SPRING

2024

DIE DESIGN PROJECT

TEAM 6
SUB TO:
DR/ RAMADAN BADAWY MOHAMED
DR/ MOHAMED HAZEM ABDEL LATIF
ENG/ ISLAM BAHGAT
ENG/ BASEM
 Name ID Contribution

Abdelrahman 1901316 COP + Report

Writing
Mohamed Arafa

Adham Ramdan 1900301 Force Calculation

Abobkr

Amr Osama Elsayed 1900333 CAD Design

Ahmed

Dana Essam El Dein 2001779 Working Drawings

+ CAD
Mohamed

Ahmed Hosny 1901652 CAD design +

Drawings
Abdelsalam

Barakat Mohamed 1900338 Sheet Utlization

Abdelsamie

Merna Lamey baset 2001662 Report Writing+

CAD Drawing

Nour waleed Mansour 2001381 Stripper Design +

COP

Osama Mohamed 1900332 Punch & Die

Dimensions
Khalaf

Rana Mohamed 2000200 Expansion

Calculations
Mahmoud

Rawan Mohamed 2000243 Construction

Drawing +
Fahem Working Drawings

Adel Shafiek 1900965 Max Punch Height

Mohamed

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Contents
1. Introduction .........................................................................................................3
2. Utilization ............................................................................................................7
3. Force Calculation .............................................................................................. 11
4. Die Block Thickness .........................................................................................12
5. Expansion ..........................................................................................................13
6. Punch & Die Dimension ...................................................................................13
7. Piercing Punch Max Height ..............................................................................15
8. Stripper Design..................................................................................................15
9. Sequence layout ................................................................................................16
10. Center of Pressure ............................................................................................16
11. Drawings ..........................................................Error! Bookmark not defined.
12. References .......................................................................................................30

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 1. Introduction
What is a Die?
A die is a machine tool commonly employed in
manufacturing to shape metal by cutting it into
desired forms or creating external threads on
items such as pipes and round rods. Dies are
designed with chamfered edges on one side to
facilitate the initiation of threads. Die stocks,
typically operated manually, are constructed
from materials such as high-carbon steel, high-speed steel, and alloy steel, and they
come in both circular and square shapes. Dies are categorized based on their specific
applications, including stamping dies for press work, casting dies for molding
processes, and drawing dies for wire production.

Different Types of Dies

➢ Simple Die:
A Simple Die is utilized when a single operation is
executed in one stroke at one stage. It is ideal for
straightforward shaping or cutting tasks.

➢ Compound Die:
A Compound Die is employed when multiple
cutting operations are conducted in a single
stroke at one stage. This die type offers certain
advantages and limitations.
Advantages of Compound Dies: High production
rate since one component is produced per stroke.
Limitations of Compound Dies:1-Higher force requirement compared to other die
types. 2-Complex design and manufacturing for more than three operations.

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 ➢ Progressive Die:
Progressive Dies are designed for multiple cutting
operations in a single stroke but at different
stages. The punched-out sheet progresses from
one stage to another until all the punching
operations are completed, with blanking as the
final step.
Advantages of Progressive Dies: 1-Comparable
high production rate as in compound dies. 2-
Reduced force requirements are achieved through
shear or staggered punches.3-Easier design and manufacturing due to operations
being performed at different stages.
Disadvantages of Progressive Dies: 1-Balancing forces on the punch head can be
challenging.2-Require setup procedures and precise alignment.2-Entire die set
removal in case of single station damage.3-Heavier compared to single station dies.

➢ Transfer Die:
Transfer Dies are like Progressive Dies, but they
initiate with blanking as the first operation. The blank
produced in the first stage is transferred from one stage
to another for subsequent punching operations.

➢ Combination Die:
Combination Dies combine multiple cutting and forming
operations in one stroke at one stage. They are versatile and
used for various tasks, such as blanking combined with
deep drawing or punching combined with bending.

➢ Multiple Die:
Multiple Dies are employed when more than one component
needs to be produced simultaneously. Several of the die types
are used in parallel to achieve this.

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 Piercing and Blanking Machines
Piercing and blanking are two common metalworking processes used to create holes,
openings, and profiles in sheet metal parts. The key machines used for these
processes include:

➢ Punch Presses
Punch presses are the most widely used machines for piercing
and blanking. They use a punch tool that is forced through the
workpiece to create the desired shape. Punch presses come in a
variety of sizes and can be manual, mechanical, hydraulic, or
pneumatic powered.

➢ Turret Punch Presses

Turret punch presses have an indexing turret that holds
multiple punch and die sets. This allows for complex
parts to be produced with a single clamping of the
workpiece, improving efficiency.

➢ Laser Cutting Machines

Laser cutting machines use a focused laser beam to melt
and vaporize the metal, allowing for very precise and
intricate cuts. They are well-suited for piercing and
blanking thin to medium gauge sheet metal.

➢ Plasma Cutting Machines

Plasma cutting machines use an electrically charged
ionized gas to rapidly cut through metal. They can
handle thicker workpieces compared to lasers and are
a cost-effective option for many piercing and
blanking applications.

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 ➢ Die Cutting Machines
Die cutting machines use a reciprocating steel rule die to
punch out shapes from sheet material. They are well-suited for
high-volume production of simple, repetitive shapes.

➢ Stamping Presses
Stamping presses use a die set to shape and form sheet
metal into the desired part geometry. They are commonly
used for complex, multi-stage piercing and blanking
operations.

The choice of machine depends on factors like the material thickness,

part complexity, production volume, and cost constraints. Proper
tooling, machine maintenance, and operator training are critical to
ensure quality and productivity in piercing and blanking operations.

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 2. Utilization
➢ Assuming this product will be made from St60.
➢ The sheet is 2000 mm length and 1000 mm wide and
1 mm thickness.
➢ We will get dimension of scrap strips (a & b) and
waste ends ( 𝑎1 & 𝑏1 ) from standard table.

Minimum dimension of scrap strips and waste ends.

𝑎1 = 𝑏1 = 2 𝑚𝑚
𝑎 = 𝑏 = 1.2 𝑚𝑚

➢
➢ Waste ends ( 𝑎1 & 𝑏1 ) will be removed and the new dimension of the sheet
will be 1996 ∗ 996 𝑚𝑚2 .

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 ➢ For best utilization we will try a lot of tries and select the one which give
highest number of products.

1. Narrow, Longitudinal:

Strip size =120+1.2+1.2=122.4 mm

𝑆𝑡𝑟𝑖𝑝 𝑙𝑒𝑛𝑔ℎ−𝑎 1996−1.2
No of product per strip = = = 11.1 ≈ 11 𝑝𝑟𝑜𝑑𝑢𝑐𝑡/𝑠𝑡𝑟𝑖𝑝
𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑤𝑖𝑑𝑡ℎ+𝑏 177+1.2

𝑠ℎ𝑒𝑒𝑡 𝑤𝑖𝑑𝑡ℎ 996 𝑠𝑡𝑟𝑖𝑝𝑠

Strips per sheet= = =8.1≈ 8
𝑠𝑡𝑟𝑖𝑝 𝑠𝑖𝑧𝑒 122.4 𝑠ℎ𝑒𝑒𝑡

𝑠𝑡𝑟𝑖𝑝𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑡

No of product per sheet= ∗ = 11 ∗ 8 = 88
𝑠ℎ𝑒𝑒𝑡 𝑠𝑡𝑟𝑖𝑝 𝑠ℎ𝑒𝑒𝑡

2. Narrow, Traverse
Strip size =120+1.2+1.2=122.4mm
996−1.2
No of product per strip = = 5.6 ≈
177+1.2
5 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝
1996 𝑠𝑡𝑟𝑖𝑝𝑠
Strips per sheet= =16.3≈ 16
122.4 𝑠ℎ𝑒𝑒𝑡

𝑝𝑟𝑜𝑑𝑢𝑐𝑡
No of product per sheet= 5 ∗ 16 = 80
𝑠ℎ𝑒𝑒𝑡

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 3. Wide, Longitudinal

Strip size =177+1.2+1.2=179.4mm

1996−1.2
No of product per strip = = 16.4 ≈ 16 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 / 𝑠𝑡𝑟𝑖𝑝
120+1.2

996 𝑠𝑡𝑟𝑖𝑝𝑠
Strips per sheet = =5.5≈ 5
179.4 𝑠ℎ𝑒𝑒𝑡

𝑝𝑟𝑜𝑑𝑢𝑐𝑡
No of product per sheet = 5 ∗ 16 = 80
𝑠ℎ𝑒𝑒𝑡

4. Wide, Traverse
Strip size =177+1.2+1.2=179.4 mm
996−1.2
No of product per strip = =
120+1.2
8 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 / 𝑠𝑡𝑟𝑖𝑝
1996 𝑠𝑡𝑟𝑖𝑝𝑠
Strips per sheet= =11.1≈ 11
179.4 𝑠ℎ𝑒𝑒𝑡

No of product per sheet= 8 ∗ 11 =

𝑝𝑟𝑜𝑑𝑢𝑐𝑡
88
𝑠ℎ𝑒𝑒𝑡

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 Position Products
Orientation
NO.

Narrow,
88
Longitudinal

Narrow, Traverse 80

80
Wide, Longitudinal

Wide, Traverse 88

We choose Narrow, Longitudinal position as it has the best utilization and less no.
of strips.
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 3. Force Calculation
➢ 𝑭 = 𝑺𝑻𝑳

S: Shear Strength = 250 Mpa

T: Sheet Thickness = 1 mm
L: cutting perimeter

➢ Press Capacity = 100 KN

➢ Assume: ɳ = 80 %

1. Piercing
𝐹1 = 250 ∗ 1 ∗ 20𝜋 = 15707.96 𝑁
𝐹2 = 250 ∗ 1 ∗ 20𝜋 = 15707.96 𝑁
𝐹3 = 250 ∗ 1 ∗ 65𝜋 = 51050.88 𝑁
2. Blanking
𝐹4 = 250 ∗ 1 ∗ 483 = 120750 𝑁

∑𝑭 = 𝟐𝟎𝟑𝟐𝟏𝟔. 𝟖 ≥ 𝟖𝟎 𝑲𝑵
➢ We need to make force reduction using angular shear.
𝑡
𝐹𝑢𝑠𝑖𝑛𝑔 𝑆ℎ𝑒𝑎𝑟 = ∗ 𝑀𝑎𝑥 𝑆ℎ𝑒𝑎𝑟𝑖𝑛𝑔 𝐹𝑜𝑟𝑐𝑒
𝑆ℎ𝑒𝑎𝑟 + 𝑡
1
➢ Assuming: Shear = t
3

1
∑Fnew = ∗ 203216.8 = 107131.35 N
1
+1
3
∑𝑭 = 𝟏𝟎𝟕𝟏𝟑𝟏. 𝟑𝟓 ≥ 𝟖𝟎 𝑲𝑵

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 ➢ Assuming: Shear = t
1
∑Fnew = ∗ 203216.8 = 101,608.4 𝑁
1+1
∑𝑭 = 𝟏𝟎𝟏, 𝟔𝟎𝟖. 𝟒 ≥ 𝟖𝟎 𝑲𝑵
➢ Assuming: Shear = 2t
1
∑Fnew = ∗ 203216.8 = 67738.93 𝑁
2+1

∑𝑭 = 𝟔𝟕𝟕𝟑𝟖. 𝟗𝟑 ≤ 𝟖𝟎 𝑲𝑵 ⇒ √
1
𝐹1 = 𝐹2 = ∗ 15707.96 = 5236 N
3
1
𝐹3 = ∗ 51050.88 = 17017 𝑁
3
1
𝐹4 = ∗ 120750 = 40250 𝑁
3

4. Die Block Thickness

𝐻 = 0.8(10 + 5𝑡 + 0.7√2𝑑)

𝐻1 = 0.8 (10 + 5(1) + 0.7√2(65)) = 18.38 𝑚𝑚

𝐻2 = 0.8 (10 + 5(1) + 0.7√2(20)) = 15.54 𝑚𝑚

𝐻3 = 0.8(10 + 5(1) + 0.7√177 + 120) = 21.65 ≃ 22 𝑚𝑚

∴ die block thickness = 22 mm

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 5. Expansion
e = (10 + 12𝑡) + 0.8𝐻
e = (10 + 12(1)) + 0.8(22) = 39.6 𝑚𝑚 ≃ 40 𝑚𝑚

∴ expansion = 40 mm

6. Punch & Die Dimension

➢ Clearance: 𝐶 = 𝛼 ∗ 𝑡 𝛼 = 0.075 for St.
⸫ 𝐶 = 0.075 ∗ 1 = 0.075 𝑚𝑚

1. Piercing
➢ 𝐷𝑝𝑢𝑛𝑐ℎ = 𝐷ℎ𝑜𝑙𝑒
➢ 𝐷𝑑𝑖𝑒 = 𝐷ℎ𝑜𝑙𝑒 + 2𝐶
1
2. Blanking 2

➢ 𝐷𝑝𝑢𝑛𝑐ℎ = 𝐷ℎ𝑜𝑙𝑒 − 2𝐶
➢ 𝐷𝑑𝑖𝑒 = 𝐷ℎ𝑜𝑙𝑒

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For Holes 1 & 2

Punch Die

∅20𝑚𝑚
∅20.15

𝐷𝑝𝑢𝑛𝑐ℎ = 20 𝑚𝑚 𝐷𝑑𝑖𝑒 = 20 + 2 ∗ 0.075 = 20.15 𝑚𝑚

For Hole 3

Punch Die

∅65𝑚𝑚
∅65.15
𝐷𝑝𝑢𝑛𝑐ℎ = 65 𝑚𝑚
𝐷𝑑𝑖𝑒 = 65 + 2 ∗ 0.075 = 65.15 𝑚𝑚
For blanking of the shape

Punch Die

R 60.075 mm R 60 mm
119.85 mm

120 mm

176.85 mm 177 mm

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 7. Piercing Punch Max Height
𝜋 2 𝐸𝐼𝑚𝑖𝑛
𝐿𝑚𝑎𝑥 =√
4𝐿𝑇(0.8𝑈𝑇𝑆)

𝜋 ∗ (20)4
𝜋2 ∗ 210 ∗ 103 ∗
𝐿𝑚𝑎𝑥 = √ 64 = 287.17 𝑚𝑚
4 ∗ 20𝜋 ∗ 1 ∗ (250)

8. Stripper Design
𝑤 122.4
𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝐻) = + 2𝑡 = + 2 ∗ 1 = 42.8 𝑚𝑚
3 3
⸫𝑯 = 𝟑𝟎 𝒎𝒎
𝑊𝑖𝑑𝑡ℎ (𝐵) = 𝑊 + 𝐶 = 122.4 + 2 = 124.4 𝑚𝑚
𝑆𝑡𝑟𝑖𝑝𝑝𝑒𝑟 𝑓𝑜𝑟𝑐𝑒 = 𝐾 ∗ 𝑃
𝑘 = 0.05 for piercing and 0.1 for blanking
⸫ 𝑠𝑡𝑟𝑖𝑝𝑝𝑒𝑟 𝑓𝑜𝑟𝑐𝑒 = 0.05(5236 + 5236 + 17017) + 0.1(40250)

= 5400 𝑁

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 9. Sequence layout
Sequence layout with consideration of expansion (red zone)

➢ expansion = 40 mm

10. Center of Pressure

∑ 𝐹. 𝑥 (21.2)(5236) + (158.2)(5236) + (268.5)(17017) + (447.5)(40250)
𝑥𝑜 = =
∑𝐹 (2)(5236) + 17017 + 40250
= 347.22 mm
∑ 𝐹. 𝑦 (2)(21.2)(5236) + (61.2)(17017) + (61.2)(40250)
𝑦𝑜 = =
∑𝐹 (2)(5236) + 17017 + 40250
= 55.02 mm

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 11. Drawings
Animation :

YouCut_20240608_064547214.mp4

Inventor files link

https://drive.google.com/file/d/1LEDTCHRFXOFR7IXWReeet1VZB7K4uouO/vi
ew?usp=sharing

Dimensions are in inches

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12. References
https://testbook.com/mechanical-engineering/types-of-dies
https://fractory.com
“Fine blanking history”Retrieved 2008-11-05.

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