Progressive die design

The part shown in the figure is to be produced on a large scale using a progressive die.
1. Draw an economical strip layout for a coil type of stock.
2. Calculate tonnage requirement and suggest a suitable press for the operation.
3. Draw the following two views of the progressive tooling
Top view of the lower part of assembly sectional front view.

Part drawing for the progressive die design

Material - Brass
τs = shear strength of given stock material = 32 kgf/mm2
t = Stock thickness = 2 mm
production quantity = 10, 00,000 (long rum)
The progressive tool performs two or more operations at different stages in each stroke. The stock
strip is advanced through a series of stations that form one or more distinct press working
operations on the strip to get the component. A progressive or follow-on die has a series of
operations.
Progressive dies are forming tools comprised of two or more stations performing different operations.
The raw material travels from the first station to the last to get transformed into the finished product.
Progressive dies are made with two or more stations arranged in sequence. Each station operates on
a workpiece or provides an idle station so that the work is completed when the last operation has been
accomplished.
Design of economic strip layout
It consists of (i) layout of the part on the strip that results in maximum material utilization (ii)
determining a correct and feasible strip layout.
Part layout

1
Terms

a Front scrap and back scrap / margin (space between parts and strip edge)
= t + 0.015 h ( h is the width of the component in given layout)
b Scarp Bridge thickness (space between parts and strip edge, and part to parts)
p Pitch, progression, advance
the distance from a point on one part to the corresponding point on the next part
lc Component length
wc Component width
w1 Width of strip
L1 Length of strip
Nc Number of blanks cut per strip
E Scrap recovery at end
t Strip thickness
L0 Length of the sheet
W0 Width of the sheet

The economic strip layout is shown in Fig maximizes the material utilization. The bridge is
determined using a thumb based on the thickness of the stock.

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m =distance from the edge of the blank to the side of the strip
t = thickness of the material
wc = width of the component/ blank = 70 mm
Lc = length of the component/ blank = 100 mm
p = pitch, progression, or advance

w1 = width of the strip

Light gauge Medium gauge Heavy gauge

Stock thickness (t) ≤ 0.8 mm 0.8 < t ≤ 3.2 mm 𝑡 > 3.2

Bridge (b) 0.8 t 3.2

Since the thickness is 2 mm, (between 0.8 mm and 3.2 mm) the bridge b = 2mm.
Given the maximum width of the part on strip h = 70,
Front edge allowance = Back Edge Allowance = t + 0.015 h = 2 + 0.015 × 70
= 3.05 mm ≈ 3mm
Thus, the width of the strip = w1 = wc + 2 a =70 + 3 + 3 = 76 mm.
Pitch = p = Lc + b =110 + 2 = 112 mm
The pitch has three meanings (i) constant distance between the two subsequent parts on a strip layout
(ii) constant distance between two subsequent stations on a progressive die (iii) travel of the strip
between two subsequent press strokes.

Given the stock in a coil form,

area of the part 110×70
Percent material utilization = × 100 = × 100
w1 × p 76×112

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 ≈ 90.4%
Stock in the form of a sheet
(i) Shearing the sheet lengthwise
L0 = length of the sheet = 5000 mm (5m)
W0 = length of the sheet = 1000 mm (1m)
W1 = width of the strip = 76 mm
pitch p = 112 mm
The diagram below shows a scheme of cutting along the length of the sheet, where hatched area E
is end-cutting wastage.

b = Lead = bridge = 2 mm
Ns = number of strips cut from the sheet
W 1000
= W0 = = 13.2 ≈ 13 (the whole number as the full strip is required)
1 76

Nc = number of components/parts cut from the strip

L0 − b 5000−2
Nc = = = 44.6 ≈ 44
p 112

NT = total number of parts obtained from the given sheet = Nc × Ns = 13 × 44

= 572
Ac = area of the component = 110 × 70 = 7700 mm2
NT × Ac 572×7700
Percent material utilization = × 100 = × 100 = 88%
W0 × L0 1000×5000

Thus, cutting along the length of the sheet resulted in material utilization of 88%.
(ii) Shearing the sheet widthwise

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Ns = number of strips cut from the sheet
L 5000
= W0 = 76
= 65.8 ≈ 65 (the whole number as the full strip is required)
1

The length of the strip-cut widthwise has a length of W0 .

Nc = number of components/parts cut from the strip
W0 − b 1000 − 2
= = = 8.9 ≈ 8
p 112
NT = total number of parts obtained from the given sheet = Np × Ns = 8 × 65
= 520
Ac = area of the component (same as above) = 110 × 70 = 7700 mm2
NT × Ac 520 ×7700
Percent material utilization = × 100 = × 100 = 80%
W0 × L0 1000×5000

Thus, cutting the sheet widthwise results in material utilization of 80%.

Thus, with the availability of stock in the form of a sheet 1000 x 5000, shearing the sheet
lengthwise to obtain strips result in higher utilization and therefore should be adopted.
Sequence of operations
The part involves the following three operations:
(i) Punching central hole of Ø 30 mm hole
(ii) Punching two rectangular slots of size 40 × 10 mm
(iii) Blanking of 70 × 110 mm
A circular hole, preferably the largest, should be punched at the first instance so that it will be used
for the piloting in the subsequent operations. Subsequently, two rectangular slots of 40 × 10 mm
will be punched on the same station so that locational accuracy between these two slots is
maintained. The blanking has to be the last operation on the die as it separates the part from the strip
and no more operations cannot be performed on the part. Therefore, a sequence of operations on the
progressive die is as follows
Station No. operation
1 Punching central hole of Ø 30 mm hole
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 2 Punching / slotting two rectangular slots 40 × 10 mm
3 Blanking of 70 × 110 mm

Tonnage calculation and press rating

F = Cutting Force = cutting perimeter × t × τs = p × t × τs
F1 = Cutting force for the first station = π × d × t × τs
= (π × 30) × 2 × 32 = 6032 kgf
F2 = 2 × [2 × (40 + 10)] × 2 × 32 = 12800 kgf
F3 = [2 × (110 + 70)] × 2 × 32 = 23040 kgf
Total cutting force requirement
F = F1 + F2 + F3
= 6032 + 12800 + 23040
= 41872 kgf ≈ 42 T
This calculating force needs to be increased by 20% to 40% depending on the:

 the obtuseness of the cutting edges

 enlarged clearance between the cutters
 variations in the thickness of the material
 other unpredictable factors
The press should be capable of delivering about 35% more force than the required. The cutting
edge of the dies and punches get blunt due to usage that incresses the cutting force considerably.
The press suitable to carry out these operations will have tonnage (considering 35% margin on
tonnage)
Press rating = 1.35 × 41872 = 54433 ≈ 57 T
A press that has a tonnage rating of more than 57 T is suitable for carryout the operation.

Press The length and depth (transverse width) of press should be more than the length and
Table width of tool to ensure proper resting of the tool on the table. Clear hole in the table
should be bigger than the scrap/ blank which fall through the table hole. When bolster
is used, the hole in bolster must be bigger than the fall through scrap/ blank

Shank Tool shank should be running fit in the shank hole. The height of the shank should be
hole 1-2 mm smaller than the shank hole depth to ensure full contact of the ram face with
the punch holder.

Shank positions the press tool on the table in such way that fall through scrap/ blank
can clear passage through the bolster and table holes,

Throat The maximum distance from the shank centre to the rear end of the tool must be less
than the throat of the press. Generally, the throat is half the table depth. Otherwise, it
will not be possible to assemble the tool shank in the shank hole in the press.

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 Opening In inclinable presses, blank / scrap bigger than the table hole is disposed off through
at back the opening in the rear frame of the press. The press is usually inclined to 300 decent
towards the rear to effect gravitational slide down of the scrap/ blank through the
opening in the rear frame.Naturally, the blanks should be smaller than the opening at
the back.

Fasteners

Components of dies are held together by using socket head cap screws. The dowel provides and
maintains accurate positioning of the component, i.e., dowel avoids misalignment. To avoid the
projection of screw heads, the head is recessed in the counterbored hole. Cap screws that are used to
hold die components are counterbored and 1/8 inch deeper than the cap screw head. This allows
additional material for die sharpening.

Screw and dowel holes should be placed near the outer edge of the die block and as far as possible
from blanking contour. All the screws and dowels should be located at 1.5 to 2 times the diameter of
screws from the component edge. The effective thread depth for screws should be 1.5 times the screw
diameter for general applications and two times the screw diameter when subjected to shock loads.
Threading hard components should be avoided as far as possible.

The die block should be drilled with clearance and counterbored to accept the cap screw. The
thread should be cut in the die shoe.

Stripping force is about 10% of the cutting force

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 1 1
Fs = stripping force = 10 × F = 10 × 57000 = 5700 kgf
Assuming, n fasteners of nominal size, Ød has been used to resist the stripping force.
π
Fs = n × × d2c × σa
4
The minimum size of the fasteners used in press tools is M10.
Let d = Ø10 mm
dc = core diameter = 0.84 x d = 0.84 x 10 = Ø 8.4 mm
yield strength
σa = Allowable tensile strength = factor of safety

High tensile medium carbon steel (C40) is used mostly for quality fasteners usch as allen screws
and other elements subjected to high tensile stress.
The material of the socket headed cap screw (Allen screw) is C40 steel and has a yield strength σ0 )
of 33 kgf/mm2
The factor of safety for the dynamic loading =1.5
σ 33
∴ σa = 1.50 = 1.5 = 22 kgf/mm2
π
Fs = n × 4 × d2c × σa
π
5700 = n × 4 x 8.422 x 22
n≈6
Thus, the number of Allen screws required is 6 and are placed at four corners and two at the center.

M10 x 1.5 mm, D = Ø10 mm

p = 1.5 mm, dk = 16 mm, s = 8.2 mm,
k = 10 mm, b = 32 mm, depth of socket = 5 mm
L = 50 mm
Screw size Head Thread length (b) Overall length range

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 Dia (dk ) Length (k)
M6 x 1.0 12 6 28 10 - 80
M8 x 1.25 16 8 34 12 - 90
M10 x 1.5 20 10 40 16 - 100
M12 x 1.75 24 12 46 20 - 105
M16 x 2.0 32 16 58 25 - 110
M20 x 2.5 40 20 70 45 - 110

Dowel pins:
Dowel pins are simple headless alloy steel cylindrical pins that are commonly used to provide and
maintain accurate positioning of the components. Two and only dowl pins are used. The high-quality
manufactured dowel pins in hardened chrome alloy steel standards, in both inch and metric sizes.

Important features

 Precision ground low alloy steel - They are soft at the core and heat-treated – ground,
lapped and honed.
 Diameters from Ø1.5mm to Ø25mm
 Surface hardness 60 HRC minimum
 Core hardness 50-58 HRC
 Chamfer and Radius.

Nominal diameter Ø mm 1.5 2 2.5 3 4 5 6 8 10 12 16 20 25

Two dowel pins of size = Ø10.05 mm are used. Length of dowel pin = 70 mm,

 Not more than two dowels are to be used to hold or locate two parts together
 Dowel length (L) is recommended to be 4 times the dowel diameter (D)
 Depth of fixed portion (F) is recommended to be 1.5 to 2 times the dowel diameter
 Depth of free portion (C) is recommended to be 1 to 2 times the dowel diameter
 Dowel pins having an interference fit in blind holes must have provision for the
 release of air. This can be either a small vent hole of diameter 1mm or a small flat that can
be ground on the dowel before insertion.
 The fits given are suitable for use up to 100ºC, provided the coefficient of thermal
expansion for the non-ferrous material does not exceed 26x10̄6

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 Fitting dowels into blind holes
When a dowel is interference-fitted into a blind hole, it increases the pressure of the air trapped in the
hole. It is recommended that the dowel should have an air release flat ground along its full length to
prevent the dowel from being ejected under the pressure of compressed air, or bursting the component
into which it is driven.

Die Block Design

A die block is defined as the block or plate from which the die profile is cut. It is usually lower
member of the tool. It provides cutting edge. Die Material is D2 steel, High carbon high chromium
(HCHCr) non-shrinking tool steel consisting of 12% chromium and 2% carbon is recommended. It
hardened to a hardness of 60 HRc. As the name implies, this steel gets little distorted in heat
treatment. Consequently, all delicate dies and punches which cannot be ground after harening are
invariably made of HCHCr tool steel. It is well- high impossible to finish small closed profiles of
blanking dies. Such dies must be made from non-shrinking tool steel. Similarly, slender punches
are made of HCHCr tool steel to minimize distortion during the heat treatment.

Carbon steels
High carbon steel (0.85% C) can be water-hardened to 62 HRc hardness. So sturdy piercing punches
and blanking punches are made from HCS. The main disadvantage of this steel is high distortion in
the heat treatment. Nonetheless, simple sturdy dies and punches can be grounf after hardening to
remove the heat treatment distortion.

The block thickness is determined using a thumb rule

3
t d = die block thickness = √T cm
T = cutting force in ton-force
3 3
t d = √T = √55 = 3.8 cm = 38 mm
Grinding Allowance (3 −5 mm) = 4 mm
∴ t d = die block thickness = 42 mm
m = margin = die around = 1.5 × t d = 60 mm
a = die around = 1.5 × t d = 60 mm

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p = pitch / progression, distance between two subsequent stations = 112 mm
The die block size is determined and drawn is 200 × 425 mm.
The margin generally ranges from (1 − 2) t d the die thickness. It is a solid cross-section around the
die cutting edge, margin should not have any weaking holes for fixing screws or dowels.

Punch and die hole sizes

c = clearance = 10 % of the stock thickness = 0.2 mm
First operation:
Punching of the central hole Ø 30 mm
punch diameter = Ø30 mm
die hole size = punch diameter + 2 × clearance = 30 + 2 × 0.2
= Ø 30.4 mm
Second operation:
Punching two rectangular slots of 10 mm × 40 mm.
The rectangular punch will have a size same as the required slot.
punch cross section = 10 mm × 40 mm
rectangular hole size in the die = punch size + 2 × clearance
= 10.4 mm × 40.4 mm
Third operation:
Blanking 110 mm × 70 mm
The die hole will be the same as the required blank size viz.

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Die hole size = 110 mm × 70 mm
punch cross-section = punch size − 2 × clearance
=109.6 mm × 69.6 mm
The distance between the die opening and outside edge of the die block should be 1.25 times the
thickness of the die block for smaller dies. This distance should be 1.5 to 2 times the die thickness
for large dies or when sharp corners are present in the die opening contour. The solid blocks that are
symmetrical face the problem of incorrect assembly, which can be avoided by fool proofing the die
block. Fool proofing is achieved by placing one dowel at some other distance from its nearest screw
hole.
Punches
The punches having more than 4” inch unguided length are avoided.

Blanking punch
The blanking punch has two parts (i) solid block of MS (ii) annualr ring made of D2 steel. The
annualr ring is fastended to the solid block using dowel pins and two with two holes and threads
for attaching the.

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Die set selection
Standard die sets are available in the market and therefore a suitable die set is selected for a given
requirement. One of the important criteria in the selection of a die set is the available area for die
mounting.
A 10 mm margin is kept around the die to determine the die area required on a die set. Hence, the
die area required is 445 mm × 225 mm. Two pin back post die set, a widely used die set

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Stripper

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The primary purpose of a stripper is to separate the stock from the punch after a blanking or piercing
operation. However, the stripper serves two other secondary functions also. Firstly, it guides the strip
if fixed to the die block surfaces. Secondly, it holds the blank under pressure before the punch
descends fully if the stripper is of a spring-loaded type.
A rectangular plate is mounted on the top of the die block. The strip is passed through the milled
channel. In general, the height of the channel should be 1.5 times the stock thickness whereas width
must be equal to the summation of strip width and clearance. The clearance is provided to take care
of dimensional variation in the width of strip. Enough clearance is provided around the punch for its
easy removal; but clearance should be less than 1.5 times the thickness of strip. The back edge of the
channel is used as a back gauge to position the strip accurately. A stock pusher is used to hold the
strip against the back edge. The wear resistance is increased by pressing hardened dowel pin along
with the back guide.

The thickness of channel stripper is found out from the size of the socket head cap screw which is
used to hold the strip in position. For example, the minimum size of socket head cap screw used in
the press tool is 10 mm. The height of its head is 10 mm. A gap of 3 mm between the top face of the
head and the top face of the stripper should be provided. It means the depth of the counter bored hole
should be at least 13 mm. A 7 mm can be left. Hence stripper plate thickness works out to be 20 mm.

The stripper is made of low carbon steel (MS). Size of the fixed stripper is same as the die block size
Viz. 425 x 200 and thickness is determined by (i) provide necessary stripping force (ii) sufficient to
accommodate the socket head cap screw used for fastening it to the de block. The later criterion when
satisfied automatically takes care of the former.

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Pilot
Piloting is one of the essential activities in strip layout design for progressive dies. The strip must be
positioned accurately in each station so that the operations are performed at the proper locations.

Generally, there are three kinds of piloting in progressive dies. When one or two circular holes of the
part are used for piloting they are called direct pilots. When one or two circular holes are created in
the scrap area and used for piloting they are called indirect pilots. When circular holes are created
inside the noncircular holes of the part for piloting purposes and in the last station, the entire holes
are punched into the desired shape they are called semi-direct pilots.

A hole is considered to be suitable as a pilot hole if it is circular and Its diameter is greater than an
allowable minimum diameter. If the diameter of the pilot is not large enough it can easily be deflected
or even broken during operation. The pilot hole also should be located far enough from other holes
of the workpiece. If the scrap area is used for indirect piloting, the amount of increase in strip width
should be minimum.

Spring-loaded pilot is generally used for workpiece having more than 1/16-inch (1.6 mm) thickness.
Therefore, two spring-loaded pilots are used – one independent piloteach for the second and the third
stations It is direct pilot that uses the central hole punched Ø30 mm. Spring retracts the pilot from
misfeed. This pilot pierces the hole if it is used for thin sheet.

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Punch hole will be smaller than the piloting hole by amount clearance as given below:
Type of accuracy
Average work 0.05 to 0.1 mm
Close work 0.025 to 0.05 mm
High precision work 0.013 to 0.018 mm

The extra length beyond the punch face should be about sheet thickness or 1.5 mm, whichever is
greater.

Punch plate

Backup plate

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Note:
Dowel pins are the fasteners used to secure two parts together. Two Dowel pins are often used for
the precise alignment of the two parts. Dowel pins, when inserted into receiving holes, are used to
join and precisely align parts of an assembly.

These steel dowel pins are machined to tight tolerances and used in typically reamed holes. A dowel
pin may have a smaller diameter than its hole so that it freely slips in, or a larger diameter so that it
must be pressed into its hole (an interference fit). The dowel holes are used as reference points to
control positioning variations and attain repeatable assembly quality. If no dowels are used for
alignment (e.g., components are mated by bolts only), there can be significant variation, or "play", in
component alignment. The play introduced by bolt threads is proportional to the size of the fasteners.
Typical drilling and milling operations, as well as manufacturing practices for bolt threads, introduce
at least 0.2 mm play for bolts up to 10 mm. If dowel pins are used in addition to bolts, the play is
reduced to approximately 0.01 mm.

Manufacturing costs are inversely proportional to mechanical tolerances and, as a result, engineers
must balance the need for mechanical precision against cost as well as other factors such as
manufacturability and serviceability. Most dowel pins are made of stainless steel (18/8, 302, or 400
series), and low alloy hardened steel and hardened and ground to 58HRc to have fit tolerance h7. The
size is 9.99 mm and 10.00mm. The length may vary from 3 mm to 75 mm (3”) is about 15 to 20 mm.

1. Dowel length (L) is recommended to be 4 times the dowel diameter (D)

2. Depth of fixed portion (F) is recommended to be 1.5 to 2 times the dowel diameter

3. Depth of free portion (C) is recommended to be 1 to 2 times the dowel diameter

4. Dowel pins having an interference fit in blind holes must have provision for the release of air.
This can be either a small vent hole of diameter 1mm or a small flat that can be ground on the dowel
before insertion. 5. Not more than two dowels are to be used to hold or locate two parts together

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Press specifications for Godrej 10 – 100 T presses
Parameter GE 10 GE 25 GE 40 GE 100
Capacity at 200 10T 25T 40T 100T
crank angle
Stroke fixed Standard 40 63 80 125
(mm)
optional 20,25,32.,50,63 32,40,50,80,100 40,50,63,100,125 63,80,100,160
Stroke Standard 8 to 40 8 to 63 8 to 80 8 to 125
adjustable
optional 8 to 63 8 to 100 8 to 125 8 to 160
Strokes per Non- 140 112 100 80
minutes (SPM) geared
Geared 70 56 50 40
Shut height Standard 200 250 280 355
high 315 400 450 560

Screw 50 50 63 80
adjustment
Slide face Standard 180 × 280 224 × 355 250 × 400 315 × 500
Flange 315 × 400 400 × 500 450 × 560 560 × 710
Shank hole 32 × 60 40 × 75 50 × 85 50 × 85
Diameter ×
depth
Back opening 250 315 355 450
Table size (FB x Standard 315 × 500 400 × 630 450 × 710 560 × 900
LR)
deep 400 × 500 500 × 630 560 × 710 710 × 900
400 × 630 500 × 800 560 × 900 710 × 1120
Height of table 800 800 800 900
from floor
Opening in the 160 × 200 × 200 × 250 × 225 × 280 × 280 × 350 ×
table L X M x Ø Ø160 Ø200 Ø250 Ø280
N
Bolster 65 75 80 100
thickness

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Overall size Non- 111 × 74 × 142 × 110 × 188 × 134 × 250 × 180 ×
A x B x C (cm) geared 235 272 313 380
Geared 111 × 74 × 138 × 110 × 184 × 134 × 240 × 180 ×
225 263 313 380
Total flywheel Non- 392 1569 3089 12260
energy (Nm) geared
Geared 784 3138 6178 24520
Motor (kW/rpm) Non- 0.75/750 2.2/750 3.7/750 7.5/750
geared
Geared 0.75/1000 2.2/1500 3.7/1500 7.5/1500
Approx. weight Non- 600 2200 4140 7500
(kg) geared
Geared 750 2500 4500 8200
Die cushion 1.25 3.15 5 11
capacity
(tonnes)

OBI press specifications for HMT 100 – 250 T presses

Parameter P 100 P 160 P 200 P 250

Capacity at 6 mm above bottom 100T 160T 200T 250T
of stroke
Stroke of slide (mm) Standard 160 160 200 200
optional 200 200 250 250
Strokes per minutes (SPM) SPM 40 35 35 30
Main drive motor (kW/rpm) 7.5/1500 11/1500 15/1500 18.5/1500
Die space
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Shut height bed to slide Standard 450 500 630 630
optional 560 630 800 800

Adjustment of slide 125 125 125 125

Slide face area (G x H) Standard 560 × 710 710 × 900 710 × 900 800 ×
1000
Bolster area (FB x LR) 710 × 1120 800 × 900 × 900 ×
1250 1400 1400
Thickness of bolster 100 125 145 145
Slide face opening 80 × 75 80 × 75 80 × 75 80 × 75
Shank hole
Diameter × depth
Opening in bed (M x L) 520 × 570 710 × 710 760 × 760 800 × 800

Frame
Type of frame Welded steel
gap
Distance between uprights 600 710 760 800
Throat (Centre of slide to back of 360 405 460 460
gap)

Height of table from floor 890 890 890 890

Press height from floor 3800 4315 4800 5000
Floor space (A x B) 2900 × 1350 3500 × 3925 × 4100 ×
1685 1800 1930
Weight (tonnes) 11 18.2 26 28.5

Cushion
Capacity (tonnes) 15.4 25.7 32 40.7
stroke 80 80 100 100
Weight (kg) 400 500 800 950

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