicacin De Motores Elctricos. WEG-seleccion-y-aplicacion-de-motores-electricos-
articulo-tecnico-espanol. http://ecatalog.weg.net/files/wegnet/WEG-seleccion-y-aplicacion-de-
motores-electricos-articulo-tecnico-espanol.pdf

Eficiencia Energtica En Motores Elctricos. Portal/0/Gie/Tecnologas/motores

http://www.si3ea.gov.co/Portals/0/Gie/Tecnologias/motores.pdf

Momento Polar de Inercia del rea. momento-de-inercia/momento-polar-de-inercia.

https://sites.google.com/site/inescedenofisica/momento-de-inercia/momento-polar-de-inercia
Esfuerzo de Torsin. physicstutorials.org. http://www.physicstutorials.org/pt/es/53-
Esfuerzo_de_Torsi%C3%B3n