DESIGN &

MANUFACTURI
NG OF CUP
WASHER BY A
PRESSTOOL
(COMPOUND
DIE)

PRESS TOOL
Press Tool is a set of plates with a relief, or depth-based design, in them. The
metal is placed between the plates,
plates and the plates are pressed up against each
other, deforming the metal in the desired fashion. This may be blanking or
piercing or bending or forming or coining etc.
There are different types of press machines:
S
Some
off th
them are
9 C-type( fixed type & open back inclinable press)
9 Single action straight side press
9 Typical Hydraulic press
For preparing cup or conical washer we use C-type or open back inclinable (OBI)
press.

WASHER
Washers are primarily used as a seat to distribute load, but they may also
provide spring tension
tension, span oversize holes
holes, insulate
insulate, seal
seal, or provide electrical
connection. Various kinds include flat, cup, conical, and helical-spring washers,
tooth or ribbed lock washers, and special-purpose washers.

CUP WASHER
The Cup Washer is a common accessory used in many industrial applications.
This tiny thing can help you deal with many problems. We use cup washers
between the nut & screw in fittingg the aluminum sheets which we use them in
the form of roofs.
APPLICATIONS:9 Cup washer can reduce vibrations of the roof which occur due to high forced
winds.
winds
9 It can be able to endure high temperatures.
9 It acts as a seal by not allowing the water inside the roof during rains due to its
special conical shape.
I short
In
h iit prevents water leakage
l k
from
f
the
h rooff

3D DIAGRAM OF CUP WASHER

3D VIEW OF CUP WASHER

WASHER USED IN ASBESTOS SHEET

WASHERUSEDINASBESTOSSHEET

2D DIAGRAM OF CUP WASHER

HOW TO PREPARE?
For the preparation of cup or conical washer 3 operations must be done.
done
They are: Blanking Operation
Piercing Operation and
Bending /Forming Operation

Blanking
It is used to produce blanks of desired contour and size by cutting them out of
the stock strip.

Piercing
This operation consist of simple hole punching. It is nearly accompanied by
blanking operation before, after or at the same time.

Bending/Forming
In this operation, the material is formed around a straight axis, which extends
completely across the material at the bend lines. It produces a plane surface,
which is at an angle to the original plane of the work piece.

DIE
INTRODUCTORY TERMINOLOGY:9 Pi
Piece Part:P t A piece
i
partt iis th
the product
d t off bl
blanking
ki di
die. It may b
be complete
l t
product or it may be only the component of a product consisting of many
different parts.
9 Stock Material:
Material:- It is a raw sheet metal from which piece part is produced.
produced
9 Die:- The word die has different meanings
A complete production tool , the purpose of which is to produce piece parts
consistently
y to required
q
specifications.
p
The female part of complete die .
9 Punch:- A punch is a male member of complete die, which mates in
conjunction with female die to produce a desired effect upon a material being
worked.
k d A di
die can be
b a simple
i
l tool
t l composed
d off punch,
h die
di bl
block
k as stripper
t i
or float.
9 Stripper:- Stripper is a device, which is used for stripping the piece part from
the punch as the punch traverses in the reverse direction.

9 Pilot:- It is locating device, which position the work or stock strip accurately
f di
for
die working.
ki
Wh
When the
th pilots
il t bring
b i th
the work
k into
i t required
i d positions,
iti
it iis
said to be registered.
9

Shedder & Knockout:- Shedder is a device,, which acts to expel

p the work piece
p
from the die cavity . Shedder actuation is done by means of knockout bars.

9 Nest Gage:- It is a device which is used to locate and position the work piece
properly in the die.
die
9 Pushers:- These are installed for the purpose of holding or required edge or
edges of the work securely in contact with the appropriate gauging member.
9 Die Stops :- It is installed in dies for the purpose of arresting the feeding
movement of the stock strip.

BLANKING
Definition:It is used to produce blanks of desired contour and size by cutting them
out of the stock strip .Blank is the desired piece part made by blanking die.
The material remaining after blanking is called as scrap
scrap .
Critical stages of shearing action in blanking:First stage-Plastic deformation:Second stage-Penetration:-

Third stage- fracture:Clearance:- It is defined as the intentional space between the punch cutting edge
Clearance:
and die cutting edge. Theoretically clearance is necessary to allow the
fractures to meet when break occurs. The amount of clearance depends upon
the kind, thickness and hardness of the work material.
I bl
In
blanking
ki th
the work
k material
t i l iis placed
l
d between
b t
the
th di
die and
d
punch, where the die should be exact and the punch requires a clearance for
the action to be performed.

FORMULAE
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 = 94.24
94 24 mm
T =thickness of the stock strip = 0.5 mm
S =shearing strength of medium carbon steel(soft) = 36
kg/sq.mm
shearing force = (1.2*94.24*0.5*36)/1000 TONS
= 2.039 TONS

STRIPLAYOUT
Strip layout plays an important role especially in the case of the design of the press tool. 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.
First method:
length of the stock strip = 1250 mm
width of the stock strip = 34 mm
area of the stock strip = 1250(34) = 42500 sq.mm
number of blanks obtained = 40
area of one blank = 706.85 sq.mm
area of 40 blanks = 40(706.85)= 28274.33 sq.mm
stock strip efficiency = area of all blanks obtained/ area of the stock strip
= 28274.33/ 42500 = 0.66 = 66%
Second method:
length of the stock strip = 500 mm
width of the stock strip = 80 mm
area of the stock strip = 500 * 80 = 40000 sq.mm
number of blanks obtained = 36
area of one blank = 706.85 sq.mm
area of 36 blanks = 36
36*706.85
706.85 = 25446.6 sq.mm
stock strip efficiency = area of all blanks obtained/ area of the stock strip
= 25446.6/40000 = 0.63 = 63%
The first method is chosen as it has higher stock strip efficiency.

Beforeblank

Afterblank

PIERCING

PIERCING:This operation consists of simple hole punching.

punching It differs from
blanking in that the punching( or material cut from stock)is the scrap and the
strip is the work piece. Piercing is nearly always accompanied by a blanking
operation before, after or at the same time.
Critical stages of shearing action in piercing:First stage
stage-Plastic
Plastic deformation:
deformation:Second stage-Penetration:-

Third stage- fracture:Clearance:- It

Cl
I iis d
defined
fi d as the
h iintentional
i
l space
between the punch cutting edge and die cutting
edge. Theoretically clearance is necessary to
allow the fractures to meet when break occurs.
occurs
The amount of clearance depends upon the kind,
thickness and hardness of the work material.
I piercing
In
i
i the
th work
k material
t i l iis
placed between the die and punch, where the
punch should be exact and the die requires a
clearance for the action to be performed.
performed

FORMULAE
Shearing force for blanking operation:
shear force F= (K*L*T*S)/1000 TONS
K =1.2 for normal clearance
L = perimeter of the hole = 24.03 mm
T =thickness of the stock strip = 0.5 mm
S =shearing strength of medium carbon
steel(soft) = 36 kg/sq.mm
shearing force = (1.2*24.03*0.5*36)/1000
TONS
= 519.048 kg = .519 TONS

BENDING

In this operation, the material is formed around a straight axis,

which extends completely across the material at the bend
lines. It produces a plane surface, which is at an angle to the
original plane of the work piece.
Procedure used in bending are: ForcesappliedduringBending
g
Stresses in bending
Plastic deformation in bending

FORMULAE

Calculationsfordomeshape:
Su=ultimatetensilestrength,48kg/mm2,
/
L=perimeterofthebendingpart
=2(15)3.14
=94.2mm
94 2mm
BendingForce=.33(S*W*T*T)/L
=(.33*48*30*.5*.5)/94.2
=1 26kg
=1.26kg
Padforce=50%(bendingforce)
=.63kg
Totalloadrequired=bendingforce+padforce
q
g
p
=1.26+.63
=1.89
=2kg

CompoundDiecalculations
Totalforcerequiredforthecompoundtool=shearingforcefor
q
p
g
blankingoperation
+shearingforceforpiercingoperation
+totalloadrequiredforbendingoperation
=2.039+.59+.002=2.541tons

COST ANALYSIS
COSTANALYSIS
COMPOUNDDIE

Manufacturing time in hours

Manufacturing cost per hour

Amount in Rs

Conventional milling

100

800

Grinding

100

900

Jig Boring, Drilling

and tapping
CNC wire cut

100

700

320

1600

Lathe turning

100

400

Cylindrical Grinding

200

600

Total cost

5000

Othercost
Other
cost
Allenscrew,dowelpins,hightensionrubber
material are purchased from markets,
materialarepurchasedfrommarkets,
includingtherawmaterialformakingthedie
andtheheattreatmentofthematerialhas
beencharged=Rs2500
Totalcostofthecompounddie=5000+2500

=Rs7500

Sideviewofthedie
d
f h d

Front view of the die

Frontviewofthedie

Machineinwhichourcompound
p
dieisplaced

CONCLUSIONS

1) TheCupwashercanbemanufacturedin3operationsnamelyblanking
operation bending operation piercing operation If we use unit dies the total cost
operation,bendingoperation,piercingoperation.Ifweuseunitdies,thetotalcost
willbemoreandthetimetakentomanufacturewillbemore.Soacompounddie
isusedtomanufacturetheproductwherealltheoperationsareperformedinone
strokeofthepress.
2) ThetotalmanufacturingcostoftheCompounddieisRs7500.
The total manufacturing cost of the Compound die is Rs 7500
3) TheCompounddieisusedinthebatchoperationof6000unitsofcup
washer.
4) Afterthebatchproductionof6000units,thenthecompounddieissentfor
machining so that it can be used again for the next batch production
machiningsothatitcanbeusedagainforthenextbatchproduction.
5) TheunitcostofthecupwasherisRs2.
6) Thelifeofthecompounddiecanbeincreasedbymachiningthevitalpartsof
thecompounddiewhicharethepunchandthedie.
7) Theimpactplatewhichisplacedbetweenthebottombolsterandpunch
The impact plate which is placed between the bottom bolster and punch
holderisreplacedifnecessarytoimprovethedielife.Alsothehightensionrubber
materialcanbereplacedifrequired.

REFERENCES
MetalCuttingAndToolDesignByB.J.RANGANATH.
MechanicalEngineeringDesignByJOSEPHSHIGLEY&
CHARLES MISCHKE
CHARLESMISCHKE.

EngineeringDesignByGEORGEDIETERANDLINDA
SCHMIDT.
FundamentalsOfToolDesignByDavidSpitler,Jeff
Lantrip,JohnNeeandDavidASmith.

THANKYOU