PROJECT REPORT 2019-20

NO. CA 38, NIDIGE INDUSTRIAL AREA, MACHENAHALLI

SHIVAMOGGA–577222

PROJECT REPORT
ON
Done at SUPANGITA ENG PVT LTD
MANUFACTURING OF PROGRESSIVE TOOL

“LINTEL ASSEMBLY”

Submitted : PARAMESHA .T
Batch No : 6th
Roll No : 1240634
Duration : 2019-20

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This is to certify that Mr. PRAMESHA.T Bearing

Reg.No:1240634. has successfully completed the PROJECT REPORT
titled Manufacturing for “PROGRESSIVE PRESS TOOL” in partial
fulfillment of sessional requirements for the award of “DIPLOMA in TOOL
& DIE MAKING” from Government Tool Room & Training Centre
SHIVAMOGGA during the year 2019-2020.

PROJECT GUIDE. PRINCIPAL

Mr. DEEPAK KUMAR Mr. H.M. SURESH

DT&TC SHIVAMOGGA GT&TC

SHIVAMOGGA

PLACE : SHIVAMOGGA
DATE:

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EVALUATION SHEET

NAME : PARAMESHA .T BATCH : 6th

REG.NO : 1240634 YEAR : 2020

SL MAX MARKS
DESCRIPTION
NO. MARKS OBTAINED

01 COMPONENT ANALYSIS 20

02 TOOL DESIGN ANALYSIS 40

03 PROCESS PLANNING 25

04 ESTIMATION AND COSTING 25

05 TOOL MANUFACTURING PROCESS 50

06 TRAILS 15

07 DEFECTS & REMEDIES 15

08 PRESENTATION 10

TOTAL 200

SIGNATURE OF THE SIGNATURE OF

THE VIVA EXAMINER EVALUTOR

PREFACE

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The process of Tool & Die Making involves a series of direct stages, which
completes in a proper planning and proper thinking and co-ordination must result
in a successive tool.

This report gives a vision to specialize in and provide ‘state-of-art’ in Tool

& Die making and designing solutions like method of design that is plotting the
imaged idea (concept design) on the paper as design, dividing the total processing
into discrete module like raw material selection ,machining ,job follow-up ,
assembly and final tryout.

This project report has been prepared with an outlook to import optimum,
information about a tool in a more easily grasping in a shoot span of time.

This project report gives a detailed knowledge of the tool making

techniques, the difficulties involved, and the skill of a toolmaker. It develops a
theoretical knowledge and shows the expressing capacity of a toolmaker.

The aim of this project is to explain each subject from foundation of the
project in a simple and clear manner.

ACKNOWLEDGEMENT

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I express my sincere gratitude to Mr.H.RAGHAVENDRA Managing Director, Government

Tool room and Training Centre for providing me an opportunity to do the project work.

I am grateful to Mr. MUTTUKUMAR RManager Training

I am grateful indebted to Mr.SURESH H M Principal,

Mr. DEEPAK KUMAR V R Project Guide&Mr.NAGARAJ. H.P who was the driving force
behind myself while passing our project. His constant encouragement and assistance was
immense help and invaluable.

I thank all my instructors andoffice staff G.T&T.C shivamoggawho have imparted me the
knowledge to carry out the project courageously Lastly I thank one and all who had their
contributed directly or indirectly for completing this project.

I convey my sincere thanks to

Shri. RAJENDRA, DESIGN MANAGER,(SUPANGITA ENG PVT LTD)

Shri. BABU M, PRESS SHOP MANAGER (SUPANGITA ENG PV T LTD)

Shri. MUTTAYIA T.M, TOOL ROOM MANAGER (SUPANGITA ENG PVT LTD)

For helping me in completing this project and in-plant Training

To the entire personnel of tool room, design, engineering, for their Co- Press tool department,
inspection department and all my seniors operation and help given to me in this report

YOURS FAITHFULLY

PARAMESHA.T

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GT&TC AT A GLANCE

Govt. Tool Room & Training Center wasestablished in the year 1972, with
the assistance of Govt.of Denmark. It has became one of the leading tool room in
imparting training and reaching international standards in manufacturing processes,
Later in the year 1992 GTTC Mysore was established GT&TC SHIVAMOGGA
was established in the year 2010. Now GT&TC has its training centers throughout
Karnataka at Bangalore, Mangalore, Maddur, Gulbarga, Kanakapura, Hospet,
Kudalasangama …etc

G.T. &.T.C offer turnkey programs and package programs for tooling.
Product development and component manufacturing facilities. It has also
embarked upon research and development activities in advanced tooling and
machining techniques. It also has been constantly working for the development f
the component and system for various R&D organizations with a view to faster
self-reliance and technological up gradation. A part from this other major activities
of the centre promotion of purposeful technical education of the youth in INDIA,
by imparting the highest degree of skill through job oriented training in relevant
fields. It is also helping trainees to get exposure to the industries through industrial
training.

ABOUT OUR INSTITUTION

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GT&TC, SHIVAMOGGA centre was started in 2010 to cater to the needs of

local industries. And to import training programmed

“DIPLOMA IN TOOL & DIE MAKING”. The duration is Three years training
followed by one year compulsory industrial training.

Already GT&TC, SHIVAMOGGA is serving many industries in & around’

‘SHIVAMOGGA’ with a set of modern general purpose machine along with
the CNC machine

GT&TC offers turnkey programs and package programs for tooling,

Product development and component manufacturing facilities. It has also

embarked upon research and development activities in advanced tooling and

machining techniques.

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It also has been constantly working for the development of the

component and systems for various R&D organizations with a view to faster
self-reliance and technological up gradation. Apart from this other major
activities of the centre are promotion of purposeful technical education of
the youth in India, by imparting the highest degree of skill through job
oriented training relevant fields. It is also helping trainees to get exposure to
the industries through In-plant training.

SKILLING INDIA :

Based on forecasts, it is estimated that between 2012 and 2022, an

incremental demand (cumulative for ten years) for 8.47million people will be
generated in Karnataka.
In the next ten years, maximum demand is expected to b for semi-skilled
workers at 43% of the total incremental demand. This is expected to follow by
minimally skilled works at 27%, skilled workers at 25% and highly skilled
workers at the remaining 5%. As per the National Skill Development Corporation
(NSDC) report there is an incremental demand of skilled man power in
Karnataka, 2012 to 2022.
Skill Development Initiative by GTTC harnesses its global best-in-class
technology and manufacturing expertise to nurture excellence in the field of
technical education. GTTC aims to bridge the gap between industry requirements
and output from the current technical education system, by providing solutions
that make technical institutes get better aligned with industry needs and produce
students who are better industry-ready.

ABOUT SUPANGITA ENG PVT.LTD

BHOMMASANDRA

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MANAGING DIRECTOR : Sri. SURESH RAO

GENARAL MANAGER : Sri. VINOD
TOOL ROOM MANAGER : Sri. MUTTAYIA T.M
PROJECT COORDINATORS : Sri. GANESH

FEATURES; Machine shop, Press machines & Welding shop, Tool room,
SPECIALTY; FOUR TYPE TVS HANDLE BAR PROJECTS
1. JUPITOR
2. WIGO
3. ZUST
4. PEP
5. CHAIN CASE

SUPANGITA ENG PVT LTD: is a company of Indian multinational company.

Engaged in manufacturing of, CUSTOMER

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Supangita eng pvt limited has started in the year 1986 at Bangalore, with a
maximum tool manufacturing facility, but with great vision. This company initially
was manufacturing single stage, progressive tool & compound tools along With
component production for customer.

As the time changed, it has gradually grown substantially big, began to

supply various types of drum seals, Latch assemblies in large scale to many of the
industries in the country as well as outside.

Supangita eng pvt limited has earned very good name in Automobile parts
press components.

Department is assigned with respective responsibilities to reach the target.

The company has disciplined staff and turns out about hundred corersannually.

It is my fortunate that, GTTC has deputed me to this industry to learn

manufacturing techniques. I am thankful to GTTC& Supangita eng pvt limited, and
the staff for having given me a great opportunity to learn Tool & Die making in a
scientific method.

SYNOPOSIS

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The main objective of the Project work is to gain the knowledge in Press
working techniques and to give a clear idea about manufacturing process.

Any product to be manufactured invariably requires tools.

Tool is an aid for the production of sheet metal components in huge volume.
It should be accurate for successful functioning of the product. Tool making is a
combination of art, mathematics and science.

Design, Manufacturing and Functioning of Press tool depends entirely on

Tool maker; hence his role is very crucial.

This Project reveals the detail of Design & Manufacturing process for Press
Tool, literature survey for the sheet metal, its techniques, Steel material used in
tool making, Heat treatment parameters which have been carried out using the best
available facilities.

Detailed analyses of the component material, its properties & functional

aspects have been mentioned. The suitability of the machine for the press tool has
been checked and detailed analysis is carried out.

Material used in the manufacturing of this tool and its properties have been studied
and listed out.

CONTENTS

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Sl. No. Description Page No. From Page No. To

1.
INTRODUCTION OF PROJECT.
13 14
2. INTRODUCTION OF PRESS
32
TOOL. 15
3.
COMPONENT ANALYSIS. 38
33
4.
TOOL DESIGN ANALYSIS. 39 54
5. RAW MATERIAL SELECTION. 55 60
6. ESTIMATION 61 65
7. TERMINOLOGY. 66 70
8. PROCESS PLANNING 71 73
9. MANUFACTURING DETAILS. 74 107
10. HEAT TREATMENT 108 112
11. POLISHING 113 116
12. INSPECTION. 117 120
13. FINAL ASSEMBLY 121 124
14. COSTING 125 128
15. TRY OUT 129 131
16. DEFECTS AND REMIDIES. 132 133
17. CONCLUSION. 134 134
18. BIBLIOGRAPHY 135 135

INTRODUCTION

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INTRODUCTION TO THE PROJECT REPORT;

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Tool can be defined as a hardware necessary to produce any article in large

quantity, it can be a jig or a fixture used for rapid machining of parts. A Press tool
used to produce identical component with the same accuracy to the entire
component.

Press working is one of the most advanced and extensively used methods of
metal working. It is efficient, less labor – consuming while offering a sparing use of
materials and yielding adequately accurate products. In most cases press working is
the final operation requiring no further machining.

Press working equipments includes different presses and tools known as dies
or press tools. All the press working operations can be classified as cutting and non-
cutting

Since this project is based on both cutting and non- cutting operations it is
necessary to have knowledge of the reactions of stock material due to the operations.

Progressive tools are the tools in which there are two or more stations are
required for the component is performed stage wise. Progressive tool is more
expensive than any other tool. Progressive tool are preferred for the quality of the
component and mass production.

INTRODUCTION TO PRESS TOOLS

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Press tool is a device used to produce similar type of components with

desired Shape and size in large volume by appling the external force.

The press tool consists of two main halves. Top half & bottom half. Die
member will be the bottom half and punch member will be in the top half.

Die contours are made according to the shape of the component required.
Die will be a female member and punch will be a male member. These two halves
are aligned and pressed under force. Press working forces are setup, Guided &
controlled in machine referred as “PRESS”.

There are SIX types of press tools

 Simple tool
 Progressive tool
 Compound tool
 Combination tool
 Rubber tool
 Dinking
SIMPLE TOOL:

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In Simple Tool only one operation is performed at each stroke of the press in
a single station. In this tool there is no stage therefore only end stopper is fitted for
locating the strip of metal.

PROGRESSIVE TOOL:

In a Progressive Tool two or more operation is performed. Simultaneously at

a single stroke of the press by mounting the separate set of die and punches at two
or more different station. The strip of metal is progressed from one station to other
station till the complete part is obtained

COMPOUND TOOL:

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Compound Tool is quite different from a progressive tool. In Compound

Tool two or more cutting operations are performed during one stroke of the press
at one station of a tool only.

COMBINATION TOOL:

In a Combination Tool both cutting and non cutting operations are performed at
one station of the tool in every stroke of the press.

RUBBER TOOL:

In this tool blanking or forming operations employs a Rubber pad in the

punch holder and punch in the die block. It operates on the principle of that when
the Rubber is compressed it transmits the pressure in all the direction the Rubber
tends to flow in a cavity in order to exert full force against the part or the
component. This type of blanking or forming is called Guerin Process.

DINKING TOOL:

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To cut paper, leather, cloth, rubber and other soft materials a dinking tool is
used. The cutting edges penetrate the material and cut it. The dinking punch digs
into the base plate. The base plate may be made of wood, rubber or sometime
plastic material.

DIFFERENT TYPES OF OPERATIONS IN PRESS TOOLS:

In addition to piercing & blanking, various other shearing & non-shearing

operations can be carried out in press tools. They are

PRESS TOOLS CLASSIFIED

ADVANTAGES

1. Accuracy related to dimensions is consistent

2. Quality components are produced
3. High rate of production is possible resulting in reduction of the component
cost.

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DIS-ADVANTAGES

1. Initial investment is considerably high.

2. Tool needs good maintenance.
3. Normally, same tool cannot be used for different sheet thickness and profiles.
4. Skilled tool maker is a must for manufacturing and maintaining the tool.
5. Breakdown of the tool is very serious and accidents are expensive.

SOME OF THE MOST COMMON MATERIALS USED ARE

 Brass (hard & soft)
 Aluminum (hard & soft)
 Copper and tin
 Stainless steel
 Copper nickel
 PhosphorBronze

SHEARING PRESS TOOLS:

 Blanking
 Piercing
 Parting off
 Lancing
 Cut-off
 Notching
 Shaving
 Trimming etc.

NON-SHEARING PRESS TOOLS:

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 Bending
 Flanging
 Coining
 Embossing
 Forming
 Drawing
 Curling
 Dimpling Press tools mainly comprises of a punch (male) & die (female), which
process the sheet metal to achieve the final finished component

SHEARING OPERATION PRESS TOOLS

BLANKING

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It is a process of producing a flat piece part from sheet metal. In this process
entire periphery is cut & the cut piece is called “BLANK”. When all the operations
are accomplished and if the piece part is ready for assembly, then it is called
“COMPONENT”. The piece part that is removed from the strip is always the work
piece and the remaining strip is called “SKELETON” this operation is called
“BLANKING”.

NOTCHING

This operation removes small amount of material from either or both edges of
the strip or blank. Notching serve to shape the cut contours of the work piece in a
progressive die or to remove excess material before a drawing or forming
operation in a progressive die. The removal of excess material allows the metal to
flow or form without the interference of the excess material on the sides

TRIMMING

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It is also a secondary operation, which imparts a certain shape to the component

or side of the strip. Trimming may also be used to remove the excess metal, which
remains after deep drawing operation or die casting. This operation provide a
smooth edge and the outer contour will be neat.

CUT-OFF

It is the process of separating the piece part from the parent material. Hence the
material is cut in a straight line. No scrap is produced in cutting off operation. Cut-
off is also used to chop off the scrap strip skeleton as it leaves the die. This makes
the scrap much easier to handle and transport.

CAM PIERECING

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Piercing a number of holes simultaneously around the shell is done in a side

cam die. Side cam converts the up and down motion of a press ram into horizontal
motion or angular motion when it is required in the nature of the work.

DINKING

This operation is performed on non-metal sheets which do not require a

die. The cutting edge of the punch will be like a knife and when the operation
is done, placing the sheet on a wooden plank or soft plate the punch penetrates
into the material and the component will cling into the opening made in the
punch. This component is ejected by spring loaded shedder mounted in the
punch opening.

NON-SHEARING OPERATION PRESS TOOLS

BENDING
Bending is shaping the material around a straight axis, This extends
completely across the material. One or more bends may be involved in bend
dies. These dies are important class of press tools. The sheet material flow in
these tools is always uniform and its thickness remains unchanged
FORMING

The operation
of forming is
similar to
bending except
that the line of

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bend is along the curved axis instead of a straight one. The metal flow is not uniform.
Forming dies

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