INTRODUCTION OF INDUSTRY

Name:-CEARS DIES AND MOULDS PVT.LTD

Product: DIES
Company Details CIN U31905MH1999PTC123142

Company Name CEARS DIES AND MOULDS PRIVATE

LIMITED
Company Status Active

Registration Number 123142

Company Category Company limited by Shares

Company Sub Category Non-Government company

Class of Company Private

Date of Incorporation 17 December 1999

Age of Company 19 years

Number of employees 150

INDUSTRIAL LAYOUT
RAW DIE
GRINDING MILLING DISPATC
SECTION MATERIAL
SECTION H
SECTION SECTION

PRESS DRILLING PRESS

MACHINE MACHINE MACHINE

VMC
VMC
MACHINE MACHINE

VMC ASSEMBLY
SECTION VMC
MACHINE
MACHINE

5 AXIS
MACHINE
INSPECTION
DEPARTMENT
DESIGN HR
LAB MANAGER
OFFICE

SECURITY
CABIN

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 What is a die?
A die is
specialized tool used in manufacturing
a

industries to cut or shape material

mostly 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.

THERE TWO TYPES OF DIE: 1) Cutting Die

2) Non Cutting Die

CUTTING DIE:
Trim Die
Shearing Die
Piercing die

NON CUTTING DIE

Draw Die
Restrike Die
Chapter no. 3

Industrial equipment's
SR NAME OF EQUIPMENT'S USE OF EQUIPMENT'S

1 Vertical machining Centre ( Profile making

VMC's)

Press machine Try out

3 Milling machine Shaping blocks

4 Grinding machine Surface finish

Radial drilling machine Drilling holes on casting and

blocks

6 Gas cutting machine Cutting raw material

Cutting raw material

Band saw machine

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 Details of industrial equipment's

Sr No.1
Equipment Name: - VERTICAL MACHINIMG
CENTRE (VMC)

Vertical machining center

A VMC is a machine with a CNC (Computer Numerical
Control) controller. As mentioned, the cutting head in this
milling machine is vertical and is a particular type of
milling machine where the spindle runs in a vertical axis
known as the "z" axis. They are typically enclosed and
most often used for cutting metal.

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 FIVE AXIS MACHINE (VMC)

o A

LORUMA

SPECIFICATION:
1. Made by :OKUMA.
2. Model no. : M604
3. Bed size :4000*2000mm
4. Travel(x y z) :4200*2500*1400mm
5. Maximum spindle speed 6000rpm
6. Maximum job weight 16000kg
7. Maximum job height 1200mm
8.Auto tool changer capacity: 50tools

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Approximate cost: about 8crore

SPECIFIC USE:
The term 5 axis refers to the numbers of direction in
which the cutting tool can move on a 5 axis machining
center the cutting tool move across the x y z linear axis as
well as on A & B axis to approach the work piece in any
direction. It is use obtaining 3D profile on the dies. It is
usually when the die profile is too complicated. it can
Works at any angle as per the programed. It saves time as
it has AUTOMATIC TOOL CHANGERS (ATC).
AUTOMATIC TOOL CHANGERS (ATC) has 50tools
tools held in it and as per the programe tool is selected
for different machining operation.

MAINTAINANCE
KIND OF WORKK TIME INTERVAL
Cleaning bed Regularly
Checking ATC 10DAYSs
Checking coolant 1 month
Checking tools 1 MONTTH

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 PRESS MACHINES
A forming press, commonly shortened to press, is a
machine tool that changes the shape of a work piece
by the application of pressure. The operator of a
forming press is known as a press-tool setter, often
shortened to tool setter. Press machine in die
industry is to verify whether the die produces the
desired product or not.
Presses can be classified according to
Their mechanism: Hydraulic, Mechanical, and
Pneumatic.

Their function: forging presses, stamping presses,

press brakes, punch press, etc.

Types of press machine: 1. Mechanical press

1. Hydraulic press Specific use: - After the die read,
press in the die industry is use for the verification of
the die by spotting. And to verify that die
manufactured produces the desired object. It is just
for TRYOUT purpose.

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 MECHANICAL PRESS:

Made by Erfurt
Press capacity 500ton
Stroke 500mm
Bed size 2000
Bed size 3100
Slide size 3100
Hole die 40mm
Max cushion load 60bar
Shut height ( max) 1080mm
Shut height ( min) 610mm

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 MILLING MACHINE:
Milling machine are very versatile machine. Cutter in
the milling machine rotates to remove the material from
the work piece present in the direction of the angle with
the tools axis .With the help of milling machine one can
perform many operation and function starting from small
objects to large ones. Surfaces they can also be used to
drill, bore, cut gears and produce slots on work piece.
Manufacturing country: - Bharat Fritz Werner
Machine cost: about 1.50 lakhs.
Specific use: facing blocks.
Sizing blocks.

MAINTAINANCE

KIND OF SERVIC ING INTERVAL

WORK
Cleaning of guide ways Weekly
Oil renewal Semi annually
Regular Inspection Weekly
Inspection oflubrication Semi annually

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 GRINDING MACHINE:
Surface grinding is use to produces smooth finish on flat
surface. It is widely used abrasive machining process in
which a spinning wheel covered in rough particle cuts the
chips of metallic or nonmetallic substance from the work
piece making a face of it flat or smooth

Manufacturer- PESH MACHINES

Machine cost: about 6 lakhs.
SPECIFIC USE:
A surface grinding machine is used to
produce a smooth accurate finish surface on a metallic
material.

MAINTAINANCE:

KIND OF SERVICING INTERVAL

WORK
Changing of wheel Weekly
Clapping or loosening of wheel daily
checking coolant level Monthly
Cleaning bed Regularly

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 RADIAL DRILLING MACHINE
Manufacturer:- Bhavya machine tools
machine cost: about 1.5 lakhs.

SPECIFIC USE:
A radial drilling machine is a special purpose drill1ng
machine it is normally has a drilling head that is mounted
to slide along radial arm.
Thus radial arm can be raised or lowered or rotated on a
vertical pole in order to adjust the position of drill above
the work piece.
It is use to drill hole in plate or casting. It is less time
consuming as we could drill hole at any point on the work
piece when it is clamped.

SPECIFICATION:

1. Machine rotates about 360 degree.

2. Spindle travels 215 mm.
3. Drilling motor - 1.5 Hp.

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 BREIF MACHINING PROCESS
Drawing of part is given form customer
Then the procedure in which the die is to be made is
decided. And BILL OF MATERIAL (popularly
known as BOM) is made. And according to BOM the
order is placed for the required material for making
of die
Then the design is sent to the foundry for making a
casting. In foundry according to design the pattern of
wood is made. And the Casting is made.
Then the casting is machined at the surface where the
blocks are fitted.
.Bill of material of consist of list the material required
the quantity and the type of metal.
Bill of material sent to the raw material section then
the material is cutted in size slightly than the bigger
dimension in bill of material.
During cutting of raw material the dimension are kept
about 5 mm bigger than desired dimension.
Then the pre machining is done on block. Pre
machining includes milling and grinding

.Then the blocks are sent to grinding. The sides of

block which are in contact with the casting are
surface finished.

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.The desired dimension is obtained in grinding then
the block is ready for assembly.
The hole are drilled on the block at the respective at
the position as per given destine. The tapping is done
by the hand by tap tool.
Once the blocks are fitted on the casting and finally
they are a ready to maintain on VMC.
On the VMC the program for the machine is made
according to the program. VMC works on the casting
or the plate to required position.
As the dies are under machine immense pressure it
has chances deforming the profile of die. To avoid
this hardening of the block are done.
After machining on VMC the blocks are again un
bolted and send for hardening.
After hardening dimension of the block become
slightly bigger than before.
Then the blocks are again sent for grinding.
Also the base of the hardened block does not remain
flat. Base of the block is flattened by spotting on the
flat surface plate. Using pneumatic machine the
uneven surfaces is flattened.
.Then the harden block are again assembled on the
casting.

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The die made should produce the desired objects for
this the die is sent to the tryout section that is on the
forging press.
Now the dies are clamped in the T slotted table of
platform of press.
Die manufactured should produce desired product for
these purpose of the die is tested by spotting.
Therefor the spotting is done metal sheet of thick
same as thickness of desire product is taken is it is
color on both side.it is place on blank holder
Then the press is operates to mass down then the part
is form. Colored stick at the profile of the die portion
where the color stick is the machined till the proper
colored is acquired at the whole die. This way whole
manufacturing process are carried out

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 TESTING OF FINAL PRODUCT

Using checking fixture

Clean the checking fixture and open the clamp

Load the part on the checking fixture
Locate the part firsts with the datum pins
Ensure that the part should rest on the rest pad and
there should not be any rocking.
Clamp the part as per the sequence Cl, C2, C3 ..

.
Verify the hole position with inserting respective
pins
Prepare the manual inspection report as per
inspection point on the checking fixture.

Verify the surface 0.0+- 0.5 dialogue

Check the trim gap 3 mm by using taper scale.
After checking the parts, unload the part.

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SAFETY INSTRUCTION

Safety instruction while working on VMC's

Ensure that only the trained personal operate the

machine.

Read the instruction manual before operating the

machine partial understanding may cause serious

injury.
Ensure that work piece hand the related fixture are

firmly secured before starting the spindle.

Keep hand and body out cutting and clamping area
while machining.
Close all covers and doors while machine is running.

Donor place tools on moving parts

Ensure regular maintenance of the machine using

maintenance manual.

Switch of power during maintenance or repair work.

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