Template Internship Report

Royal Mechanical
University
An Internship Report on
Design of Blanking Die (Press Tool)
Submitted in partial fulfillment for the award of

the degree of
Bachelor of Engineering
In
Mechanical Engineering
Internship carried out at

www.royal-mechanical.com
an online school for mechanical engineers owned by
Maxpertise Technology Labs Pvt. Ltd.
Bengaluru - 560074
Internship Report Submitted By

Name Roll No.
Manjunath 123456
Internal Guide External Guide

Dr. Shiva Shankar Mr. Prasannakumar Shankar
Professor & HOD CEO
Department of Mechanical Engineering Department of Tooling Design
College of Engineering Maxpertise Technology Labs Pvt. Ltd.
College of Engineering
Bengaluru - 560074
Internship Report: Design of Blanking Die (Press Tool) in Catia V5
Acknowledgment
I want to express my special thanks and sincere gratitude to the below individuals for the
opportunity, guidance, and support for this Internship's successful completion.
Dr. Shiva Shankar Mr. Prasannakumar Shankar

Professor & HOD CEO
Department of Mechanical Engineering Maxpertise Technology Labs Pvt. Ltd.
Mr. Ganesh
Assistant Professor
Department of Mechanical Engineering
Mr. Subramanya
Internship Co-Ordinator
Department of Mechanical Engineering
Thanks & Regards,

Manjunath (123456)
Page 1 / 57
About the Company
www.royal-mechanical.com
www.royal-mechanical.com is an online school for mechanical engineers owned by

Maxpertise Technology Labs Pvt. Ltd.
The objective of www.royal-mechanical.com is to offer job oriented courses for

mechanical engineres, bridge the gap between the academia and the industry.
www.royal-mechanical.com offers job orietend online courses in below areas
CAD Skills Technical Skills Soft Skills
 Catia v5  Tooling Design – Jigs,  How to Get Mechanical

 Fusion 360 Fixtures, and Press Tools Engineering Jobs?
 Product Design –  Spoken Engilish for
Automotive, Aerosapce, Mechanical Engineers
and Industrial
Automation.
 Geometric Dimensioning
and Tolerancing (GD&T)
www.royal-mechanical.com offers job orietend online courses in below domains
 Automotive
 Aerospace
 Industrial Automation
Please do visit www.royal-mechanical.com for more information.
Page 2 / 57
Internship Certificate
(After Printing the Report,
Replace this page with the
Internship Certificate provided by the company)
Page 3 / 57
Table of Contents
1. The objective of this Internship.....................................................................................................8
2. About Catia V5...............................................................................................................................8
3. About the Press & Press Tool.........................................................................................................8
4. About Blanking..............................................................................................................................8
4.1. Cutting Clearance...................................................................................................................9
5. The Design Process........................................................................................................................9
6. Design of Blanking Die (Press Tool)..............................................................................................10
6.1. Understand Requirements...................................................................................................10
6.1.1. The Part Material.........................................................................................................11
6.1.2. The Part Material Thickness.........................................................................................11
6.2. Concept Design (Strip Layout Design)..................................................................................11
6.2.1. Check Material Availability...........................................................................................11
6.2.2. Calculate Punch & Die Dimensions..............................................................................12
6.2.3. Calculate the Bridge Dimensions.................................................................................13
6.2.4. Calculate the Pitch.......................................................................................................14
6.2.5. Calculate the Material Utilization................................................................................15
6.2.6. Final Design of the Strip Layout Drawing.....................................................................16
6.3. Force and Tonnage Calculations..........................................................................................17
6.3.1. Perimeter Calculations.................................................................................................17
6.3.2. Shear Force Calculations..............................................................................................17
6.3.3. Tonnage Calculations...................................................................................................18
6.3.4. Press Selection & Specifications...................................................................................18
6.4. Detail Design........................................................................................................................20
6.4.1. Die Plate.......................................................................................................................20
6.4.2. Locator Pin...................................................................................................................21
6.4.3. Strip Guide Plates and the Strip Support Plate.............................................................22
6.4.4. Strip Pusher..................................................................................................................22
6.4.5. Die Back Plate..............................................................................................................25
6.4.6. Die Shoe.......................................................................................................................26
6.4.7. Guide Pillar...................................................................................................................26
6.4.8. Stroke End Block..........................................................................................................30
6.4.9. Die Assembly Lifting Hooks..........................................................................................30
6.4.10. Screws and Dowels for Die Assembly...........................................................................31
6.4.11. Blanking Punch.............................................................................................................31
Page 4 / 57
6.4.12. Stripper Plate...............................................................................................................32

6.4.13. Punch Holder...............................................................................................................36
6.4.14. Punch Back Plate..........................................................................................................36
6.4.15. Top Plate......................................................................................................................37
6.4.16. Guide Bush...................................................................................................................38
6.4.17. Punch Assembly Lifting Hooks......................................................................................38
6.4.18. Screws and Dowels for the Punch Assembly................................................................38
7. Manufacturing Drawings.............................................................................................................39
7.1.1. Assembly Drawing (Sheet -1).......................................................................................40
7.1.2. Assembly Drawing (Sheet -2).......................................................................................41
7.1.3. Die Plate Drawing.........................................................................................................42
7.1.4. Locator Pin Drawing.....................................................................................................43
7.1.5. Rear Strip Guide Plate Drawing....................................................................................44
7.1.6. Front Strip Guide Plate Drawing..................................................................................45
7.1.7. Strip Support Plate Drawing.........................................................................................46
7.1.8. Strip Pusher Drawing...................................................................................................47
7.1.9. Die Back Plate Drawing................................................................................................49
7.1.10. Die Shoe Drawing.........................................................................................................50
7.1.11. Blanking Punch Drawing..............................................................................................51
7.1.12. Punch Holder Drawing.................................................................................................52
7.1.13. Punch Back Plate Drawing............................................................................................54
7.1.14. Top Plate Drawing........................................................................................................55
7.1.15. Guide Pillar Drawing....................................................................................................57
7.1.16. Guide Bush Drawing.....................................................................................................58
8. Data Sheets..................................................................................................................................59
Table of Figures
Figure 1: Blanking Operation.................................................................................................................9
Figure 2: Illustration of Cutting Clearance.............................................................................................9
Figure 3: The Design Process...............................................................................................................10
Figure 4: The Part Drawing..................................................................................................................10
Figure 5: The Strip Layout Design Procedure.......................................................................................11
Figure 6: Raw Material Size.................................................................................................................12
Figure 7: Raw Material Slitting.............................................................................................................12
Figure 8: Feed Bridge Dimensions.......................................................................................................14
Figure 9: Edge Bridge Dimensions.......................................................................................................14
Page 5 / 57
Figure 10: Pitch Dimensions................................................................................................................15

Figure 11: Strip layout Drawing...........................................................................................................16
Figure 12: Component Perimeter........................................................................................................17
Figure 13: Press...................................................................................................................................19
Figure 14: Press Bolster.......................................................................................................................19
Figure 15: Press Adapter Plate.............................................................................................................20
Figure 16: Die Plate..............................................................................................................................21
Figure 17: Locator Pin..........................................................................................................................21
Figure 18: Strip Guide Plates and Strip Support Plate..........................................................................22
Figure 19: Spring Design Procedure.....................................................................................................22
Figure 20: Strip Pusher........................................................................................................................25
Figure 21: Die Back Plate.....................................................................................................................26
Figure 22: Die Shoe..............................................................................................................................26
Figure 23: Design Procedure – Guide Pillar..........................................................................................27
Figure 24: Guide Pillar.........................................................................................................................30
Figure 25: Stroke End Block.................................................................................................................30
Figure 26: Die Assembly Lifting Hooks.................................................................................................31
Figure 27: Screws and Dowels for Die Assembly.................................................................................31
Figure 28: Blanking Punch...................................................................................................................32
Figure 29: Stripper Plate, Stripper Springs, and Shoulder Bolt............................................................36
Figure 30: Punch Holder......................................................................................................................36
Figure 31: Punch Back Plate.................................................................................................................37
Figure 32: Top Plate.............................................................................................................................37
Figure 33: Guide Bush..........................................................................................................................38
Figure 34: Punch Assembly Lifting Hooks............................................................................................38
Figure 35: Screws and Dowels for Punch Assembly.............................................................................39
Table of Tables
Table 1: Objectives of Internship...........................................................................................................8
Table 2: Values of Cutting Clearance.....................................................................................................9
Table 3: Calculations – Cutting Clearance, Punch Shape & Die Shape.................................................13
Table 4: Feed Bridge Dimensions.........................................................................................................13
Table 5: Calculations – Feed Bridge & Edge Bridge..............................................................................13
Table 6: Calculations – Total Number of Components........................................................................15
Table 7: Utilization Calculations...........................................................................................................16
Table 8: Perimeter Calculations...........................................................................................................17
Table 9: Shear Force Calculations........................................................................................................18
Table 10: Press Tonnage Calculations..................................................................................................18
Table 11: Die Plate Thickness Calculations..........................................................................................21
Table 12: Strip Weight Calculations.....................................................................................................23
Table 13: Push Force Calculations.......................................................................................................23
Table 14: Spring Length Calculations...................................................................................................24
Table 15: Spring Constant Calculations................................................................................................24
Table 16: Maximum Spring Deflection Calculations............................................................................25
Page 6 / 57
Table 17: Strip Pusher Spring Specifications........................................................................................25

Table 18: Transition Slenderness Ratio Calculations............................................................................27
Table 19: Cross Section Area Calculations (guide Pillar.......................................................................27
Table 20: Area Moment of Inertia Calculations...................................................................................28
Table 21: Radius of gyration Calculations............................................................................................28
Table 22: Slenderness Ratio Calculations............................................................................................28
Table 23: Critical Buckling Stress Calculations.....................................................................................29
Table 24: Critical Buckling Load Calculations.......................................................................................29
Table 25: Actual Load Calculations......................................................................................................30
Table 26: Cutting Clearance Calculations.............................................................................................32
Table 27: Stripping Force Calculations.................................................................................................32
Table 28: Stripper Plate Thickness Calculations...................................................................................33
Table 29: Spring push Force Calculations............................................................................................33
Table 30: Stripper Stroke Calculations.................................................................................................34
Table 31: Spring Total Length Calculations..........................................................................................34
Table 32: Spring Constant Calculations................................................................................................35
Table 33: Spring Maximum Deflection Calculations............................................................................35
Table 34: Stripper Spring Specifications..............................................................................................35
Page 7 / 57
1. The objective of this Internship

Below mentioned are the top three objectives of the Internship carried out at Maxpertise
Technology Labs Pvt. Ltd., Bengaluru.
(1) (2) (3)
Learn Catia V5 Learn Design of Blanking Die Design of Blanking Die (Press
(Press Tool) Tool)
Learn the below-mentioned Learn Design of Blanking Die Mini Project: Design of
modules of Catia V5 for the "Power Screw Support Blanking die using Catia V5 for
 Sketcher workbench Bracket" of a "Car Scissor Jack" the below part.
 Part design workbench
 Assembly workbench
Insert the image of the
 Drafting workbench part/component.
Table 1: Objectives of Internship
2. About Catia V5
Catia is a Software developed by the French company DASSAULT SYSTEMES, which is used for
 CAD (Computer-Aided Design)
 CAM (Computer-Aided Manufacturing)
 CAE (Computer-Aided Engineering)
Full-Form of CATIA is Computer-Aided Three-dimensional Interactive Application.
Catia V5 is the most preferred design software by the world's leading companies in Automotive,
Aerospace, Defence, Transportation, Medical Devices, Industrial Machinery, Ship Building,
Architecture, Construction, Power, Petroleum, Engineering Services, and many more.
3. About the Press & Press Tool

Press: A Press is a Machine which provides the Force necessary to cut/form the sheet metal
workpiece
Press Tool: A "Press Tool" is a "Tool," which cuts or forms the sheet metal workpiece. "Press Tool" is
also Called "Stamping Die." Press Tool is used predominantly in the automotive industry.
4. About Blanking
Blanking is a shearing operation performed on the sheet metal.
Page 8 / 57
The Blank (Useful Product) is sheared from the Raw Material (Sheet Metal Strip)
Figure 1: Blanking Operation
4.1. Cutting Clearance

Cutting Clearance: The space/gap between Punch's cutting edge and the cutting edge of the die.
Proper clearance is very much essential for the shearing to happen
Figure 2: Illustration of Cutting Clearance
Cutting Clearance for Blanking (6% to 8% of sheet metal thickness)

Precision Blanking = 6% of sheet metal thickness
Ordinary Blanking = 8% of sheet metal thickness
Table 2: Values of Cutting Clearance
5. The Design Process

Below mentioned flow chart depicts the design process to design the Blanking Die (Press Tool)
Page 9 / 57
Figure 3: The Design Process
6. Design of Blanking Die (Press Tool)
6.1. Understand Requirements

Below mentioned drawing depicts part drawing for which the Blanking die (press tool) is designed.
Figure 4: The Part Drawing
Page 10 / 57
6.1.1. The Part Material

As per the part drawing, the part material is LOW CARBON HIGH STRENGTH COLD ROLLED STEEL AS
PER IS 14491 of GRADE: 260Y
As per IS 14491, for LOW CARBON HIGH STRENGTH COLD ROLLED STEEL AS PER IS 14491 of GRADE:
260Y
σy = 260 N/mm2
σt = 350 N/mm2
6.1.2. The Part Material Thickness

As per the part drawing, the part material thickness is 3.15mm.
6.2. Concept Design (Strip Layout Design)

Below mentioned flow chart depicts the design process to design the Strip Layout
Figure 5: The Strip Layout Design Procedure
6.2.1. Check Material Availability

Of all the sizes available with the material supplier, below mentioned raw material size is selected.
Length = 2500mm
Width = 1000mm
Page 11 / 57
Figure 6: Raw Material Size

The Raw material can be slit along its Length or its Width.
Slit along Length Slit Along Width
Figure 7: Raw Material Slitting
6.2.2. Calculate Punch & Die Dimensions

Calculations – Cutting Clearance, Punch Shape & Die Shape
Cutting Clearance = 8% of sheet metal thickness

(Considering Ordinary
= 8% x 3.15 mm
Blanking)
= 0.252 mm
Page 12 / 57
Die Opening Dimension = Component Dimension
= 62.5mm x 24mm
Punch Shape Dimension = Component Dimension - (2 * Cutting Clearance)
= (62.5 – (2 x 0.252)) mm x (24 – (2 x 0.252)) mm
= 61.996 mm x 23.496 mm
Table 3: Calculations – Cutting Clearance, Punch Shape & Die Shape
6.2.3. Calculate the Bridge Dimensions

Feed Bridge is a function of the length of the component.
Table 4: Feed Bridge Dimensions
Calculations – Feed Bridge & Edge Bridge
Feed Bridge = 1.25 * t
= 1.25 * 3.15
= 3.9375 mm
Edge Bridge = 1.2 * 3.9375
= 4.725 mm
Table 5: Calculations – Feed Bridge & Edge Bridge
Page 13 / 57
Figure 8: Feed Bridge Dimensions
Figure 9: Edge Bridge Dimensions
6.2.4. Calculate the Pitch

Pitch = Edge Bridge + Shape Opening Width Pitch = Edge Bridge + Shape Opening Length
= 3.9375 + 23.496 = 3.9375 + 61.996
= 27.434 = 65.934
Page 14 / 57
Figure 10: Pitch Dimensions
6.2.5. Calculate the Material Utilization
Calculations – Total Number of Components
1. Slit along the Length 2. Slit along the Width
Strip Width = 71.446mm 32.946mm
Strip Width with

= 71.446  0.3 mm 32.946  0.3
Tolerance
MMC of Strip Width = 71.746 mm 33.246 mm
Sheet Metal Width Sheet Metal Length

=
No. of Strips per Sheet MMC of Strip Width MMC of Strip Width
Metal 1000 2500

= = 13.9 = 13 = 75.2 = 75
71.746 33.243
Sheet Metal Length Sheet Metal Wi dth

=
No. of Components per Pitch Pitch
Strip 2500 1000

= = 91.1 = 91 = 15.2 = 15
27.434 65.934
No. of Strips per Sheet No. of Strips per Sheet
Total No. of Components = Metal x No. of Components Metal x No. of Components
per Sheet Metal per Strip per Strip
= 13 x 91 = 1183 75 x 15 = 1125
Table 6: Calculations – Total Number of Components
Page 15 / 57
By slitting the sheet metal along its length, we produce a higher number of components.
Utilization Calculations for Slit along the Length
Total No. of Components

= 1183
per Sheet Metal
Area of Component = 1438.65 mm2
Total Utilized Area
=
Areaof Sheet Meal
Material Utilization
= ¿ ) x 100
= 68%
Table 7: Utilization Calculations
6.2.6. Final Design of the Strip Layout Drawing
Figure 11: Strip layout Drawing
Page 16 / 57
6.3. Force and Tonnage Calculations

6.3.1. Perimeter Calculations
Figure 12: Component Perimeter
Perimeter Calculations
Perimeter = (53.48 * 2) + (24.7 * 2) + (0.95 * 4)
= 107.0 + 49.4 + 1.9
= 160.16 mm
Table 8: Perimeter Calculations
6.3.2. Shear Force Calculations

The formula to calculate the Shear Force is
0.8∗p∗t∗TS
Fsh = 1000
Calculations – Shear Force
Fsh = Shear Force tonnes = 14.41
p = Perimeter of Shear mm = 160.16
Page 17 / 57
t = Thickness of Sheet mm = 3.15
TS = Tensile Strength of Material kg/mm2 = 35.7
Table 9: Shear Force Calculations
6.3.3. Tonnage Calculations

The formula to calculate the press tonnage is
PT = 1.5 * F sh
Press Tonnage Calculations:
PT = Press Tonnage tonnes = 21.62
Table 10: Press Tonnage Calculations
6.3.4. Press Selection & Specifications

Press Capacity / Tonnage  Calculated Press Tonnage
We will design the press tool for the 40tonnes Press available in the production facility.
Below mentioned Press shall be used for the component production.
Page 18 / 57
Figure 13: Press
Press Bolster Drawing is as shown below.
Figure 14: Press Bolster
Press Adapter Plate Drawing is as shown below.
Page 19 / 57
Figure 15: Press Adapter Plate
6.4. Detail Design

The design of the press tool is created using Catia V5 software. All essential calculations related to
the press tool design are outlined in this chapter.
6.4.1. Die Plate

The die plate's function is to provide the cutting edge for shear or blank the sheet metal strip.
The formula to calculate the die plate thickness is
F sh∗L3
Td ¿ ∛ ( 16∗E∗W ∗δ ¿
Die Plate Thickness Calculations
Max. Allowable Die Plate

𝞭 = mm = 0.08
Deflection
Fsh = Shear Force kg = 14410
L = Length of Die Plate mm = 182.5
Page 20 / 57
E = Young's Modulus of Steel Kg/mm2 = 21.4 x 103
W = Width of Die Plate mm = 144
Td = The thickness of Die Plate mm = 28.1 ≈ 30
Table 11: Die Plate Thickness Calculations

The 3D design of the Die Plate using Catia V5 is shown below.
Figure 16: Die Plate
6.4.2. Locator Pin

The function of the locator pin is to locate the sheet metal strip along the feed direction.
The 3D design of Locator Pin using Catia V5 is shown below.
Figure 17: Locator Pin
Page 21 / 57
6.4.3. Strip Guide Plates and the Strip Support Plate

The function of the strip guide plates is to guide the sheet metal strip.
The function of the strip support plate is to support the sheet metal strip.
The 3D design of Locator Pin using Catia V5 is shown below.
Figure 18: Strip Guide Plates and Strip Support Plate
6.4.4. Strip Pusher

The strip pusher's function is to push the sheet metal strip against the rear strip guide plate. The
strip pusher is spring-loaded.
Below mentioned is the procedure to design the spring.
(2)
(1) (3)
Calculate the Spring
Calculate the Push Force Spring Selection
Constant
Figure 19: Spring Design Procedure
Strip Weight Calculations
Strip Width, W = 71.5 mm
Strip Length, L = 2500 mm
Strip Thickness, T = 3.15 mm
Page 22 / 57
Strip Volume, V =WxLxT

= 71.5 x 2500 x 3.15
= 563062.5 mm3
Density of Steel,  = 0.000008 kg/mm3
Strip Mass, m =Vx

= 563062.5 x 0.000008
= 4.5 kg
Acceleration due to Gravity, a = 9.8 m/s2
Strip Weight, F =mxa

= 4.5 x 9.8
= 44 N
Table 12: Strip Weight Calculations
Push Force Calculations
Strip Weight, F = 44 N
Co-efficient of Friction (Steel on Steel),  ≈ 0.7
Push Force, N =xF

= 0.7 x 44
= 30.8 N
The spring Force ≥ 30.8N
Table 13: Push Force Calculations
Spring Length Calculations
SPACE AVAILABLE = 28.5mm
SPACE AVAILABLE 90% TO 95% OF TOTAL LENGTH (FREE

LENGTH)
TOTAL LENGTH (FREE LENGTH) SPACE AVAILABLE

=
90%
28.5
=
0.9
Page 23 / 57
= 31.7mm
Generally, Springs are available in steps of 5mm length.
TOTAL LENGTH (FREE LENGTH) = 30mm
Table 14: Spring Length Calculations
Spring Constant Calculations
COMPRESSED LENGTH = SPACE AVAILABLE - STROKE

= 28.5 - 2
= 26.5mm
2mm is the interference what we have designed between the Strip Pusher and the Strip
@26.5mm we need the Push Force
SPRING CONSTANT PUSH FORCE

=
TOTAL STROKE
PUSH FORCE
=
TOTAL LENGTH - COMPRESSED LENGTH
15.4
=
30 - 26.5
15.4
=
3.5
= 4.4 N/mm
Select a Spring with Spring Constant 4.4 N/mm or more
Table 15: Spring Constant Calculations
Maximum Spring Deflection Calculations
MAXIMUM COMPRESSED = SPACE AVAILABLE – MAXIMIM STROKE

LENGTH = 28.5 - 3
= 25.5mm
Additional 1mm is the clearance between the Strip and the Front Strip Guide Plate
Page 24 / 57
MAXIMUM DEFLECTION TOTAL LENGTH - MAX. COMPRESSED LENGTH

= x 100
TOTAL LENGTH
30 - 25.5
= x 100
25.5
4.5
= x 100
25.5
= 15%
Select a Spring with an allowable deflection of 15% or more.
Table 16: Maximum Spring Deflection Calculations
Spring Selection (From Standard Catalogue)
Inner Diameter, Di > 10mm
Outer Diameter, Do 14mm
Wire Diameter, d 1.7mm
Free Length, L 30mm
Maximum Force, N 88.3N
Spring Constant, N/mm 4.4 N/mm
Max. Allowable Deflection (% of Free Length) > 15%
Table 17: Strip Pusher Spring Specifications
The 3D design of Strip Pusher using Catia V5 is shown below.
Figure 20: Strip Pusher
Page 25 / 57
6.4.5. Die Back Plate

The function of the die backplate is to absorb energy/force coming from the die plate.
The 3D design of Die Back Plate using Catia V5 is shown below.
Figure 21: Die Back Plate
6.4.6. Die Shoe

The function of the die shoe is listed below
 Absorbs the Force coming from the Die Plate.
 Used to Fasten the Die Assembly to Press Bolster using U-Slots
 Has Provision to mount the Guide Pillars.
The 3D design of Strip Pusher using Catia V5 is shown below.
Figure 22: Die Shoe
6.4.7. Guide Pillar

Guide pillars and the guide bushes are used to locate the die assembly and the punch assembly.
Page 26 / 57
Below mentioned is the procedure to design the Guide Pillar.
Figure 23: Design Procedure – Guide Pillar
The formula to calculate the Transition Slenderness Ratio is
TSR = √ 2 π 2E
Sy
Transition Slenderness Ratio Calculations
E = Young's Modulus of Steel N/mm2 = 210 x 103
Sy = Yield Strength of Steel N/mm2 = 250
TSR = Transition Slenderness Ratio - = 128.8
Table 18: Transition Slenderness Ratio Calculations
The formula to calculate the Cross-Sectional Area is

πd2
A= 4
Cross Section Area Calculations (Guide Pillar)
d = The diameter of the Pillar mm = 25
A = Cross Sectional Area mm2 = 314.2
Table 19: Cross Section Area Calculations (guide Pillar
Page 27 / 57
The formula to calculate the Area Moment of Inertia Calculations is mentioned below.
πd4
I= 64
Area Moment of Inertia Calculations
d = The diameter of the Pillar mm = 20
I = Area Moment of Inertia mm4 = 7854.0
Table 20: Area Moment of Inertia Calculations
The formula to calculate the Radius of Gyration is mentioned below.
Rg = √ I
A
The Radius of Gyration Calculations
I = Area Moment of Inertia mm4 = 19174.8
Rg = Radius of Gyration mm = 5.0
Table 21: Radius of gyration Calculations
The formula to calculate the Slenderness Ratio is mentioned below.

Le
SR = Rg
Slenderness Ratio Calculations
L = Length of Pillar mm = 230-50 = 180
Le = Effective Length of Pillar mm = 2 x 180 = 360
Rg = Radius of Gyration mm = 5.0
SR = Slenderness Ratio - = 72
Table 22: Slenderness Ratio Calculations
Page 28 / 57
The formula to calculate the Critical Buckling Stress is mentioned below.

π2E
σ cr = SR 2
Critical Buckling Stress Calculations
E = Young's Modulus of Steel N/mm2 = 210 x 103
SR = Slenderness Ratio - = 72.0
σ cr = Buckling Stress N/mm2 = 399.8
Table 23: Critical Buckling Stress Calculations
The formula to calculate the Critical Buckling Load is mentioned below.
F cr =σ cr A
Critical Buckling Load Calculations
σ cr = Buckling Stress N/mm2 = 399.8
F cr = Buckling Load N = 125604.1
Table 24: Critical Buckling Load Calculations
Actual Load Calculations
Shear Force, Fsh = 14410 kg

= 141362.1 N
No. of Pillars =2
Actual Force / Pillar 141362.1

=
2
= 70681.1 N
Critical Buckling Load, F cr = 125604.1 N
Page 29 / 57
F cr  Actual Force/Pillar
Design is Safe
Table 25: Actual Load Calculations
The 3D design of Guide Pillar using Catia V5 is shown below.
Figure 24: Guide Pillar
6.4.8. Stroke End Block

The Stroke End Block acts as a stopper to indicate the bottom dead center.
The 3D design of Stroke End Blocks using Catia V5 is shown below.
Figure 25: Stroke End Block
Page 30 / 57
6.4.9. Die Assembly Lifting Hooks

The function of the lifting hooks is to lift the die assembly.
The 3D design of Lifting Hooks using Catia V5 is shown below.
Figure 26: Die Assembly Lifting Hooks
6.4.10. Screws and Dowels for Die Assembly

The screws are used to fasten, and the dowels are used to locate the functionally critical parts.
Catalog parts in Catia V5 are used for the 3D assembly.
Figure 27: Screws and Dowels for Die Assembly
6.4.11. Blanking Punch

The Blanking Punch is used in combination with a Die Plate to Blank the sheet metal.
Page 31 / 57
It has the cutting edge to shear the sheet metal.

For the blanking operation, the cutting clearance is provided on the Punch.
Cutting clearance Calculations
= 8% of the sheet metal thickness
= 0.08 x 3.15 = 0.252mm
Table 26: Cutting Clearance Calculations
The 3D design of Blanking Punch using Catia V5 is shown below.
Figure 28: Blanking Punch
6.4.12. Stripper Plate

The function of the Stripper Plate is to Strip the Sheet Metal Strip from the Punch.
The formula to calculate the stripping Force is
F st=0.1∗Fsh
Stripping Force Calculations
Fst = Stripping Force tonnes = 1.44
Table 27: Stripping Force Calculations
The formula to calculate the thickness of the stripper plate is

F s t∗L 3
Ts ¿ ∛ ( 16∗E∗W ∗δ ¿
Stripper Plate Thickness Calculations
Page 32 / 57
𝞭 = Max. Allowable Stripper Plate Deflection mm = 0.08
Fst = Stripping Force kg = 1440
L = Length of Stripper Plate mm = 182.5
E = Young's Modulus of Steel Kg/mm2 = 21.4 x 103
I = Moment of Inertia mm4
W = Width of Stripper Plate mm = 144
Ts = The thickness of the Stripper Plate mm = 13
Table 28: Stripper Plate Thickness Calculations
Below mentioned is the procedure to design the spring.
(2)
(1) (3)
Calculate the Spring
Calculate the Push Force Spring Selection
Constant
Push Force Calculations
PUSH FORCE = STRIPPING FORCE

= 14126.4 N
NO. OF SPRINGS =4
PUSH FORCE / SPRING TOTAL PUSH FORCE

=
NO . OF SPRINGS
14126.4
=
4
= 3531.6N
Table 29: Spring push Force Calculations
Stripper Stroke Calculations
Page 33 / 57
STRIPPER STROKE = STRIP THICKNESS + PUNCH ENTRY INTO

DIE + 1
= 3.15 + 1 + 1
= 5.15mm
Table 30: Stripper Stroke Calculations
Spring Total Length Calculations
SPACE AVAILABLE = COMPRESSED LENGTH + STRIPPER

STROKE
= 60 + 5.15
= 65.15mm
SPACE AVAILABLE 90% TO 95% OF TOTAL LENGTH (FREE

LENGTH)
TOTAL LENGTH (FREE LENGTH) SPACE AVAILABLE

=
90%
65.15
=
0.9
= 72.4mm
Generally, Springs are available in steps of 5mm length.
Table 31: Spring Total Length Calculations
Spring Constant Calculations
COMPRESSED LENGTH = 60mm
@60mm we need the Push Force of 3531.6N
Page 34 / 57
SPRING CONSTANT PUSH FORCE

=
SPRING STROKE
=
PUSH FORCE
3531.6
=
70 - 60
3531.6
=
10
= 353.16 N/mm
Select a Spring with Spring Constant 353.16 N/mm or more
Table 32: Spring Constant Calculations
Spring Maximum Deflection Calculations
MAXIMUM COMPRESSED LENGTH = 60mm
MAXIMUM DEFLECTION =
TOTAL LENGTH
x 100
70 - 60
= x 100
70
10
= x 100
70
= 14.29%
Select a Spring with an allowable deflection of 15% or more
Table 33: Spring Maximum Deflection Calculations
Spring Selection
Free Length, L 70mm
Spring Constant, N/mm ≥ 353.16 N/mm
Page 35 / 57
Maximum Allowable Deflection (% ≥ 15%

of Free Length)
Inner Diameter, Di 17.5mm
Outer Diameter, Do 35mm
Spring Constant, N/mm 441 N/mm
Table 34: Stripper Spring Specifications
The stripper plate's 3D design, the die spring, and the shoulder bolt using Catia V5 are shown below.
Figure 29: Stripper Plate, Stripper Springs, and Shoulder Bolt
6.4.13. Punch Holder

The Function of the Punch Holder is to Hold and Accurately Position the Punch.
The 3D design of the Punch Holder using Catia V5 is shown below.
Page 36 / 57
Figure 30: Punch Holder
6.4.14. Punch Back Plate

The Function of the Punch Back Plate is to Absorb the Force coming from the Punch.
The 3D design of the Punch Back Plate using Catia V5 is shown below.
Figure 31: Punch Back Plate
6.4.15. Top Plate

The Function of the Top Plate is listed below
 Holds all the parts of the Punch Assembly.
 Absorbs the Force coming from the Punch and the Punch Back Plate.
 Used to Fasten the Punch Assembly to Press Slide / Adaptor Plate using U-Slots
 Has Provision to mount the Guide Bushes.
The 3D design of the Top Plate using Catia V5 is shown below.
Page 37 / 57
Figure 32: Top Plate
6.4.16. Guide Bush

Guide pillars and the guide bushes are used to locate the die assembly and the punch assembly.
The 3D design of the Guide bush using Catia V5 is shown below.
Figure 33: Guide Bush
6.4.17. Punch Assembly Lifting Hooks

The function of the lifting hooks is to lift the Punch assembly.
The 3D design of Lifting Hooks using Catia V5 is shown below.
Page 38 / 57
Figure 34: Punch Assembly Lifting Hooks
6.4.18. Screws and Dowels for the Punch Assembly

The screws are used to fasten, and the dowels are used to locate the functionally critical parts.
Catalog parts in Catia V5 are used for the assembly.
Figure 35: Screws and Dowels for Punch Assembly
7. Manufacturing Drawings
All the manufacturing Drawings, including the assembly drawings of the Press Tools, are shown in
this chapter. The drawings are created using Catia V5.
Page 39 / 57
7.1.1. Assembly Drawing (Sheet -1)
Insert the drawing in this space
Page 40 / 57
7.1.2. Assembly Drawing (Sheet -2)
Page 41 / 57
7.1.3. Die Plate Drawing
Page 42 / 57
7.1.4. Locator Pin Drawing
Page 43 / 57
7.1.5. Rear Strip Guide Plate Drawing
Page 44 / 57
7.1.6. Front Strip Guide Plate Drawing
Page 45 / 57
7.1.7. Strip Support Plate Drawing
Page 46 / 57
7.1.8. Strip Pusher Drawing
Page 47 / 57
7.1.9. Die Back Plate Drawing
Page 48 / 57
7.1.10. Die Shoe Drawing
Page 49 / 57
7.1.11. Blanking Punch Drawing
Page 50 / 57
7.1.12. Punch Holder Drawing
Page 51 / 57
7.1.13. Punch Back Plate Drawing
Page 52 / 57
7.1.14. Top Plate Drawing
Page 53 / 57
7.1.15. Guide Pillar Drawing
Page 54 / 57
7.1.16. Guide Bush Drawing
Page 55 / 57
8. Data Sheets
Page 56 / 57

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Royal Mechanical

Submitted in partial fulfillment for the award of

Internship carried out at

Internship Report Submitted By

Internal Guide External Guide

Dr. Shiva Shankar Mr. Prasannakumar Shankar

Thanks & Regards,

About the Company

www.royal-mechanical.com is an online school for mechanical engineers owned by

The objective of www.royal-mechanical.com is to offer job oriented courses for

www.royal-mechanical.com offers job orietend online courses in below areas

CAD Skills Technical Skills Soft Skills

 Catia v5  Tooling Design – Jigs,  How to Get Mechanical

www.royal-mechanical.com offers job orietend online courses in below domains

Please do visit www.royal-mechanical.com for more information.

6.4.12. Stripper Plate...............................................................................................................32

Figure 10: Pitch Dimensions................................................................................................................15

Table 17: Strip Pusher Spring Specifications........................................................................................25

1. The objective of this Internship

(1) (2) (3)

Table 1: Objectives of Internship

3. About the Press & Press Tool

Figure 1: Blanking Operation

4.1. Cutting Clearance

Figure 2: Illustration of Cutting Clearance

Cutting Clearance for Blanking (6% to 8% of sheet metal thickness)

5. The Design Process

Figure 3: The Design Process

6. Design of Blanking Die (Press Tool)

6.1. Understand Requirements

Figure 4: The Part Drawing

6.1.1. The Part Material

6.1.2. The Part Material Thickness

6.2. Concept Design (Strip Layout Design)

Figure 5: The Strip Layout Design Procedure

6.2.1. Check Material Availability

Figure 6: Raw Material Size

Slit along Length Slit Along Width

Figure 7: Raw Material Slitting

6.2.2. Calculate Punch & Die Dimensions

Cutting Clearance = 8% of sheet metal thickness

Die Opening Dimension = Component Dimension

Punch Shape Dimension = Component Dimension - (2 * Cutting Clearance)

= (62.5 – (2 x 0.252)) mm x (24 – (2 x 0.252)) mm

Table 3: Calculations – Cutting Clearance, Punch Shape & Die Shape

6.2.3. Calculate the Bridge Dimensions

Table 4: Feed Bridge Dimensions

Calculations – Feed Bridge & Edge Bridge

Feed Bridge = 1.25 * t

Edge Bridge = 1.2 * 3.9375

Table 5: Calculations – Feed Bridge & Edge Bridge

Slit along Length Slit Along Width

Figure 8: Feed Bridge Dimensions

Slit along Length Slit Along Width

Figure 9: Edge Bridge Dimensions

6.2.4. Calculate the Pitch

= 3.9375 + 23.496 = 3.9375 + 61.996

Figure 10: Pitch Dimensions