SME TOOL ROOM

INDO GERMAN TOOL ROOM AURANGABAD

(A Govt. of India society, Ministry of MSME)

An ISO 9001:2008 & ISO 14001:2004 Tool Room & Training Centre

PROJECT REPORT

A PROJECT REPORT ON DESIGN OF

PROGRESSIVE TOOL

FOR PARTIAL FULFILMENT OF

POST DIPLOMA IN TOOL DESIGN &

CAD/CAM
BY

MANKAPE PRATIK DATTA [240042317]

HIWALE SANKET RADHAKRUSHNA [240042320]

 MSME TOOL ROOM

INDO GERMAN TOOL ROOM AURANGABAD

(A Govt. of India society, Ministry of MSME)

An ISO 9001:2008 & ISO 14001:2004 Tool Room & Training Centre

DESIGN DEPARTMENT

CERTIFICATE OF APPROVAL OF PROJECT WORK

Certify that the project work in the Design Department was successfully
carried out by the following student PRATIK DATTA MANKAPE &
SANKET RADHAKRUSHNA HIWALE of PDTD & CAD/CAM JULY
24 BATCH, in the partial full filament for the award of Post Diploma In Tool
design & CAD/CAM of the INDO GERMAN TOOL ROOM, Aurangabad
during the period of July 2024 TO July 2025.The project has been approved as
it satisfies the academic requirements in respect of project work prescribed for
the post diploma.

Mr.Arnab Bhattacharjee Mr. Anand Nikalje

(Project Guide) (Course co-
ordinator)

Mr. G. S. Awsekar
(Manager (CAD / CAM))
 ACKNOWLEDGEMENT

I am very thankful to Mr.R.D.PATIL (General Manager, Indo-German

Tool Room) for assigning me the live project in the Design Department.

I would like to express my sincere thanks and gratitude towards

CAD/CAM Manager MR.G.S.AWSEKAR for their expert guidance and
valuable time. Also I would like to express my sincere thanks for their
valuable guidelines, instructions and creative criticism which proved to be
very fruitful.

At last I would like to thank all the members of IGTR and collage for
their Co-operation.
 INDEX
1 INTRODUCTION
1.1 Introduction Press Tool
1.2 Cutting operation
1.3 Non- Cutting Operation
1.4 Classification of press tool
2 DESIGN CONSIDERATION
2.1 Design of press tool
2.2 Press tool terminology
3 LITERATURE REVIEW
3.1 Literature Review
3.2 Summary
3.3 Literature Gap
4 METHODOLOGY
4.1 Component details and Strip layout
4.2 Selection of Press Tool
4.3 Press Tool Calculations
4.4 CAD modelling
5 DRAFTING
6 BILL OF MATERIAL
7 3D PART
8 FLOW CHAT FOR MANUFACTURING
9 COST ESTIMATION
10 RESULT
11 CONCLUSIONS & RECOMMENDATIONS
12 REFERENCES
1. INTRODUCTION

1
 In mechanical and robotics systems, motor mounting brackets play a crucial role
in providing structural support and maintaining alignment between components. This
final project focuses on the design, fabrication, and implementation of custom L-shaped
motor brackets, developed to securely mount motors to a base structure in various
engineering applications. These brackets are essential for ensuring motor stability, precise
alignment, and efficient torque transfer, especially in systems where motors are subject to
dynamic loads and continuous operation.
The brackets designed for this project feature a central circular cut-out to
accommodate the motor shaft and multiple peripheral holes to allow for flexible
mounting options. The L-shape design offers a strong and compact form factor, making it
suitable for tight spaces and multi-directional support. Galvanized steel was selected as
the primary material due to its strength, durability, and resistance to corrosion, ensuring
the brackets perform reliably in a range of environmental conditions.
The development process included concept design, CAD modeling, stress
analysis, fabrication, and testing. Computer-aided design software was used to create
accurate models and perform simulations to validate the bracket’s strength and fit.
Standard manufacturing processes such as laser cutting and metal bending were used to
produce the final components.
Testing focused on structural integrity, load-bearing capacity, and ease of
integration with various motor types and frames. The brackets performed successfully,
meeting design requirements and demonstrating excellent mechanical performance..
This report outlines the design approach, development process, and performance
evaluation of the motor brackets. The project highlights the significance of well-
engineered structural components in mechanical systems and demonstrates how
thoughtful design can enhance the overall functionality and reliability of motor-driven
mechanisms.

INTRODUCTION TO PRESS TOOL

2
I. Need for Press Tool Design

Press working is a chip less manufacturing process comes under cold working. It is
also called as stamping. So, design process used for this type of tool called as press
tool design.
In this the deformation of sheet metal is brought about by the process of slip of
planes.
It produced an improved surface finish, scale free and bright surface and closer
dimensional tolerances.
Press components are applicable in automobiles, electrical equipment’s, electronics,
utensils, mining equipment’s, ships etc.

II. Introduction & Potential Application Are as for Cad

Computer Aided Design technology was initiated in the aerospace industry but is
now widely spreading in all industries.
It can be defined most simply as the use of computers to translate a product’s specific
requirements into the final physical product. With this system, a product is designed,
produced and inspected in one automatic process.
It plays a key role in areas such as design, analysis, production planning, detailing,
and documentation, N/C part programming, tooling fabrication, assembly, jig &
fixture design, quality control & testing. CAD technology can be optimized by using
computers to integrate companywide management of engineering information.
CAD system is best suited for drawing offices where frequent modification are
required and several parts repeat. It must be remembered that it is very easy with
computer to make modifications and very fast to draw part profile once its details are
fed into computer.

1.1 CUTTING OPERATION

3
1. Blanking: A shearing operation that creates a hole in sheet metal by separating
an Interior section. The removed piece of metal is the desired section.

2. Piercing: A shearing operation that creates a hole in sheet metal by separating an

interior section. The removed piece of metal is the desired section.

3. Coining: A metalworking operation used to create raised surfaces and imprints in

metal. Coining is a relatively severe operation that creates variations in metal
thickness.

4. Cut off: A shearing operation that performs a single cut in order to

separate a piece of metal from the original stock. Each cut separates a new part.

5. Lancing: A shearing operation that performs a single cut in order to separate a

piece of metal from the original stock. Each cut separates a new part.

6. Notching: A shearing operation that removes a section from the outer edge of
the metal strip or part.

7. Parting: A shearing operation that performs two cuts simultaneously in order

to separate a piece of metal from the original stock. A parting operation produces
metal scrap along with the part.

8. Shaving: A shearing operation that smoothest and finishes a

previously cut edge. Shaving operations produce a minimal amount of scrap.
9. Trimming: A shearing operation that removes an uneven section from the top rim
of a previously worked part. Trimming operations typically follow drawing operations
of sheet metal.

10. Perforating: The press tool operation in which a number of holes are produced.

1.2 NON-CUTTING OPERATIONS

4
1. Bending: The shaping of sheet metal by straining the metal around a straight axis.
A bending operation compresses the interior side of the bend and stretches the exterior
side.

2. Drawing: For sheet metal, a forming operation that transforms a flat disc of stock
into a hollow cup with an enclosed bottom. Drawing operations can also create boxes
and more intricate shapes as well.

3. Bulging: A forming operation that increases the diameter of a portion of a

hollow

Cylindrical part bulging also slightly shortens the part, and it requires the use of a
Rubber punch or pressurized fluid.

4. Curling (Beading): A forming operation that creates a curved rim around the top
of a hollow part.

5. Embossing: A metalworking operation used to create raised surfaces or lettering in

sheet metal. There is theoretically no change in metal thickness during embossing.

6. Flanging: A bending operation that bends the edge of a part in order to add
stiffness. Flanging most often creates a 90° bend in the metal.
7. Flattening: Another term used for a hemming operation. A bending operation that
bends and folds an edge of sheet metal back upon itself. Hemming conceals the sharp
edge of sheet metal.

8. Necking (Swaging): A forming operation that reduces the diameter of a

portion of a hollow cylindrical part. Necking also slightly lengthens the part.

9. Seaming: A bending operation that joins the interlocking edges of two

separate metal sheets together by folding them over one another.

10. V- bending: A bending operation performed by compressing the sheet metal

between a matching V-shaped punch and die

3 Types of Presses

5
There are different criteria of classification of presses into different categories. These
criteria related classifications and their descriptions are discussed below.
I. According To the Power Source

These power sources are categorized as:

1. Manually operated or Power Driven

These presses are used to process thin sheet of metal working operations where less
pressure or force is required.
II. According To the Type and Design of Frame

The type and Design of frame depending on the design of the frame these are classified
as inclinable, straight side, adjustable bed, gap frame, and horning and open-end.
1. Inclinable Frame Press

Its frame is called inclinable due to its capability to tilt back up to some angle. It can be
locked into nay of its inclined position as shown in figure. Its back is open to exit the
scrap so it is also called open back inclinable press.

2. Straight Side

These presses have straight side type frame which is preferred for presses having large
bed area and high tonnage. This offers greater rigidity and capable of longer strokes. The
frame consists of vertical and straight sides so it is called straight side press.
3. Adjustable Bed Type Press

It is also called knee and column type press because it has a knee type bed supported on
its column shaped frame. Its bed (knee) can be adjusted at any desirable height by
moving it vertically up or down with the help of power screws. In this structure there is
slight lack of rigidity as compared to other structures. It is shown in figure below.
It consists of a vertical frame, top of which over hangs towards the front. The
overhanging position serves for housing for driving mechanism and ram control.
The frame consists of a front face as a work table called horn.
III. According To the Position of Frame

6
Presses can also be categorized by the position off ram as described below:
1. Vertical Frame

Vertical frame type of press is already been discussed, it cannot be adjusted like
inclinable frame. Gap, adjustable bed, straight side, open-end and horning presses are
example of vertical frames.
2. Horizontal Frame

It has a fixed frame in horizontal position. It provides the facility of auto ejection of
produced part and scrap due to gravity.
3. Inclined Frame
Like inclinable frame, inclined frame press has an inclined frame but fixed, it cannot be
adjusted to any other angle.

IV. According To Mechanism Used To Transmit Power to Ram

1. Crank Press

It consists of crankshaft driven by a flywheel; rotary motion of the crankshaft is

converted into reciprocating motion with the help of a connecting rod connected to ram.
2. Cam Driven Press

In this press, a cam is used to press the ram down words and suitably located springs
restore the original position of ram when pressure is applied is removed.
This mechanism has a limitation of size of the press.
3. Eccentric Press

In this press the driving shaft carries an eccentric integral with it. One end of the
connecting rod carried an attachment of revolving eccentric and its other end is
connected to ram. As the eccentric shaft revolves, the offset between the eccentric center
and the center of rotation of the shaft provides the required movement.

4. Knuckle Press
7
This press is driven with the help of knuckle joint mechanism. The main advantage of
this press is partial back thrust is transferred to crankshaft, its major portion is
transferred to back crown which is capable to hear. This enables the application of this
press for heavier jobs with high intensity of blows.
5. Screw Press

This is known as power screw or percussion press. There is a vertical frame, its job
forms a nut. There is a flywheel at the top of and engages the ram at its bottom. The
flywheel is driven by a friction disc and the rotating screw lowers and raises the ram. The
flywheel is accelerated by friction drive. Its total energy is expanded in striking the work,
bringing it to a halt. The intensity of blow can be regulated by adjusting the height of the
die. These presses have a limitation that the ram movement is slow so these are
recommended for sheet metal work only.

V. According To the Purpose of Use

Some of the operations require low stroke strength and some larger stroke strength. In
the same way requirements of stroke length is different for different operations. So
depending on power and stroke length presses are classified as given below depending
on their suitability of performing different operations:
a) Shearing Press
b) Seaming Press
c) Straightening Press
d) Punching Press
e) Extruding Press
f) Coining Press
g) Forging Press
h) Rolling Press
i) Bending Press

2. DESIGN CONSIDERATION

8
I. Design of Press Tool

Design of any press tool involves following steps:-

 Determination of force (press tonnage) required for the operation.

 Selection of press for required force, work piece size and shape.

 Determination of shut height of the tool.

 Strip layouts and comparing material utilization.

 Computing all plates’ thickness and margins.

 Design of locating elements.

 Draw the die plan and selection of pillar die set.

 Calculate the punch lengths and select mounting methods.

 Find the centre of pressure.

II. Press Tool Terminology

9
  TOP PLATE

 THRUST PLATE (BACKPLATE)

 PUNCH HOLDER PLATE

 STRIPPER PLATE

 DIEBACK PLATE

 DIE HOUSING

 BOTTOM PLATE

 FASTENERS

 GUIDE PILLARS

 GUIDE BUSHES

 PUNCHES

 SHANK

 LIMIT BOLTS

3.LITERATURE REVIEW

10
 3.1 Literature Review
3.1.1 Title: Study and Analysis of Press Tool Design
Authors: Gaurav C. Rathod, Dr. D. N. Raut, Samadhan Adlinge
Journal name & Year: International Journal of Engineering Research &
Technology (IJERT), 2017
Abstract: This paper investigates the design and functional aspects of press tools
used in sheet metal operations such as blanking, piercing, and bending. The study
emphasizes the importance of precision in tool design to enhance efficiency, reduce
material waste, and improve component accuracy. It covers critical parameters like
die clearance, punch-die alignment, and material selection. The research also
discusses the role of CAD software in creating optimized tool designs, ultimately
contributing to higher productivity and extended tool life.
3.1.2 Title: Design Optimization of Frame of Mechanical Press Machine
Authors: G. J. Pol, A. R. Jadhav, S. J. Kadam, S. V. Kumbhar, J. G. Shinde
Journal name & Year: ARME – Advances in Research in Mechanical
Engineering, 2021
Abstract: This study focuses on optimizing the structural design of a mechanical
press machine frame to enhance performance and reduce material usage. Utilizing
Finite Element Analysis (FEA), the research identifies stress distribution and
deformation under operational loads. The findings suggest that strategic modifications
in frame geometry can lead to significant improvements in strength-to-weight ratio,
ensuring durability while minimizing costs.
3.1.3 Title: Design Calculation and Analysis of Progressive Press Tool for Square
Washer Authors: Shiv Shankar Kumar Prasad, Asita Kumar Rath
Journal Name & Year: International Research Journal on Advanced Science Hub
(IRJASH), 2021
Abstract: This paper presents the design and analysis of a progressive press tool
tailored for manufacturing square washers. The tool facilitates multiple sheet metal
operations—piercing, piloting, and blanking—in a single stroke using a single-row,
one-pass layout. The die block is crafted from EN8 steel, while the inserts utilize tool

11
steel. The design process employs SOLIDWORKS for modelling, AutoCAD for scrap
strip layout, and ANSYS for structural analysis, ensuring the tool's components can
withstand operational forces. The resulting tool is optimized for producing square
washers used in automotive, construction, and aerospace industries.
3.1.4 Title: Design, Development and Analysis of Press Tool for an Industrial Part
Authors: Rupali Chavan, Navneet Patil
Journal Name & Year: International Journal of Mechanical and Industrial
Technology, 2016
Abstract: This paper presents the design and analysis of a progressive press tool
tailored for manufacturing a specific industrial component. The tool comprises four
workstations, each performing sequential operations—cropping and piercing,
additional piercing, and two bending stages—culminating in the production of the
final part with each press stroke. Utilizing SolidWorks 2013 for modeling and the
3DQuickPress add-on for die design, the study emphasizes the integration of multiple
operations into a single tool to enhance production efficiency. The research
underscores the benefits of progressive die design in reducing manufacturing time and
improving part consistency.
3.1.5 Title: A Review on Process of Press Tool Design and its Manufacturing
Authors: Anil Parmar, Darshit Patel, Kalp Patel, Badal Patel, Maulik Patel
Journal Name & Year: Imperial Journal of Interdisciplinary Research (IJIR),
2017
Abstract: This paper provides a comprehensive overview of the press tool design
and manufacturing process, emphasizing its significance in sheet metal working for
both industrial and commercial applications. It categorizes various tooling types,
including sheet metal press tools, plastic molding dies, forging tools, jigs and fixtures,
gauges, and cutting tools. The review underscores the importance of innovative
approaches in press tool development to meet the evolving demands of manufacturing
industries.

3.2 Summary

12
 The collected studies provide a comprehensive understanding of press tool design,
development, and optimization in modern manufacturing. From foundational design
principles to structural analysis and advanced software integration, each paper offers
unique insights into improving press tool performance and efficiency. Rathod et al.
focus on the precision and CAD-based optimization of general press tools, while Pol
et al. emphasize structural frame improvements in mechanical press machines using
FEA. Prasad and Rath contribute a detailed case on progressive tool design for square
washers with practical CAD/FEA applications, and Chavan and Patil extend this to a
multi-stage progressive tool for complex industrial parts. Finally, Parmar et al. deliver
a holistic review of press tool processes and types, highlighting evolving techniques
in toolmaking. Together, these works reflect the growing significance of analytical
design, simulation, and process integration in enhancing tool reliability, productivity,
and innovation in the field of manufacturing.

3.3 Literature Gap

Existing literature on press tool design lacks holistic approaches tailored to
specific component geometries and functions. There is limited focus on reducing
material waste through optimized sheet nesting. Tool durability and efficiency are also
underexplored, with minimal research on advanced materials or wear-resistant
coatings. These gaps indicate the need for an integrated approach that addresses
accuracy, material usage, and long-term tool performance.

4. Methodology

13
4.1 Component details and Strip layout

Fig. strip layout

Fig. Component 3D part

Detail
In the current design of the press tool, The parts shown in the image are L-shaped
motor mounting brackets, specifically designed for DC geared side shaft motors.
14
Basic Information: Type: L-shaped motor clamp or mounting bracket. Material:
Sturdy metal, often zinc-plated or similar for corrosion resistance. Design: Features
an L-shape with pre-drilled holes for mounting and a large central circular hole to
accommodate the motor shaft or body. Use: Motor Mounting: Used to securely mount
DC geared motors onto a solid surface, such as a chassis, robot frame, or other
structures in robotics, DIY projects, or similar
Application: Stability Provides stable support for the motor, preventing movement
and ensuring proper alignment during operation.
Convenience: Simplifies the process of integrating motors into projects by offering a
standardized and secure mounting solution

Fig. Strip Layout

4.2 Selection of Press Tool

After observing the component we reached the conclusion that first we need to do
piercing operation and parting off then blanking and bending, otherwise if we do

15
blanking first then we will have to do the operation on the blanked component instead
of sheet metal which will be harder to manufacture and will increase cost due to
addition of fixtures to hold the component while manufacturing operations.

Fig. Operation Sequence

4.3Press Tool Calculations

Step 1. Read the drawing carefully to identify the customer requirement.

16
Step 2. Identify the operation: Piercing And Blanking Operation.

Step 3. Required tool: Simple Progressive Tool.

Step 4. Strip Layout and Economy Factor

 Thickness= 2 mm
 Material= MS
 Shear strength= 420 N/mm2

` Strip Layout
Scrap Bridge, S= 1.5 × t = 1.5 x 2= 3 mm
Pitch= 103+3=103mm
Width= 60+3+3= 66mm

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘 𝑥 𝑛𝑜,𝑜𝑓 𝑟𝑜𝑤

Economy factor, E = ×100
𝑝𝑖𝑡𝑐ℎ 𝑥 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝

= 5274.4 X 1 X 100
103 X 66

= 5274.4
6798

= 77.60%

UTTING CLEARANCE

The ideal clearance can be calculated by the following formula

Clearance = C X S X √ T max/10

17
 Where C is a constant
= 0.005 for very accurate component
= 0.01 for normal components
S = sheet thickness in mm
T max = shear strength of the stock material in N/mm2

CLEARANCE PER SIDE

Clearance / side = C X S X √ T max

10
= 0.01 x 2 x 6.42
= 0.01 x 12.96
= 0.1296 mm/side
C is a constant = 0.005 for very accurate component &0.01 for normal component

CUTTING FORCE CALCULATIONS AS PER STATIONS

Thickness of sheet = 2 mm
Material = ms
Shear Strength = 420 N/mm^2
Perimeter of the component = 330 mm

Where,
S = Shear strength in N/mm 2
L= Perimeter of the component in mm
T = Sheet Thickness in mm

1. STATION-1

1. STAGE-1
= 330 x 2 x 420

18
 = 277200 N
= 27.72 ton

2. STAGE-2
= 94.24 x 2 x 420
= 79161.6 N
= 7.916 ton

3. STAGE-3
= 15.7 x 2 x 420 x 10
=131880 N
=13.18 ton

TOTAL CUTTING FORCE

= 27.72+7.9+13.18
= 48 TON

CALCULATIONS PLATE THICKNESS

STATION - 1

THICKNESS OF DIE PLATE 1 AND 2 ( Td ) = 3 √ Fsh

= 3.6 cm X 10
= 36 mm

THICKNESS OF PUNCH HOLDER PLATE 1

= 0.8 X (Td)
= 0.8 X 36
=28.8mm

19
 = 29 mm (approx.)

THICKNESS OF STRIPPER PLATE 1

= 0.8 X (Td)
= 0.8 X 36
= 29 mm (approx.)

THICKNESS OF BOTTOM PLATE = 1.5 X ( Td )

= 1.5 X 36
= 54 mm (approx.)

THICKNESS OF TOP PLATE = 1.25 X ( Td )

= 1.25 X 36
= 45 mm

THICKNESS OF THRUST / BACK PLATE = 0.3 X (Td)

= 0.3 X 36
=10.8 mm
= 11 mm

STRIPPING FORCE CALCULATION:

8 % to 10%of total cutting force = 10 % of 47 TONN

= 0.1 x 47 TONN.
= 4.7 Ton
= 5 Ton
BENDING FORCE CALCULATION :-

S=SHEET THIKNESS

Π = 3.14 STD

20
D = DIE OPENING

T = TAU MAX

BENDING FORCE CALCULATION = S X Π X D X T

= 2 X 3.14 X 70 X 420

= 6.28 X 70 X 420

= 184632 N

= 18.46 TON

21
4.4 CAD Modelling

Progressive Press Tool Assembly :

Fig. Progressive Presstool Assembly

22
5. DRAFTING P.T ASSEMBLY

Fig . Total Deformation of Punch

23
6. BILL OF MATERIAL

12 Bottom Plate 1 MS

11 Die Plate 1 HCHCr

10 Stripper Plate 1 OHNS

9 Punch 5 HCHCr

8 Punch Holder Plate 1 OHNS

7 Thrust Plate 1 OHNS

6 Top Plate 1 MS

5 Pillars 4 EN 33,35

4 Bolts 8 -

3 Dowels 4 -

2 Bush 4 EN 33,35

1 Pilots 2 HCHCr

Sr No. Description Quantity Material

7. 3D PART
24
TOP PLATE

THRUST PLATE

25
PUNCH HOLDER PLATE

STRIPPER PLATE

26
 DIE PLATE

BOTTOM PLATE

27
PUNCHES

PILLAR

28
 BUSH

WASHER

8. FLOW CHART FOR MANUFACTURING

29
 DESIGN

PART DRAWINGR ELEASE

RAW MATERIAL

MATERIAL PREPARATION

PRE MACHINING BENCH WORK

PRECISION MACHINING

HEAT TREATMENT

GRINDING

POLISHING

INSPECTION

ASSEMBLY TRYOUT

30
9. COST ESTIMATION

The basic criteria is being used to estimate the cost of tooling

which depends upon the following major cost heads:-

1. Cost of design.

2. Cost of raw material and standard parts.

3. Cost of manufacturing process.

4. Cost of subsequent process such as heat-treatment, plating, black

iodizing, etc.

5. Cost of in process and final inspection.

6. Cost of assembly and tryouts.

7. Cost of overheads and transportations, packaging and forwarding.

8. Profit and taxation.

Based on above guidelines the total cost of the tool was estimated
as follow.

31
1.Designing and modeling cost:-

24 hours  2D designing.

16 hours  3D modeling.

2D designing cost = 300 per hrs.

3D modeling cost = 500 per hrs.

2D designing cost = 24 x 300 = 72, 00 Rs.

3D modeling cost = 16 x 500 = 8,000 Rs.

--------------

Total Designing cost = 160000 Rs.

32
Material cost :-

For estimating the material cost of the product, following steps are
as follows :-
• Find out the volume of material.
• Multiply it with density of material.

The drawing of product to be manufactured are broken up into

smaller, simpler parts and their volume is calculated by applying
the formulae:-
Volume of square or rectangular cube = L x B x H.
Where,
L = length of piece.
B = breadth of piece.
H = Height of piece.
Volume of cylinder = 2пrh.
Where,
п = constant i.e.:- 3.14.
r = radius of piece.
h = height of piece.
Volume of pyramid = (L x B x H) / 3.

Where, L = length of piece.

B = breadth of piece.
H = Height of piece

33
COST OF M.S. per Kg. 95 Rs.

COST OF EN-8 per Kg. 110 Rs.

COST OF OHNS per Kg. 210 Rs.

COST OF EN-31 per Kg. 180 Rs.

COST OF HCHCr per Kg. 350 Rs.

Density of steel = 7.86 gm/cm³.

Total weight of M.S. = 407 kg.
Rs. 95/kg
= 38665 Rs.

Total weight HCHCr. =25.27kg

Rs.350/kg
= 8844.5 Rs.

Total weight OHNS. = 8.77 kg.

Rs. 210/kg
= 1841 Rs.

Total weight EN-31. = 13.96 g.

Rs. 180/kg

Total cost of EN-31 = 2512 Rs.

34
 Total weight EN-8. = 20.29 kg.
Rs. 110/kg

Total cost of EN-8 = 2231.9 Rs.

Other material cost = 13500 Rs.

Standard parts cost = 37706 Rs.

Total raw material and standard part cost = 105299Rs.

Pre-machining cost (In hours):-

1. Lathe 290/-
2. Milling 290/-
3. Surface grinding 290/-
4. Cylindrical grinding 290/-

The tool requires,

1. Lathe = 16 hrs.
2. Milling = 20 hrs.
3. Surface grinding = 22 hrs.
4. Cylindrical grinding = 8 hrs.

35
 Lathe operation cost = 16 x 290 = 4600 Rs.
Milling operation cost = 20 x 290 = 700 Rs.
S.G. Operation cost = 18 x 290 = 5200 Rs.
C.G. Operation cost = 08 x 290 = 2300 Rs.
-------------
120000 Rs.

Total pre-machining cost = 12,0000 Rs.

Precision machining cost :- (In hours)

1. CNC lathe  575 /-

2. CNC milling  1000 /-
3. CNC wire cut  750 /-
4. CNC EDM  575 /-

Tool requires,
1. Lathe  0 hrs.
2. Milling  5 hrs.
3. Wire cut  8 hrs.
4. EDM  1 hrs.

36
 Lathe operation cost = 0 x 575 = 0 Rs.
Milling operation cost = 5 x 10000 = 5,0000 Rs.
W/c operation cost = 8 x 7500 = 60000 Rs.
EDM cost = 1 x 600 = 600 Rs.
---------------
170750 Rs.

Total precision machining cost = 170,750 Rs

• Heat-treatment cost :- (In hrs.)

Conventional heat-treatment cost = 800 Rs.

Total heat-treatment cost = 42,000 Rs.
• Fitting assembly cost :- (In hours)

Cost per hour = 140 /-

Total fitting assembly cost = 18,000 Rs.
• Inspection cost :-

Conventional = 2000 /-
CMM = 1000 /-

Total inspection cost = 74800 Rs.

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TOTAL COST OF THE TOOL.

TOTAL DESIGNING COST = Rs 1,60000//-

TOTAL MATERIAL COST & STANDARD
PART COST = Rs 1,05299/-

TOTAL PRE MACHINING COST = Rs 120,000 /-

TOTAL PRECISION MACHINING COST = Rs 1,70,750 /-

TOTAL HEAT TREATMENT COST = Rs 42000/-

TOTAL FITTING / ASSEMBLY COST = Rs 18,000/-

TOTAL INSPECTION COST = Rs 74800/-

TOTAL COST OF TOOL = Rs 6,90849/-

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 10.RESULTS

From the structural analysis carried out above it was found that maximum

deformation for punch and die plate were 0.013 & 0.0064 mm. And equivalent stress

was found to be 0.258 & 0.8816 MPa. So, it can be concluded that our design is safe

as 100% load was applied after which only very small amount of deformation was

found in die plate and punch.

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 11. CONCLUSIONS & RECOMMENDATIONS

1. The project was a medium for me to enhance my knowledge in the field of

Tool Design. It helped me lot in better understanding of the concepts of

Press Tool design.

2. During the project, I had to communicate with various departments and

authorities to solve the problems and difficulties around in between. It has

helped to improve my abilities to work as a student.

3. The project for press tool design was required to be completed in a

specific period of time for which I had to work to the best of my abilities to

complete the modelling of the component, its 2D drafting & assembly.

4. In the project work, I got an opportunity to study the press tool design right from

modelling of component, its 2D drafting & assembly as per planned time

period, which stretched our limits to achieve the goal.

5. It was a nice opportunity for me to learn about the tools, thus

enhancing my knowledge.

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 12.REFERENCES

1. Press Tools Design and Construction by P H JOSHI.

2. Press tool IGTR.

3. DME Standard.

4. Websites

a) www.google.com

b) https://en.wikipedia.org/wiki/press tool

c) https://en.wikipedia.org/wiki/propressive tool design.

5. Indo German Tool Room, Aurangabad.

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