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International Journal of Modern Trends in Engineering and Research

www.ijmter.com e-ISSN No.:2349-9745, Date: 28-30 April, 2016

@IJMTER-2016, All rights Reserved 1025

Design of Multi sliding Tool to Increase in Productivity of Lock Plate- A Review

Sagar R. Ghuge1, Sachin P. Kakade2 1Department of Mechanical Engineering, MET’s Institute of Engineering, [email protected] 2Department of Mechanical Engineering, MET’s Institute of Engineering, [email protected] ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Abstract-The objective of project to increase productivity, reduce material handling cost, labour cost, eliminate operations, reduce raw material consumption and manufacturing time of lock plate with help of multi sliding machine tools design. Now days which are done by stamping with help of compound tools on mechanical press. To achieve these objectives we will design new 3D tool with the help of UG NX software. Keywords-Multi-sliding machine, Lock Plate, UG NX software, Increase Productivity, Raw material –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

I. INTRODUCTION

A four-slide, also known as a multi slide, multi-slide, or four-way, is a metalworking machine tool used in the manufacture high volume of small stamped components from bar or wire stock. The stamping press is described most simply as a horizontal press which uses cams to control tools. This machine is used for progressive or transfer stamping operations.Many people familiar with fourslide or multi sliding machines believe that it can do everything a punch press can do for small components. To put it simply, a fourslide machine is a stamping plant in itself.Progressive die uses in punch press to blank out metal parts and stampings, a slide machine goes a step further. Small strip cut are made in the metal strip, with the addition of slides, cams, stock straighten and slides feedsthese cuts into and around the strip, complicated shapes, forms and secondary operations can be completed before the final part is ejected from the machine. Though the complicated tooling, and may seem a bit expensive at first, often the amount savings in piece price by eliminating costly secondary operations can be quickly make up for high tooling cost.The raw materialfour-slides used in usually limited by its formability and not the machine capabilities. Usually the forming characteristics and bending radiallyare the most limiting factors. The mostly used materials are: Low-carbon cold rolled steel, Spheroid zed cold rolled spring steel, type 300 and 400 stainless spring steels,Beryllium-copper alloys, Copper alloys.

Figure 1: Multi sliding Machine Figure 2: Power Press

International Journal of Modern Trends in Engineering and Research (IJMTER) Volume 3, Issue 4, [April 2016] Special Issue of ICRTET’2016


II. LITERATURE REVIEW

Literature review shows that considerable amount of researches have been reported in experimental, modeling and analysis of air bending. The following relevant areas are reviewed: (a) Sheet metal bending and mechanics of spring back and bend force, (b) modeling of bending process and (c) Interstitial Free steel sheet. Clear and credible reviews of previous important literatures are briefly discussed here. A number of researches have been carried out on the performance of bending processes. Sheet metal bending is one of the most widely applied sheet metal forming operations. The understanding of the bending mechanics is aimed at obtaining two kinds of information important for industrial applications. KhooSuiyang, XieLihua, Zhao Shengkui and Man Zhihong et al [1] In this paper, multi surface sliding cooperative control scheme is presented and new multiple sliding surfaces are proposed. It is proven that, for the setup that each agent is described by a chain of integrators, where the last integrator is perturbed by a bounded disturbance; leader–follower consensus can be achieved on these sliding surfaces if the communication graph has a directed spanning tree. Also, sliding variables can be driven to the sliding surfaces in fast finite time by the non-smooth control law. The fast finite-time Lyapunov stability theorem, the terminal sliding control technique, and the adding a power integrator design approach are used in our proposed control. Simulation results demonstrate the effectiveness of the proposed scheme. Kim Hong Seok and KocMuammer et al [2] presented a rate independent anisotropic plasticity model accounting the Bauchinger effect and applied in FE forming and spring back analysis. investigated the effect of temperature gradient on the final part quality of lightweight materials and the stress distribution of the blank elements was compared to gain a fundamental understanding of the spring back mechanism in warm forming. They also predict spring back and bend allowance simultaneously in air bending process. The statistical design can be used to obtain as much information as possible from a minimum number of experiments. Over many decades the bending of sheets and their spring back has been studied by analytical approach and many useful results have been obtained. However, much less attention has been paid to the case of bending of sheets and spring back through statistical approach. Delivering reliable, high quality products at a low cost has become the key factor for survival in today’s global economy. For this fact, the prediction of spring back of the product at the design stage is very essential. Designing for quality is cheaper than trying to inspect after production. So, new philosophy, technology and advanced statistical tools must be employed to design the products of high quality at low costs. Response surface methodology is a collection of mathematical and statistical techniques which is useful for modeling and analysis of engineering problems. Daniel Lepadatu, AbdessamadKobi, Xavier Baguenard, Luc Jaulin et al [3] In manufacturing process, the quality of final products is significantly affected by both product design and process variables. However, historically tolerance research primarily focused on allocating tolerances based on product design characteristics of each component. This work proposes to expand the current tolerance practices, and presents a new optimization method of tolerance mechanical systems using interval computation for the prediction of system response. The proposed methodology is based on the development and integration of three concepts in process optimization: mechanical tolerance, response surface methodology, and interval computation method. An industry case study is used to illustrate the proposed approach. Harlow Gary et al [4] described the probability modeling to estimate variability in the dimensions of a component and the effect of stress-strain behavior; the model parameters and the statistical variability in material properties on spring back transformed into desirability function.



Perduijn and Hoogenboom et al [5] derived a simple explicit bending couple curvature relation for small and larger curvatures and they verified the model with experimental results. The second is an estimation of the bend force for selection of press capacity, strength analysis and design of dies. Vallance and Matlock et al [6] studied the friction behavior of zinc-based coated sheet steels and laboratory scale friction analysis techniques that involve sheet sliding over cylindrical dies also introduced a new test procedure for the bending under tension friction test. Reviewing the literature, it is found that a researcher has been studying the 10 phenomenon of spring back for nearly six decades. There have been diverse efforts to evaluate and/or decrease spring back in the sheet metal forming industry for a long time.

III. RESEARCH GAP

MD Industries is one of the popular manufactures in small Machining as well as sheet metal components like washers, shims, shafts etc. Sheet metal parts are manufactured by stamping root, because of complexity and functional requirement of part, designer has to introduce number of tools which result into more time for manufacturing, high labour cost and low productivity. The major advantage of the four-slide machine is its ability to complete all of the operations required to form the component from start to finish. Moreover, it can handle certain parts that transfer or progressive dies cannot, because it can manipulate from various axes. Due to this flexibility it reduces the cost of the finished part because it required less machines, setups, and handling. Also, because only one machine is required, less space is required for any given component. As compared to standard stamping presses the tooling is usually inexpensive, due to the simple tools design. A four-slide can commonly produce 20,000 to 70,000 finished parts per 16-hour shift, depending on the number of operations per part; this speed commonly results in a lower cost per part. Finally, this machine is only feasible to usage on high volume parts because of the long lead time required to set up the tooling.

IV. NEED OF INVESTIGATION We have taken the one part to study following parameters:- Part Name-Lock Plate Lock Plate is used in Cummins engine for locking purpose. Lock plate is manufacture by stamping root in three stages which is explain as below,

1. Blanking of outer profile and inner diameter piercing Operation :-

Figure 3: Banking and Pricing



2. ID forming :-

Figure 4: ID Forming

3. Bending Operation :-

Figure 5: Bending Operation

To eliminate above operation and convert it in to one stage we have to introduce new multi sliding tool.



V. OBJECTIVE

• To reduce raw material consumption. • To productivity should be increased more than the stamping. • To reduce material handling cost. • To reduce labour cost. • To eliminate operation. • To reduce manufacturing time.

VI. METHODOLOGY While the problem is being investigated on distinct fronts, this discreet work has been focus on new tooling & cam design which will help to increase the productivity and many more advantages. Possible design options would be deal with in the context of exact problem and the feasible solution is expected to be arrived through limited number of iterations. Only the critical area to be concern would be studied for the work and suitable solutions can be found out while concluding the work. Practically recommended solution will reduce cost of part and increase the productivity.

VII. ADVANTAGES No other solution or result offers a more comprehensive or powerful toolset for product development. NX delivers:

1. Advanced solutions for conceptual design, 3D modelling and documentation. 2. Multidiscipline simulation for structural, thermal, motion, flow multi physics and

optimization applications. 3. Complete part manufacturing solution for tooling, machining and quality inspection.

VIII. EXPECTED OUTCOME

Partially recommended solution will be achieved following points:

1. Increase in productivity. 2. Reduce raw material consumption. 3. Reduce labour cost. 4. Eliminate operations. 5. Reduce material handling.

REFERENCES

[1] Khoo S. ,Xie L., Zhao S. and Man Z. “Multi-surface sliding control for fast finite-time leader–follower consensus with high order SISO uncertain nonlinear agents” International Journal of Robust and Nonlinear Control 10 November 2014, Volume 24, Issue 16 pp 2388-2404.

[2] Kim H. and Koç M. “Numerical investigations on spring back characteristics of aluminum sheet metal alloys in warm forming conditions” J Mater Process Technol ”Journal of Materials Processing Technology 08/2008 204 (1-3):370-383.

[3] Lepadatu et al D. “Spring back of stamping process optimization using response surface methodology and interval computation” Quality Technology & Quantitative Management, June 2008, Vol. 6, No. 4, pp. 409-421.

[4] Harlow G. “Mechanistically based probability modeling, life prediction and reliability assessment” Metallurgical and Materials Transactions, May 2004, Volume 13, Number 1.

[5] Perduijn R. and Hoogenboom S. “The Pure bending sheet” Journal of Materials Processing Technology, 1 April 1995, Volume 51, Number 1, pp. 274-295(22).

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