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Mech ivyear-ppt on bearing cup-ppt

sudharsan s
sudharsan s

This seminar discusses the design and manufacturing of bearing cups. It describes the different types of presses and dies used in the process, including blanking, piercing, and drawing dies. Calculations are shown for determining the required forces for each operation. The total force required for the compound die is estimated to be 8.4 tons. The cost of manufacturing the die is estimated to be Rs. 9000. The seminar concludes that bearing cups can be efficiently manufactured in batches of 6000 using this compound die.

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SEMINAR ON DESIGN AND MANUFACTURING OF BEARING CUP y L. DINESH REDDY 07241A0304 y R. SHIVA KUMAR 07241A0319 y B. THARUN VISHNU 07241A0323
INTRODUCTION y Press Tool y Press Tool is a set of plates with a relief, or depth-based design, in them. The metal is placed between the plates, and the plates are pressed up against each other, deforming the metal in the desired fashion. y There are different types of press machines: y Some of them are:- y C-type( fixed type & open back inclinable press) y Single action straight side press yy Typical Hydraulic press
DIE y A Die is an assemblage of parts used for producing different sheet metal components. y The Die is also called press tool as the dies are used on different types of presses based on the cutting forces required for the component. y In this project a blanking die, piercing die, drawing die is produced for production of bearing cap used to protect from dust from bearings of a ceiling fan.
y There are different types of die to press relationships:- y Press Shut height yy Capacity of press y Feed Height Materials used for making die sets:- 他 HCHC 他 Mild steel
Bearing cup y Our Project lays emphasis on the design of sheet metal dies for production of bearing cup used to protect the bearings by preventing the dust to enter .The main objective of the our project is to design a bearing cup by the following operations:- y Blanking Operation y Piercing Operation y Drawing Operation
3D-diagram of bearing cup
3D view of bearing cup
Blanking operation y Blanking: Blanking is used to produce blanks o b a s of desired contour and size by cutting them out of the stock strip. Blank is the desired piece part made by Blanking operation. y Remaining after blanking is called as scrap
Inverted top view of blanking and piercing die plate
3D diagram in catia
Piercing operation y Piercing: This operation consists of simple hole punching. It differs from blanking in that the punching (or material cut from stock) is the scrap and the strip is the work piece. yy Piercing is nearly always accompanied by a blanking operation before, after or at the same time.
Top view punch and stripper plate
3D diagram in catia
Drawing operation y A flat blank is formed into a cup by forcing a punch against the center portion of a blank that rests on the die ring.
Top view of drawing die
3D diagram in catia
Die placed in open back inclined press
Strip layout y Strip layout plays an important role especially in the case of the design of the press tool. yy Strip decides the economic utilization of the work piece and helps in the decrease of cost of the job and reduction in the production time by increasing the number of components.
Working
Design calculations Blanking calculations : y Shearing force for blanking operation: Shear force F= (K*L*T*S)/1000 TONS K =1.2 for normal clearance L = perimeter of the blank = 188.4 mm T =thickness of the stock strip = 1 mm S =shearing strength of mild steel = 21 kg/sq.mm Shearing force = (1.2*188.4*1*21)/1000 TONS = 4.7 TONS
Piercing Calculations: y Shearing force for piercing operation: y Shear force F= (K*L*T*S)/1000 TONS y K =1.2 for normal clearance y L = perimeter of the hole = 78.5 mm y T =thickness of the stock strip = 1 mm y S =shearing strength of mild steel = 21 kg/sq.mm y Shearing force = (1.2*78.5*1*21)/1000 TONS y = 2.6 TONS
Drawing calculations : y Shearing force for drawing operation: y Shear force F= (K*L*T*S)/1000 TONS yy K =1.2 for normal clearance y L = perimeter of the hole = 78.5 mm y T =thickness of the stock strip = 1 mm y S =shearing strength of mild steel = 21 kg/sq.mm yy Shearing force = (1.2*78.5*1*21)/1000 TONS = 1.2 TONS
Total tool calculations y Total force required for the compound tool= y shearing force for blanking operation + shearing force for piercing operation + total load required for drawing operation =4.7+2.5+1.2=8.4tons
Cost analysis y COMPUND DIE Manufacturing time in hours Manufacturing cost per hour Amount in Rs y Conventional milling 12 100 1200 y Grinding 10 100 1000 y Jig Boring, Drilling 10 100 1000 and tapping CNC wire cut 5 320 1600 y Lathe turning 6 100 600 y Cylindrical Grinding 3 200 600 yy Total cost 6000
Other costs y Allen screw, dowel pins, high tension rubber ubbe material are purchased from markets, including the raw material for making the die and the heat treatment of the material has been charged = Rs 3000 yy Total cost of the compound die = 6000 + 3000 =Rs.9000
Conclusions 1) The Bearing cup can be manufactured in 3 operations namely blanking operation, drawing operation, piercing operation. 2)The Compound die is used in the batch operation of 6000 units of bearing cups. 3)The unit cost of the bearing cup is Rs 3. 4) The life of the compound die can be increased by machining the vital parts like punch and the die. 5)The impact plate which is placed between the bottom bolster and punch holder is replaced if necessary to improve the die life.
References y Tool design by Cyril Donaldson, Donaldson Mn. y Fundamentals of tool design by David Spitler,John G.Nee,David Alkire Smith,Society of Manufacturing Engineers. y Fundamentals of press working by David Alkire Smith.

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Mech ivyear-ppt on bearing cup-ppt

  • 1. SEMINAR ON DESIGN AND MANUFACTURING OF BEARING CUP y L. DINESH REDDY 07241A0304 y R. SHIVA KUMAR 07241A0319 y B. THARUN VISHNU 07241A0323
  • 2. INTRODUCTION y Press Tool y Press Tool is a set of plates with a relief, or depth-based design, in them. The metal is placed between the plates, and the plates are pressed up against each other, deforming the metal in the desired fashion. y There are different types of press machines: y Some of them are:- y C-type( fixed type & open back inclinable press) y Single action straight side press yy Typical Hydraulic press
  • 3. DIE y A Die is an assemblage of parts used for producing different sheet metal components. y The Die is also called press tool as the dies are used on different types of presses based on the cutting forces required for the component. y In this project a blanking die, piercing die, drawing die is produced for production of bearing cap used to protect from dust from bearings of a ceiling fan.
  • 4. y There are different types of die to press relationships:- y Press Shut height yy Capacity of press y Feed Height Materials used for making die sets:- 他 HCHC 他 Mild steel
  • 5. Bearing cup y Our Project lays emphasis on the design of sheet metal dies for production of bearing cup used to protect the bearings by preventing the dust to enter .The main objective of the our project is to design a bearing cup by the following operations:- y Blanking Operation y Piercing Operation y Drawing Operation
  • 7. 3D view of bearing cup
  • 8. Blanking operation y Blanking: Blanking is used to produce blanks o b a s of desired contour and size by cutting them out of the stock strip. Blank is the desired piece part made by Blanking operation. y Remaining after blanking is called as scrap
  • 9. Inverted top view of blanking and piercing die plate
  • 10. 3D diagram in catia
  • 11. Piercing operation y Piercing: This operation consists of simple hole punching. It differs from blanking in that the punching (or material cut from stock) is the scrap and the strip is the work piece. yy Piercing is nearly always accompanied by a blanking operation before, after or at the same time.
  • 12. Top view punch and stripper plate
  • 13. 3D diagram in catia
  • 14. Drawing operation y A flat blank is formed into a cup by forcing a punch against the center portion of a blank that rests on the die ring.
  • 15. Top view of drawing die
  • 16. 3D diagram in catia
  • 17. Die placed in open back inclined press
  • 18. Strip layout y Strip layout plays an important role especially in the case of the design of the press tool. yy Strip decides the economic utilization of the work piece and helps in the decrease of cost of the job and reduction in the production time by increasing the number of components.
  • 20. Design calculations Blanking calculations : y Shearing force for blanking operation: Shear force F= (K*L*T*S)/1000 TONS K =1.2 for normal clearance L = perimeter of the blank = 188.4 mm T =thickness of the stock strip = 1 mm S =shearing strength of mild steel = 21 kg/sq.mm Shearing force = (1.2*188.4*1*21)/1000 TONS = 4.7 TONS
  • 21. Piercing Calculations: y Shearing force for piercing operation: y Shear force F= (K*L*T*S)/1000 TONS y K =1.2 for normal clearance y L = perimeter of the hole = 78.5 mm y T =thickness of the stock strip = 1 mm y S =shearing strength of mild steel = 21 kg/sq.mm y Shearing force = (1.2*78.5*1*21)/1000 TONS y = 2.6 TONS
  • 22. Drawing calculations : y Shearing force for drawing operation: y Shear force F= (K*L*T*S)/1000 TONS yy K =1.2 for normal clearance y L = perimeter of the hole = 78.5 mm y T =thickness of the stock strip = 1 mm y S =shearing strength of mild steel = 21 kg/sq.mm yy Shearing force = (1.2*78.5*1*21)/1000 TONS = 1.2 TONS
  • 23. Total tool calculations y Total force required for the compound tool= y shearing force for blanking operation + shearing force for piercing operation + total load required for drawing operation =4.7+2.5+1.2=8.4tons
  • 24. Cost analysis y COMPUND DIE Manufacturing time in hours Manufacturing cost per hour Amount in Rs y Conventional milling 12 100 1200 y Grinding 10 100 1000 y Jig Boring, Drilling 10 100 1000 and tapping CNC wire cut 5 320 1600 y Lathe turning 6 100 600 y Cylindrical Grinding 3 200 600 yy Total cost 6000
  • 25. Other costs y Allen screw, dowel pins, high tension rubber ubbe material are purchased from markets, including the raw material for making the die and the heat treatment of the material has been charged = Rs 3000 yy Total cost of the compound die = 6000 + 3000 =Rs.9000
  • 26. Conclusions 1) The Bearing cup can be manufactured in 3 operations namely blanking operation, drawing operation, piercing operation. 2)The Compound die is used in the batch operation of 6000 units of bearing cups. 3)The unit cost of the bearing cup is Rs 3. 4) The life of the compound die can be increased by machining the vital parts like punch and the die. 5)The impact plate which is placed between the bottom bolster and punch holder is replaced if necessary to improve the die life.
  • 27. References y Tool design by Cyril Donaldson, Donaldson Mn. y Fundamentals of tool design by David Spitler,John G.Nee,David Alkire Smith,Society of Manufacturing Engineers. y Fundamentals of press working by David Alkire Smith.