Department of Mechanical Engineering

Design of Manufacturing Tools and Dies (MEng 5371)

Chapter Three
Design of Dies

1
By: Mulisa Jiregna (MSc)
 DIE DESIGN
What is die mean in manufacturing concept?
• The die may be defined as the female part of a complete tool for producing work in
a press.

• It is also referred to a complete tool consists of a pair of mating members for

producing work in a press. OR

• The word “die” in itself means the complete press tool in its entirely, with all the
punches, die buttons, ejectors, strippers, pads, and blocks, simply with all its
components assembled together.
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 DIE OPERATIONS
Just exactly what operations are performed in dies?
• Blanking: a predetermined shape of • Cut off: strip of suitable width is cut
piece is cut from the work piece. to length.

• Figure: A blank and strip from which • Figure: Part separated from strip in
it has been cut cut-off operation

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• Piercing: Piercing dies pierce holes in • Compound: compound dies pierce
previously blanked, formed or drawn and blank simultaneously at the same
parts. station.

• Figure: Holes pierced in previously • Figure: The part is blanked and

drawn part pierced simultaneously in a compound
die

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• Bending: Bending dies apply simple • Drawing: Drawing die transform flat
bends to stampings. A simple bend is sheets of metal into cups, shells, or
one in which the line of bend is other drawn shapes by subjecting the
straight. material to sever plastic deformation.

Figure: Stamping bent in a bending die Figure: Shell drawn from a flat sheet

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 CLASSIFICATION OF DIES
• The dies may be classified according to the types of press operation and according
to the method of operation.
1. According to type of press operation
According to this criterion, the dies may be classified as cutting dies and forming
dies.
i. Cutting Dies
• These dies are used to cut the metal by cutting or shearing action.
• The common cutting dies are: blanking dies, perforating dies, notching dies,
trimming dies, shaving and nibbling dies.
ii. Forming Dies
• These dies change the appearance of the blank without removing any stock.
• Theses dies include bending, drawing, and squeezing dies etc.

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2. According to the method of operation
i. Simple Dies
• Simple dies or single action dies perform single operation for each stroke of the
press slide.
• The operation may be one of the operation listed under cutting or forming dies.
ii. Compound dies
• In these dis, two or more operations may be performed at one station. Such dies
are considered as cutting tools since, only cutting operations are carried out.

Figure: Compound die producing washer by blanking and piercing simultaneously 7

iii. Combination Dies
• In this die also, more than one operation may be performed at one station.
• It is different from compound die in that in this die, a cutting operation is
combined with a bending or drawing operation, due to that it is called
combination die.

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 DIE COMPONENTS

The main components for die tool sets are;

• Die block – This is the main part that all the other parts are attached to.

• Punch plate – This part holds and supports the different punches in place.

• Blank punch – This part along with the blank die produces the blanked part.

• Pierce punch – This part along with the pierce die removes parts from the blanked
finished part.

• Stripper plate – This is used to hold the material down on the blank/pierce die and
strip the material off the punches.
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 BENDING DIE DESIGN
• Bending is the metal working process by which a straight length is transformed
into a curved length.
• During the bending operation, the outer surface of the material is in tension and
the inside surface is in compression.
• Here, due to the applied forces, the top layers are in tension and bottom layers are
in compression.

• The plane with no stresses is called the neutral axis.

• The neutral axis should be at the center when the material is elastically deformed.
• But when the material reaches the plastic stage, the neutral axis moves downward.
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 Conti…

The accuracy and success of the bending process depends upon the operating
parameters as well as,

• Material properties,

• Clearance,

• Radius of the die and punch,

• Friction condition etc.

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 TYPES OF BENDING

Bending can be divided in to;

i. V-bending

ii. U-bending

iii. Edge bending (Wiping die bending)

iv. Air bending

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 V-Bending

• One of the most significant sheet metal bending operations is V – Die bending.

• In V-bending, a wedge-shaped punch forces the metal sheet or strip into a wedge-
shaped die cavity.

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 Edge Bending (Wiping Die Bending)
• In edge bending, a flat punch forces the stock against the vertical force of the die.
• One edge of the sheet is bent to 90 degree while the other end is restrained by the
material itself and by the force of blank holder/pad.

Figure: Edge Bending

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 U-Die Bending and Channel Bending

• U- die bending and Channel Bending is performed when two parallel bending
axes are produced in the same operation.

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 Air Bending
• In air bending, there is no need to change any equipment or dies to obtain different
bending angles because the bend angles are determined by punch stroke.
• The forces required to form the parts are relatively small, but accurate control of
the punch stroke is necessary to obtain the desired bend angle.

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BENDING TERMINOLOGY

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 Bend Allowance
• Bend allowance refers to the extra length that needs to be reserved for the sheet
when bending the sheet to ensure that the shape after bending meets the
requirements.
• This is because during the bending process, the inner and outer surfaces of the
sheet will stretch or compress, and the bend allowance is used to compensate for
this change.
• Bend allowance, B = α (R + K T)
Where α = bend angle, radians
R = inside radius of the bend, mm
K = location of neutral axis from bottom surface (= 0.33 when R < 2T
and = 0.50 when R > 2T )
T = sheet thickness, mm

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 Bend radius

• As the ratio of the bend radius to the thickness of sheet (R/T) decreases, the
tensile strain on the outer fibers of sheet increases.

• If R/T decreases beyond a certain limit, cracks start appearing on the surface of
material. This limit is called Minimum Bend Radius for the material.

• Minimum bend radius is generally expressed in terms of the thickness of material,

such as 2T, 3T, 4T, etc.

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 Bending Force
• The bending load may be calculated from the knowledge of material properties
and the die characteristics.
• It is dependent on the sheet thickness and material properties.
• The force required to bend a material is calculated by;
Fb =
Where Fb = bending force, L = length of the bent part, s = ultimate tensile strength.
T = blank thickness
K = 1.33 for die opening of 8T
= 1.20 for die opening of 16T
= 0.67 for U bending
= 0.33 for a wiping die
W = width between the contact points or die opening dimension
= 8T for V-bends 20
 SPRING-BACK PHENOMENA
• When the bending pressure is removed at the end of the deformation operation,
elastic energy remains in the bent part, causing it to recover partially toward its
original shape.
• This elastic recovery is called spring back, defined as the increase in included
angle of the bent part relative to the included angle of the forming tool after the
tool is removed.
• The major problem in bending process is the spring back or spring-go.
• The spring back is dependent on the parameters such as
ratio of die radius to sheet thickness,
sheet thickness,
blank holder force and
coefficient of friction

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 Factors Affecting Spring -back
Some factors that increase spring-back are;
• Higher material strength;

• Thinner material;

• Lower modulus of elasticity;

• Larger die radius;

• Greater wipe-steel clearance;

• Less irregularity in part outline, and

• Flatter part-surface contour.

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 Reduction/Minimization of the spring-back

• Spring-back can be minimized with additional tensile stress through the thickness
by using;

i. Over-bending

ii. Bottoming

iii. Coining

iv. Stretch bending

v. Rotary bending

vi. Double bending

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 Conti…

i. Coining

• In coining, compressive stress is applied to bending region to increase the amount

of plastic deformation.

• This reduces the amount of spring-back.

Figure: Coining 24
 Conti…

ii. Bottom bending

• In bottom bending, the final position of the punch is set such that the clearance
between the punch and die surface is less than the blank thickness.

• As a result, the material yields slightly and reduce the spring-back.

Figure: Bottom Bending

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 Spring-back ratio

• The spring-back ratio is defined as the final angle after spring-back divided by the
initial stamping angle.

• The spring-back factor, K, will show the ratio of the final bend angle to the initial bend
angle.

• In figure below; bent material is shown in two positions:

Bent and closed in the die (angle α i) and

After unloading (angle α f).

• As it can be seen, after unloading bend angle is smaller than when being closed in the
die [Ri < Rf and αi > αf ]. 26
 Conti…

Figure: Illustration of spring – back phenomena

• Spring-back characterization is expressed by spring-back ratio (factor) K;
K=
Where; αf – bend angle after unloading
αi – bend angle - workpiece is closed in the die
• From the above equation it is evident that in case K = 1 there is no spring back (αi =
αf) and in case K = 0 complete elastic recovery of the bent material takes place (αf = 0).
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 DESIGN OF BLANKING AND PUNCHING DIES

• Blanking and punching dies are known as cutting dies. They may be simple,
combination, or compound.

• Blanking: is the operation of cutting a flat shape from sheet metal. The required
product of the operation is called blank and the hole and metal left behind is
discarded as waste.

• Punching/Piercing: is a cutting operation by which various shaped holes are

made in sheet metal.
It is similar to blanking, except that in punching, the hole is the desired
product, and the material punched out to form the hole being waste. 28
29
Conti…
Phases of the Blanking and Punching process

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• In phase I: the work material is compressed across and slightly deformed
between the punch and die,
The stress and deformation in the material do not exceed the elastic limit. This
phase is known as the elastic phase.
• In Phase II: the bent work material is pushed farther into the opening die by
the punch.
This concentration of outside forces causes plastic deformation at the rim of
the material.
At the end of this phase, the stress in the work material close to the cutting
edges reaches a value corresponding to the material shear strength, but the
material resists fracture. This phase is called the plastic phase.
• During Phase III: the strain in the work material reaches the fracture limit, and
micro-cracks appear which turn into macro-cracks, followed by separation of the
parts of the workpiece.

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 Design variables of Punching and Blanking Dies
The major variables in these processes are as follows;

a) Punch force, F;

b) Speed of the punch;

c) Surface condition and materials of the punch and die;

d) Condition of the blade edges of the punch and die;

e) Type of lubricant; and

f) Amount of clearance between the punch and die.

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 Blanking and punching clearance
• Clearance c, is the space between the punch and the die opening.
• It is the major factor determining the shape and quality of the blanked or punched
edge.
If the clearance is too large, the sheet metal is bent and subjected to tensile
stresses instead of undergoing a shearing deformation.
Clearance is generally expressed as a percentage of the material thickness, but
some authorities recommend absolute values.

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 Conti…
• The theoretical method expresses clearance as a function of thickness of the
material and the shear strength of the material.
That is;

Where;
T= thickness of material (mm)
k= a coefficient that depends on the type of die
= Most frequently uses, k = 0.01.
For a die of metal ceramic, k= 0.015 to 0.18.
= Shear strength of material and
UTS= Ultimate tensile strength
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 DESIGN OF DIE BLOCK
• A die block is a construction component that houses the opening and receives
punches

• The angle of the cone, α= 10˚ to 20˚ for material of thickness T <1 mm, and α
=25˚ to 45˚ for material of thickness T ≥ (1 to 5) mm.
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 Conti…
Die Block Dimensions

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The thickness of the die block H, and the width of the wall .
• The height (thickness) H of the block is calculated by the formula
H= (10+5T + 0.7
T= material thickness
Where
a, b = opening die dimensions
C= constants whose value depends on the mechanical properties of the work piece.

The wall thickness ‘e’ is given by the formula

e= (10 up to 12) + 0.8H
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• The bending stress of the die block is:

• For a rectangular die block, the following formula must be

• Where
• For round punch, the bending stress may be calculated by the formula

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Example:
For example, it may be required to calculate the dimensions of the rectangular die
block of heat treated alloy tool steel. The die block is supported by two supports at a
distance of l = 120mm.The workpiece material has a thickness of T =3mm and UTS
= 372MPa. The workpiece dimensions are a = 100mm and b = 120mm.
Solution:
The height of the die block(H) is;
H= (10+5T + 0.7
H= (10+5(3) + 0.7
The height of the die block can be rounded to H= 40 mm.
Then wall thickness e is;
e= (10 up to 12) + 0.8H
e= 12 + 0.8(40) = 12 + 32 = 44mm
The value of ‘e’ may be rounded to e = 50 mm.
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 Conti…
• The die block dimensions are:
A = a + 2e = 100 + 2(50) = 200mm
B = b + 2e = 200 + 2(50) = 300mm
• The blanking force is:
F = 2(a + b) T 0.8 (UTS)
F = 2(100 +200) (3) 0.8 (373) = 53.663KN
• The press capacity of the blanking die:
 The rated capacity of press is the force which the slide or ram with exert near
the bottom of the stroke.
Capacity = 1.1 x blanking force; which is 10% more than blanking force.

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 Conti…
• The bending stress is:

• These dimensions are acceptable because 402.6MPa<490.5MPa, that is

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 DESIGN OF PUNCH

• The main considerations when designing punches are;

they should be designed so that they do not buckle;

they should be strong enough to withstand the stripping force, and

they should not be able to rotate as a result of the cutting action.

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 Punch Face Geometry
• It is possible to control the area being sheared at any moment by making the
punch and die surface at an angle (beveled). The main types of punch face
geometries are;
a) Flat face surface,
b) Concave face surface,
c) Bevel face surface, and
d) Double bevel face surface.

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 Conti…
Methods for Assembling Punches
• When assembling the punch into a punch plate, or the die into the die block, a
certain tightness of fits is mandatory.
• Because of the high probability of damage, they must be designed so that they can
be easily removed and replaced.
• Deflection or buckling of punches may be avoided by making the body diameter of
the punch larger than the cutting diameter or by guiding the punch through
a bushing.

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 Conti…
• Sometimes it is necessary to insert a hardened backing plate between the head of
the punch and punch holder.
• Whether or not it is necessary to use a backing plate is dependent on the
specific pressure between the head of the punch and the punch holder. If the
following condition is satisfied.
P= =
The above result shows that backing plate is not necessary.

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 Conti…
• Total length of punch
The maximum length of a punch may be calculated with the aid of the
formula:

Where; Ltot = total length of the punch

d = punch diameter of the punch
E = modulus elasticity
t = thickness of punched material

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Punching force
• The general punching force formula;

Punching force = perimeter x thickness x shear strength

= Pe x t x

• If the tool shape is round or circular shape:

F=Dxtx

• Example: calculate punching force for rectangle tool with the dimension of
40mm x 60mm, the material is 4mm thick Stainless Steel T316L.

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Solution

The rectangle perimeter; P = 2 x (40 + 60) = 200mm = 0.2m

The material thickness, t = 4mm = 0.004m

The shear strength of Stainless steel = 482.63Mpa

Punching Force;

F = 0.2 x 0.004 x 482.63

= 0.386N

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Compression stress
For punching force F and areas of the punch A, the compression strength of the
punch is calculated by the formula;

Where ; F = Punching force,

A = punch cross section are

= permissible compression stress

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 Buckling calculation

• For a punch fixed at one end and guided at the other end, as shown in Fig.
above, the critical force may be calculated by using the Euler formula
Fcr =
• The critical force exerted by a guided punch is 8 times greater than exerted by a
free-end punch (un-guided punch).
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• Subsequently the critical length of an unguided round punch can be calculated:
lcrit =

• The maximal length of a guided punch is times larger than that of a force and
punch.

• The critical- buckling pressure for the guided punch is given by the relationship;

Pcri =

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 DESIGN OF STRIPPER PLATE

• When a punch shears its way through a work piece, the material contracts
around the punch to the degree that it takes a substantial force to withdraw the
punch from the material.

• Efficient removal of the workpiece and scrap from the die increases productivity,
quality, and workplace safety.

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Types of stripper
• Generally, there are two types of strippers: the solid stripper and the elastic
stripper.

Figure: mounting a simple solid stripper

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Stripper Force
• The force required to strip the material from the punch, may be calculate by the
following equation;
Fs = CsF
Where; Cs = stripping constant
F = Punch force
Values for Cs are given in Table

54
Conti…

55
 Conti…
• Helical springs, shown in the figure below, are used to produce
the force necessary to strip the scrap strip from the punch.
Fmax =

fmax =

F = Fmax L = (n+1.5)d+nS
• You must consider;
Maximum static force
Total deflection of the spring
Spring force
Length of the spring
Where; d = diameter of wire, D= outside diameter of helical spring,
τ= shearing stress, G = modulus of elasticity, n= number of active coils,
S = distance between two coils (S min =0.1d at maximum loaded spring). 56
• If rubber pads, as shown in Fig 5.43, are used to produce the force necessary to
remove the scrap strip from the punch.
• Maximum deflection is fmax = (0.35 upto 0.40)h
• The stripper force may be calculated by this formula; F = PA
where;
A = cross sectional area of rubber pad. According to Fig. 5.43, the cross sectional
area is; A = ()
p = permitted specific pressure for rubber pad. For Fmax = 0.40h,
p = 3.5Mpa

Figure: Rubber pad: a) non-loaded b) loaded

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Minimal Thickness of stripper Plates
The thickness of a stripper plate can be calculated by using the formula;
h= 1/3W + 2t
Where; h = minimum stripper plate thickness
W = stock width
t = stripper material thickness

Reading Assignment
Die components for guiding and stopping
• Stock guides, Guide rails, French notch punches, Pilots, and Die stops.

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 DRAWING DIE DESIGN
• Drawing is a metalworking process which uses tensile forces to stretch metal or
glass.
• As the metal is drawn (pulled), it stretches thinner, into a desired shape and
thickness.
Types of drawing operations
• Deep drawing
• Shallow drawing
• Wire drawing
• Bar or rod drawing

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Conti…

60
 Forces acting on drawn cup
• Blank-holder’s pressure,
• Friction between the drawn shell and other components of tooling

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Re-drawing
• Final shape of a container can be reached by more drawing steps, these
operations are called as re-drawings.

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 Deep drawing die design parameters
Drawing ratio

• Measurement of the amount of drawing performed on sheet metal blank can be

quantified.

• This can be done with the drawing ratio. The higher the drawing ratio, the more
extreme the amount of deep drawing.

• Drawing ratios can help determine the maximum amount of deep drawing
possible.

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 Conti…

• The drawing ratio is roughly calculated as; Dr =

Where Db = is the diameter of the blank and Dp = is the diameter of the punch.

• The limit to the drawing ratio for an operation is usually 2 or under.

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Percent reduction
The drawing operation relies on the ductility of the blank material.
The amount of straining or the draw ability is represented by the percentage
reduction which is expressed in terms of the diameter of the blank and the shell.
The percent reduction, P is given by; P = 100[1-

Table: Percent reduction

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Height of a shell

• The maximum height attainable from a given blank size can therefore be
calculated.
h=

Where; h = height of shell

D = blank diameter
d = mean diameter of shell
The height of a shell subjected to n- redrawing operations may be calculated
hn =

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Drawing Speed
• The speed with which the punch moves through the blank during drawing, is
termed as the drawing speed.

• Particularly harder and less ductile materials are likely to be excessively thinned
out due to excessive drawing speeds.
Table: Drawing speed of some elements

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Blank Size
• It is generally difficult to find the exact size of the blank needed for drawing a given
cup, because of thinning and thickening of the metal sheet during the drawing
operation.
• The diameter of the blank can be calculated using the following relations;

Where;
r = corner radius on the punch
h = height of the shell
d = outer diameter of the shell
D = blank diameter
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Drawing Force
 The forming force (P) necessary for a cylindrical drawing is the force with which
the punch pushes a circular blank into the die.
Referring to Figure 5.56; the forming force of cylindrical drawing becomes;

P=Kx
Where
P = drawing force
K = Coefficient
= circumference ratio (3.14)
d = drawing diameter
t = Plate thickness
= Tensile strength
The value of k is depend on the drawing ratios.

Figure 5.56: Drawing force

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Blank holding force

• The blank holding pressure required depends on the wrinkling

tendency of the cup, which is very difficult to determine.

• The maximum limit is generally to be one third of the drawing force.

Blank holding force =

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Clearance
• The clearance between the walls of the punch and the die is a very important
parameter in deep drawing operations.

Where; c = clearance
T = material thickness
k = coefficient

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Draw die radius
Higher the radius, higher would be the freedom for the metal to flow; it can be
made as large as possible.
Too small a radius causes the thinning and tearing of the side walls of the cups.

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Die diameter
• Die diameter for each draw can be determined using the following formula;
Die diameter = punch diameter + 2(clearance)

Punch diameter
• Punch diameter for the first draw is equal to the diameter of the cup to be drawn
(d), and for other draws equal The cup diameter at that draw.

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Number of draws
• Number of draw (s) necessary to produce the desired product (cup) depends on "cup
height over cup diameter" (h/d) ratio as shown in (Table b).
Table: The relationship between the (h/d) ratio and number of draws
If h/d < 0.75 the no. of draws =1
If 0.75 < h/d < 1.5 the no. of draws = 2
If 1.5 < h/d < 3 the no. of draws = 3
If 3 < h/d < 4.5 the no. of draws = 4

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 FORGING DIE DESIGN
• Forging is a manufacturing process involving the shaping of metal using localized
compressive forces.
• The blows are delivered with a hammer (often a power hammer) or a die.
• Forging is often classified according to the temperature at which it is performed;
i. Cold forging (a type of cold working),
ii. Warm forging, or hot forging (a type of hot working).
i. Cold forging process: the process where a metal is plastically deformed at room
temperature with application of huge pressure.
ii. Hot forging process: the process where a metal is plastically deformed above
the room temperature with application of low pressure.

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• Based on arrangement of Dies; forging can be classified as;
(a) open-die forging, (b) impression-die forging, and (c) flash-less (closed die)
forging.
a) Open Die Forging: the work is compressed between two flat (or almost flat) dies,
thus allowing the metal to flow without constraint in a lateral direction relative to
the die surfaces.

Figure: open-die forging

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b) Impression-die forging: the die surfaces contain a shape or impression that is
imparted to the work during compression, thus constraining metal flow to a
significant degree.
• In this type of operation, a portion of the work metal flows beyond the die
impression to form flash.

Figure: Impression-die forging

77
 Design parameters of forging die
a) Forging Temperature
• Increasing the hot forging temperature (which is far above the recrystallization
temperature of the material) reduces the flow stress, the strain hardening
coefficient and hence the resistance of the material to deform.
b) Friction and Lubrication
• The forging load applied to the die is transmitted to the workpiece through the die
interface. So, frictional conditions at the interface is vital to the metal flow.
• Appropriate lubricants are used during metal forming operation to reduce friction,
forging load and die wear, so as to improve the metal flow in the lateral direction.
• Lubrication is possible in cold forging and under condition of high forging
pressure and high temperature the lubricant is squeezed out or burnt. 78
c) Forge ability of the Material
• The forge ability of a metal refers to the ability to undergo deformation without
causing defects such as discontinuities or crack.
• The forge ability also depends on material characteristics such as tendency for grain
growth, oxidation and so on.
d) Shape factor of Component and Die
• The metal flow in the die cavity is greatly influenced by the geometry of component
and die.
• The simple shaped parts are easier to forge, compared to the complex shapes.
• The components having higher surface area per unit volume can be termed as a
complex shape for forging.
• As a result, forging load tends to increase for complete filling of the die cavity.

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e) Die Temperature
• Preheated dies are generally used in the hot forging process to avoid chilling effect at
die and workpiece interface which hinders the metal flow at surfaces.
• The heated dies also facilitate die filling and reduce forging pressures.
• Typically, the die is heated in the range of 250 - 400 ℃, based on complexity of
workpiece.
f) Draft Angle in Design
• Draft refers to the taper generated in the internal and external sides of a closed die
forging to facilitate easy removal of components from the die cavity.
• The selection of draft angle should be optimal, as excess draft angle increases
allowances in component; thus, increasing the final weight of component.

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g) Flash and Gutter Design
• Flash refers to the excess metal normally attached at the
periphery of the workpiece that is subsequently trimmed
in a separate die. It is formed in the flash land.
• The flash produced during closed-die forging is scrap
material and may in many cases have a volume that is
more than 50% of the final part volume.
• The choice of the appropriate width and thickness of the
flash land is an important part of the forging process
design.
• Flash Gutter is the cavity designed to accept the excess
metal extruded out through the flash land.
• The gutter must be large enough to accommodate the flash
produced.
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• For calculation of the flash width, the following empirical equation is used;
30 𝑡 where: w = flash width
𝑤=

√ [ ]
2 D = equivalent diameter
3 2𝐷
𝐷 + 1+ h = height of rib
h (2 𝑟 +𝐷
r = radial distance from center rib
t = flash thickness

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h) Design Considerations for Fillet and Corner Radii
• Design of fillet and corner radii affect grain flow, forging load, die wear, grain
flow and the amount of metal to be removed during machining.
• So, proper selection of the fillet and corner radii is a vital aspect in the forging
die design.
• As a rule, all possible sharp corners must be avoided in forging design as they
tend to weaken both the dies and finished forgings.
• Sharp corners in dies can lead to premature die failure due to fracture as a result
of associated stress concentrations, high stresses and so on.
i) Forging allowances
• Parts produced by hot forging require machining on surfaces that will locate with
other parts in a final product.
• Thus, the detailed shape features of a forging are developed from the required-
machined part by adding various allowances.
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j) Forging load in Impression die forging (IDF)
• Prediction of forging load in CDF is quite
difficult because of complexity involved:
Using empirical relations: P =
Where;
 = effective true stress
At = cross sectional area of the forging at the
parting line, including flash
C1 = a constant, depends on the complexity
of the forging
C1 = 1.2 to 2.5 for upsetting cylinder between
the flat dies, 3 to 8 for simple closed die
forging, 8 to 12 for more complex shapes
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 Blow and injection molding die Design
Blow Molding
 “It is a plastic processing technique which is used to produce hollow plastic parts
by inflating a heated plastic unit it fills a mold and forms the desired shape”

 The raw material used for processing in blow molding is called parison.

 Parison is a perform tube that is hollow and it has a hole at one end.

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 Injection molding
Injection molding is the most widely used polymeric
fabrication process.
The injection molding process is primarily a sequential operation that
results in the transformation of plastic pellets into a molded part.
Identical parts are produced through a cyclic process involving the
melting of a pellet or powder resin followed by the injection of the
polymer melt into the hollow mold cavity under high pressure.
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 Parameters for injection molding process
1. Material Parameters
• Amorphous, Semi crystalline
• Pressure-Volume-Temperature (PVT) Behavior
•Viscosity
2. Geometry Parameters
•Wall Thickness of Part
• Number of Gates
•Gate Location
•Gate Thickness and Area
•Type of Gates: Manually or Automatically Trimmed
3. Manufacturing Parameters
•Fill Time
•Packing Pressure Level
•Mold Temperature
•Melt Temperature
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Thank you!!

The End!!

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