Safe Area Safe Area Safe Area Safe Area Blanking Module 1 Blanking
Safe Area Blanking Module 1Blanking. Safe Area Blanking2 Sections of the Module Overview of mechanical press Setup/ Line change First piece quality.
Dec 23, 2015
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Blanking
Safe Area
Safe AreaSafe Area
Safe Area
Blanking Module
1
Safe Area Safe Area
Safe Area Safe Area
Blanking 2
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 3
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
Blanking
Safe Area
Safe AreaSafe Area
Safe Area
Overview of Mechanical Press
4
Safe Area Safe Area
Safe Area Safe Area
Blanking 5
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 6
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 7
Mechanical Press Front View
Crankshaft
BaseBolster Plate
Ram
Pitman
Flywheel
Controlling mechanism( control panel)
Gear
Clutch
MotorAir Counterbalance
Slide way
Safe Area Safe Area
Safe Area Safe Area
Blanking 8
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 9
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 10
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 11
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 12
Die and Die parts
Guide posts
Ram
Punch holder
Punch
Die Holder
Bolster Plate
DieWork piece
StripperEjector Pins
Safe Area Safe Area
Safe Area Safe Area
Blanking 13
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 14
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 15
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 16
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 17
Blanking
Separation of the metal by the movement of one stationary die and one moving punch
DieClearance
Work piece
Blank
Punch
Fracture
Safe Area Safe Area
Safe Area Safe Area
Blanking 18
Clearance
Proper Clearance
Insufficient Clearance
Proper clearance – clean fracture surface
Insufficient clearance- ragged and damaged fracture surface
Punch
ClearanceDie
Work piece
Sheared edge
Clearance
Safe Area Safe Area
Safe Area Safe Area
Blanking 19
Clearance
Excessive Clearance
Excessive clearance- burr and greater distortion on fractured surface Clearance
Blanking
Safe Area
Safe AreaSafe Area
Safe Area
Setup / Line change
20
Safe Area Safe Area
Safe Area Safe Area
Blanking 21
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 22
Setup/Line change
Setup/ line change is the procedure of changing dies of the machine for different product as per their specification
Safe Area Safe Area
Safe Area Safe Area
Blanking 23
Tools for Setup/Line change
T bolt ( 1” X 150 ) & Nut 1“ Pipe and L spanner No. 38
Safe Area Safe Area
Safe Area Safe Area
Blanking 24
Equipment for Moving dies for Setup/ Line change
Die Cart Overhead Crane
Safe Area Safe Area
Safe Area Safe Area
Blanking 25
Die Storage Area
E
N
W
S
Safe Area Safe Area
Safe Area Safe Area
Blanking 26
Initial Setup/ Line change
Remove the roller conveyor
Remove the exit chute
Safe Area Safe Area
Safe Area Safe Area
Blanking 27
Initial Setup/ Line change
Remove scrap executing chute
Safe Area Safe Area
Safe Area Safe Area
Blanking 28
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 29
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 30
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 31
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 32
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 33
Step by Step Procedure -Setup/ Line change ( Contd.)
11. Detach the die arm and start shut height adjustment
Safe Area Safe Area
Safe Area Safe Area
Blanking 34
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 35
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.)
Blanking 36
Safe Area Safe Area
Safe Area Safe Area
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.)
Safe Area Safe Area
Safe Area Safe Area
Blanking 37
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 38
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.)
Safe Area Safe Area
Safe Area Safe Area
Blanking 39
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.)
Safe Area Safe Area
Safe Area Safe Area
Blanking 40
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.)
Safe Area Safe Area
Safe Area Safe Area
Blanking 41
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.)
Safe Area Safe Area
Safe Area Safe Area
Blanking 42
21. Apply grease on pillars
22. Place the roller conveyor for keeping stacked sheet
Step by Step Procedure -Setup/ Line change ( Contd.)
Safe Area Safe Area
Safe Area Safe Area
Blanking 43
23 . Place the exit chute
24 . Place the scrap executing chute
Step by Step Procedure -Setup/ Line change ( Contd.)
Blanking
Safe Area
Safe AreaSafe Area
Safe Area
First Piece Quality as Per Standards
44
Safe Area Safe Area
Safe Area Safe Area
Blanking 45
Startup Checks
Image Check Observation
Air pressure 3 to 5 Kg/cm2
Clutch pressure 6 Kg/cm2
Balancing pressure 6 Kg/cm2
Safe Area Safe Area
Safe Area Safe Area
Blanking 46
Control Panel
1.Release emergency
2.Power ON
3.Main control ON
Safe Area Safe Area
Safe Area Safe Area
Blanking 47
Control Panel
4.Main Motor ON
5.Hydraulic pump ON
6.Lubrication pump ON
Safe Area Safe Area
Safe Area Safe Area
Blanking 48
Control Panel
7.Select foot or hand switch mode for operation
Safe Area Safe Area
Safe Area Safe Area
Blanking 49
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 50
Step by Step Procedure- Operation
3. Press the foot switch
4.For cutting second and third piece continue the process
Safe Area Safe Area
Safe Area Safe Area
Blanking 51
Step by Step Procedure- Operation
5. Place the last scrap in the scrap bin
Blanking
Safe Area
Safe AreaSafe Area
Safe Area
Dimensional Checks and Limits
52
Safe Area Safe Area
Safe Area Safe Area
Blanking 53
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 54
Vernier Caliper
Outside Jaw
Inside Jaw
Depth ProbeMain scale(mm)Vernier scale
Retainer
Blanking 55
Safe Area Safe Area
Safe Area Safe Area
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 56
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 57
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 58
Dimensional Checking of a Blank
Spoke taper and blank size
Check visually for burr at spoke and arch of the blank
Safe Area Safe Area
Safe Area Safe Area
Blanking 59
Dimensions of two Running Products
Model K
Model A
Blank diameter- 420 mm
Blank diameter- 370 mm
Blanking
Safe Area
Safe AreaSafe Area
Safe Area
Troubleshooting Related to Defects
60
Safe Area Safe Area
Safe Area Safe Area
Blanking 61
Outgoing Defects
Short piece
Edge burr
Safe Area Safe Area
Safe Area Safe Area
Blanking 62
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 63
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
Safe Area Safe Area
Safe Area Safe Area
Blanking 64
Clearance
Proper Clearance
Insufficient Clearance
Proper clearance – clean fracture surface
Insufficient clearance- ragged and damaged fracture surface
Punch
ClearanceDie
Work piece
Sheared edge
Clearance
Safe Area Safe Area
Safe Area Safe Area
Blanking 65
Clearance
Excessive Clearance
Excessive clearance- burr and greater distortion on fractured surface Clearance
Blanking
Safe Area
Safe AreaSafe Area
Safe Area
Autonomous Maintenance
66
Blanking 67
Safe Area Safe Area
Safe Area Safe Area
Breakdown Why ? Action
Autonomous Maintenance
Related Documents
