Safe Area Blanking Module 1Blanking. Safe Area Blanking2 Sections of the Module Overview of mechanical press Setup/ Line change First piece quality.
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Blanking Module
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Sections of the Module
Overview of mechanical press Setup/ Line change First piece quality as per standards Dimensional checks and limits Troubleshooting related to defects Autonomous Maintenance
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Objective
At the end of this module, you will be able to: Understand the importance of blanking Demonstrate practical ability in
Setup/Line change Dimensional checks and limits Troubleshooting related to defects
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Overview of Mechanical Press
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Press
Press is a mechanically powered machine that shears, punches, forms or assembles metal or other material by means of cutting, shaping, or with the help of combination dies attached to slides
A press consists of a Stationary bed Ram (or slides) having a controlled reciprocating motion toward and away
from the bed surface or from TDC to BDC The ram is guided in a definite path by the frame of the press
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Mechanical Press Single Stroke
Mechanical press works on single stroke.
Single stroke means one complete stroke of the slide, usually initiated from a full open position or top dead center, followed by closing down movement or moving downwards at bottom dead center, and then a returning to the full openposition or top dead center.
BDC
TDC
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Mechanical Press Front View
Crankshaft
BaseBolster Plate
Ram
Pitman
Flywheel
Controlling mechanism( control panel)
Gear
Clutch
MotorAir Counterbalance
Slide way
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Mechanical Press Parts
Base : It is main supporting member for work piece holding dies and different controlling mechanisms of press. Size of the table limits the size of work piece that can be processed on a press
Frame : Frame constitutes of the main body of the press located at one edge of its base. It houses support for ram, driving mechanism and control mechanisms. Some of the press have column shaped frame
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Mechanical Press Parts
Ram : This is main operating part of the press which works directly during processing of a work piece. Ram reciprocates to and fro within its guide ways with prescribed stroke length and power. The stroke length and power transferred can be adjusted as per the requirements. Ram at its bottom end carries punch to process the work piece
Pitman : It is the part which connects the ram and crankshaft
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Driving Mechanism : Crankshaft and eccentric mechanisms is used in mechanical press . These mechanisms are used to drive ram by transferring power from motor to ram
Controlling Mechanisms : Controlling mechanisms are used to operate a press under predetermined controlled conditions.
Controlling mechanisms controls Length of stroke of ram Power of the stroke Transfer of power can be disengaged with the help of clutch provided with
driving mechanisms as per need
Mechanical Press Parts
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Mechanical Press Parts
Flywheel : It is used for storing the energy( reservoir of energy) for maintaining constant speed of ram when punch is pressed against the work piece. Flywheel is placed in the driving mechanism just before the clutch in the sequence of power transmission
Bolster Plate : It is a thick plate attached to the bed or base of the press. It is used to clamp the die assembly rigidly to support the work piece. The die used in press working may have more than one part that is why the phrase die assembly is being used at the place of die
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Die and Die parts
Guide posts
Ram
Punch holder
Punch
Die Holder
Bolster Plate
DieWork piece
StripperEjector Pins
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Die Parts
Punch Holder : Punch holder is clamped to the ram of press. It holds the punch below it
Punch : It is the main tool of die assembly which directly comes in contact of work piece during its processing
Die Holder : It is also called die shoe. Its work as a support for the die block and it is rigidly fastened to the bolster plate of the press
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Die Parts
Stopper : Stopper are used for maintaining correct spacing of the sheet metal
Pilots : Pilot is used for correct location of blank Strippers : Stripper is used to discard the work piece out side the press
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Die Parts
Knockouts : Knockout is also a type of stripper which is used generally in case of inverted dies
Pressure Pads : Pressure pads are the plates which grip the work piece very tightly at the ends
Guide Posts : Guide posts are used for correct alignment of punch and die shoe
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Die Parts
Punch Plate : Punch plate serves as a guide way to hold the punch in right position and properly aligned
Backing Plate : Backing plate is used to distribute pressure uniformly over the whole area (to maintain uniform stress)
Die Retainer : Die retainer is fixed to the bed (base) of the press to hold the die block in correct alignment with the movement of punch
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Separation of the metal by the movement of one stationary die and one moving punch
DieClearance
Work piece
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Punch
Fracture
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Clearance
Proper Clearance
Insufficient Clearance
Proper clearance – clean fracture surface
Insufficient clearance- ragged and damaged fracture surface
Punch
ClearanceDie
Work piece
Sheared edge
Clearance
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Clearance
Excessive Clearance
Excessive clearance- burr and greater distortion on fractured surface Clearance
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Setup / Line change
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Objective
At the end of this topic, you will be able to: Understand the importance of setup/ line change Demonstrate practical ability in setup/ line change
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Setup/Line change
Setup/ line change is the procedure of changing dies of the machine for different product as per their specification
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Tools for Setup/Line change
T bolt ( 1” X 150 ) & Nut 1“ Pipe and L spanner No. 38
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Equipment for Moving dies for Setup/ Line change
Die Cart Overhead Crane
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Die Storage Area
E
N
W
S
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Initial Setup/ Line change
Remove the roller conveyor
Remove the exit chute
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Initial Setup/ Line change
Remove scrap executing chute
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Step by Step Procedure -Setup/ Line change
1. Stopper is used between the blanking dies to stop the withering of the cutting edges of the dies
2. Place the stopper at the pillar and set the height between lower and upper die
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Step by Step Procedure -Setup/ Line change
3.Stop the press at bottom dead center
4.Loosen the bolts and remove all the bolts before moving the ram
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Step by Step Procedure -Setup/ Line change ( Contd.)
5.Move the ram upwards
6.Wrap the crane chain on the second die hooks properly and move it with the help of overhead crane
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Step by Step Procedure -Setup/ Line change ( Contd.)
7. Place the Second die that is going to be fitted in the press on the die cart and bring the die cart in front of the press
8.Attach die arm
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Step by Step Procedure -Setup/ Line change ( Contd.)
9.Place die cart in front of the press
10.Unload the first die on the die cart
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Step by Step Procedure -Setup/ Line change ( Contd.)
11. Detach the die arm and start shut height adjustment
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Shut Height
Shut Height Setting
12.Shut Height : Total opening between the ram and base when ram is at its bottom dead center(BDC).
Base
Ram at BDC
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i)Switch on the shut height adjustment switch
ii)Shut height downward adjustment switch
iii)Shut height upward adjustment switch
Control Panel
Shut Height Setting ( Contd.)
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Product Shut height + 0.5 mm
CAR/ZEN(MINOR), MOD-A, CAR-MINOR/ OMNI-MINOR 597.0
MOD-C 593.0
ALTO (E)/MOD-B/ WAGON-R (VXI) & ZEN(D) / ESTEEM 620.0
207 DI / SC, TELCO/BOLERO/ SCORPIO & CAMPER 621.0
MODEL - K, M&M TRACTOR FRONT,PIAGGIO,SCOOTER, ACTIVA 600.0
HONDA-LQ 595.0
Shut Height Setting ( Contd.)
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Step by Step Procedure -Setup/ Line change ( Contd.)
iv) Check the shut height with scale as per the requirement
v) Always set the shut height with an additional 10mm as specified in the table
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13. Unload the second die from the die cart and place it on the bed
14. Detach the die arm from the die cart
Step by Step Procedure -Setup/ Line change ( Contd.)
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15. Move the die cart backwards to its appropriate position
16.Do die centering from front to back or slot to slot
Step by Step Procedure -Setup/ Line change ( Contd.)
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17. Fit all the bolts in the dies
18. Tighten the upper bolts and keep the lower bolts loose
Step by Step Procedure -Setup/ Line change ( Contd.)
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19. Do the centering of the pillar by taking 2 to 3 idle stroke
20. Tighten the lower bolts after centering
Step by Step Procedure -Setup/ Line change ( Contd.)
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21. Apply grease on pillars
22. Place the roller conveyor for keeping stacked sheet
Step by Step Procedure -Setup/ Line change ( Contd.)
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23 . Place the exit chute
24 . Place the scrap executing chute
Step by Step Procedure -Setup/ Line change ( Contd.)
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First Piece Quality as Per Standards
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Startup Checks
Image Check Observation
Air pressure 3 to 5 Kg/cm2
Clutch pressure 6 Kg/cm2
Balancing pressure 6 Kg/cm2
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Control Panel
1.Release emergency
2.Power ON
3.Main control ON
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Control Panel
4.Main Motor ON
5.Hydraulic pump ON
6.Lubrication pump ON
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Control Panel
7.Select foot or hand switch mode for operation
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Step by Step Procedure- Operation
1.Take a sheet from stack and check for incoming defects
2. Check that die rollers are not loose and sheet is butted properly with the stopper
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Step by Step Procedure- Operation
3. Press the foot switch
4.For cutting second and third piece continue the process
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Step by Step Procedure- Operation
5. Place the last scrap in the scrap bin
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Dimensional Checks and Limits
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Dimensional Check Tools
Vernier Caliper is a precision measuring instrument
It is used to measure the inside and outside diameter , width and thickness of parts with an accuracy of 0.02mm
Vernier Caliper
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Vernier Caliper
Outside Jaw
Inside Jaw
Depth ProbeMain scale(mm)Vernier scale
Retainer
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Sl. No Description Application
1 Outside jaw To measure external diameter Width of an object
2 Inside jaws To measure internal diameter
3 Depth probe To measure depth of an object or a hole
4 Main scale Scale marked in mm
5 Vernier scale Interpolated measurements in mm
6 Retainer Used to block movable parts
Vernier Caliper Parts
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Least Count of a Vernier Caliper
The Least Count of a Vernier Caliper can be calculated using the formula
Vernier Scale has 49 main scale divisions divided into 50 vernier scale divisons i.e., 49 divided into 50 parts 1 VSD = 49/50 mm =0.098 mm 1 MSD = 1mm L.C = 1mm -0.098 mm = 0.02 mm
1 main scale divisionLeast count 1 vernier scale division
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How to find the Total Reading (TR)
T.R = Total reading MSR = Main scale reading CV = Coinciding vernier scale reading L.C = Least count
T.R MSR CV L.C
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Dimensional Checking of a Blank
Spoke taper and blank size
Check visually for burr at spoke and arch of the blank
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Dimensions of two Running Products
Model K
Model A
Blank diameter- 420 mm
Blank diameter- 370 mm
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Troubleshooting Related to Defects
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Outgoing Defects
Short piece
Edge burr
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Troubleshooting Related to Defects
Image Defect Cause Remedy
Short Piece 1.Improper butting
1. Do proper butting of
sheet
2. Sheet length short
2.Inform your supervisor for
short sheet length
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Troubleshooting Related to Defects
Image Defect Cause Remedy
Edge burr1.Improper clearance of
dies
1.Set up the standard
clearance of dies
2.Burr in the incoming product
2. Inform your supervisor for burr in sheet
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Clearance
Proper Clearance
Insufficient Clearance
Proper clearance – clean fracture surface
Insufficient clearance- ragged and damaged fracture surface
Punch
ClearanceDie
Work piece
Sheared edge
Clearance
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Clearance
Excessive Clearance
Excessive clearance- burr and greater distortion on fractured surface Clearance
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Autonomous Maintenance
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Breakdown Why ? Action
Autonomous Maintenance
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