e-ISSN: 2582-5208

International Research Journal of Modernization in Engineering Technology and Science

( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:08/August-2022 Impact Factor- 6.752 www.irjmets.com

DESIGN OF PROGRESSIVE TOOL FOR TOP STRIP CONNECTION

Vrushabh Lambade*1, Vaibhav Bankar*2
*1M.Tech Student, Dept. Of Mechanical Engineering Vidarbha Institute Of
Technology Nagpur, Maharashtra, India.
*2Assistant Professor, Department Of Mechanical Engineering Vidarbha Institute Of
Technology Nagpur, Maharashtra, India.
DOI : https://www.doi.org/10.56726/IRJMETS29562
ABSTRACT
The design and Manufacturing, along with the analysis of the Progressive press tool, are designed primarily to
carry out the operation on the sheet metal components. This is one crucial phase in sheet metal manufacturing.
The components are manufactured using piercing, punching, and blanking processes, which have high
dimensional accuracy; therefore, most industries depend on the press tool. The top connection strip is a part
that is used in the connection of the electrode of capacitors in series to get the more output voltage or current
generally, this type of series connection of capacitors are used in PFC (power factor correction) sectors for
controlling power factors in industrial plants, electricity department substation, etc. The top connection of the
capacitor is a sheet metal component made up of high purity copper material. Hence, based on the high
production requirement of the same, an advanced tool for the Manufacturing of the top connection is needed.
The project work consists of the design and Manufacturing of the progressive tool, the sequence of operations is
planned initially, and then the press tool is designed. The design will make in AUTOCAD 2016, and solid
modelling in Solid edge.
Keywords: Press Tool, Piercing, Blanking, Sheet Metal, Punching.
I. INTRODUCTION
The new top connection strip is the component which is made up of a sheet metal, and the material is of high
purity copper, which is platted with the Tin for the soldering connection with the electrode of the capacitor. The
design and development of the advanced tools for the sheet metal components is one of the crucial and critical
phases in the sheet metal industry. An advanced tool can perform a series of the operation on the sheet metal to
produce the final part as two or more stations during each press stroke to develop a workpiece as the strip
stock moves through the die. So that each working station performs one or more distinct die operations, but the
strip must move from the first station through another next station to produce a complete final part. Dies are
used in various forming and pressing stamping operations to obtain the required size and shape of the product.
Metal forming operations are essential in mass production skills, and the experience of the die designer is a
more critical aspect in the design and development of the die [1]. Press stamping is used as a prime preference
for the mass production of numerous mechanical components. Parts with a complex shape can be formed or
stamped by using a progressive die [2]. A new top connection strip used in the assembly of the PFC capacitor is
required to manufacture using the progressive die. As the requirement of the components significantly
increases by the customer, it is required to manufacture the components in less production time. Operations
like blanking, piercing, bending, forming, hole flanging, etc., can be performed using a press tool process. The
main operation that is accomplished using a press tool is actively piercing and blanking. Presswork is defined
as a chip-less manufacturing process by which various components are made from sheet metal. The main
features of the press tool are a frame that supports a ram or a slide and a bed and a source of mechanism for
operating the ram in line and routine with the bed [3].
COMPONENT DETAILS:
The New top strip connection used in a Power control Capacitor Assembly, the following component has to be
designed to meet its application.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:08/August-2022 Impact Factor- 6.752 www.irjmets.com

Figure 1: Product Drawing

II. MATERIAL PROPERTIES
1) Thickness of sheet – 1 mm.
2) Length of component – 76 mm.
3) Width of component – 35 mm.
4) Material of component – Copper ETP DIN 1751-E-Cu57-F25-1(Tin coating on both sides: 8um u 2um).
5) Shear strength – 150 Mpa @ 230C.
6) Pierced hole – ø8.5x2.
7) Flanged hole – ø4.7.
8) Tolerance stands for Components- ISO2769
III. DESIGN OF TOOL
The design of the press tool required the following data –
 Component drawing
 Work piece material
 Press equipment details
 Accuracy of the work piece
 Number of the work piece to be manufactured
 The entire life of the tool in terms of the number of components produced.
 Safety requirements.
Based on the above data, the design process is followed by the following steps.
 Strip layout
 Cutting force calculation
 Shearing clearance between punch and die
 Hole Flanging Calculation.
 Creation of bill of material
 Drafting of assembly and different parts.
In addition to the primary data listed above, only the following input was required for designing, and drafting
blanking dies using Solid edge.
 Type of blanking and piercing and hole flanging profiles.
 Dimensions of blanking contour with tolerances.
 The thickness of the strip.

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International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:08/August-2022 Impact Factor- 6.752 www.irjmets.com
 Centre of pressure.
 Dimensional details of all parts of the tool.
IV. DESIGN CONSIDERATION
1. The Size, shape, and Operations to be performed on the component.
2. Selection of the tool includes simple, progressive, compound, combination, etc.
3. Selection of proper strip layout.
4. In the Progressive tool, the strip layout must cover all the stages in proper sequence, considering the rigidity
of the die in mind.
5. We considered the Tonnage required & calculations related tools, such as economy factor, plate thicknesses,
etc.
6. Try to construct a tool that can be easily modified in the future.
7. Shank location should be given at the center of the tool.
8. The tool must be rigid considering its involvement in the type of products such as mass, batch, etc.
9. Re-sharpening allowance must be added to punch and die-cutting edges.
10. The tool must withstand all the lateral thrust acting on it during operation.
STRIP LAYOUT
Singe row single pass:-
The blanks are arranged identically in a single row in this strip layout. The strip is passed through the tool only
once to punch out the blanks from it.
In a single row single pass strip layout, the blanks are arranged in two possible ways:
1. Wide run
2. Narrow run
Wide run:-
Strip layout is a very commonly used strip layout. In a comprehensive run strip layout, the length of the
component is aligned with the width of the strip. Therefore the pitch distance has become shorter. This reduces
the cycle time and increases the production rate with easy strip feeding. In a comprehensive run layout, more
no. of blanks are produced from a given strip length.

Figure 2: Wide strip Layout

Narrow run:-
Strip layout is rarely used, because in this layout the pitch distance is large which increase the cycle time and
numbers of strips. This layout is used only when the grain direction of component is important.

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International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:08/August-2022 Impact Factor- 6.752 www.irjmets.com

Figure 3: Narrow strip Layout

Factor affecting the strip layout:-
The selection of strip layout depends upon following factors.
 Shape of the blank.
 Strip material.
 Production rate.
 Burr side.
 Width of the strip.
 Grain direction.
1) Front Scrap Bridge (A):-

Where,
t = Thickness of strip 1 mm.
w = width of strip 35 mm.

2) Front ,Back and scrap bridge (B) :-

When P < 2 inch
When P > 2 inch
Here P is pitch

Where,
l = Length of Component = 76 mm.
B = Scrap bridge = 1.5 mm

In our case pitch P is 77.5 mm which is greater than 2 “(i.e. 50.8 mm) hence front, back and scarp bride will be
calculated by -
When P > 2 inch

3) Strip width (H) :-

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Volume:04/Issue:08/August-2022 Impact Factor- 6.752 www.irjmets.com
Where,
W = width of component = 35 mm.
B = front and back scrap = 1.5 mm.

ECONOMY FACTOR CALCULATION:

It is a factor which tells about the utilization of strip. The utilization of strip should not be less than 60%. The
designer should try by position the blank in all possible ways to get the minimum 60% strip utilization.

Where,
Area of Blank = 2610 mm2.
No of Rows = 01 Nos.
Strip Width = 79 mm.
Pitch = 36.5 mm.

( )

( )

( )

Where,
Area of Blank = 2610 mm2.
No of Rows = 01 Nos.
Strip Width = 38 mm.
Pitch = 77.5 mm.

( )

( )
CONCLUSION:-
From the calculation of the economic factor, it was found that the narrow run strip layout has a 90.5% economy
factor and the comprehensive run strip layout has an 88% economy factor; hence it is efficient to go with the
narrow strip layout factor.
1. SELECTION OF PRESS:
The designer has to select the type of press to be used properly. The selection of press depends upon various
points. While selecting a press, the following points should be considered.
1) Force required cutting the metal
2) Stroke length
3) Size and type of die
4) Method of feeding and size of sheet blank
5) Shut the height
6) Type of operation.
Perimeter calculations:-
1) Perimeter for Pierced holes: - 36.1283 x 2 = 72.256 mm2 (Calculated from CAD).
2) Perimeter for Slots: - 78.5664x 2 = 157.1328 mm2. (Calculated from CAD).
3) Perimeter for Blanking: - 228.009 mm2. (Calculated from CAD).

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International Research Journal of Modernization in Engineering Technology and Science
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Volume:04/Issue:08/August-2022 Impact Factor- 6.752 www.irjmets.com
The numerical calculation was carried out to predict the scrap rate, scrap bridge, economic factor, cutting force,
stripping force, press selection, and calculation of different part sizes.
FORCE CALCULATION:-
1) Hole Flanging Force calculation:
( ) -----------------------------Eq-01
Where,
D Flanged hole diameter in mm
Flange hole punch diameter in mm.
Ultimate tensile strength in Mpa @ Room temperature for component material.
220 Mpa.

Where,
D Flanged hole diameter in mm.
t thickness of the sheet in mm.
H height of the hole flange in mm.
r Radius (fillet) in mm.

Figure 4: Hole Flange

Flange hole Punch diameter calculation.

.
Hole Flanging Force
( )
( )

2) Force calculation for Slot Piercing operations (both the slots):-

-----------------------------Eq-02
Where,
P Perimeter for Slots in mm2.
t thickness of the sheet in mm.

3) Force calculation for Hole Piercing operations (both the holes):-

-----------------------------Eq-03

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( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:04/Issue:08/August-2022 Impact Factor- 6.752 www.irjmets.com

4) Force calculation for Blanking operation :-

-----------------------------Eq-04

5) Total Force required to perform all the operations by the press:-

( ) ( )
( ) ( )
( ) ( ) ( ) ( )

6) Stripping Force calculation :-

( )
( )

7) Total Press tonnage required calculation:-

*( ) ( )+ * +

2. TOOL ASSEMBLY:

Figure 5: Progressive Tool assembly

V. RESULT & DISCUSSION
In the present study, the die for the strip of the copper (ETP DIN 1751-E-Cu57-F25-1) material from a 1 mm
thick sheet is designed using the AutoCAD. The mathematical calculation to define the various parameters, such
as shear strength, stripping force, press force, etc., is then used as the reference for the die design.
VI. CONCLUSION
In the operation of the metal, forging productivity is an essential concern as it has a direct impact on the cost of
production. To reduce operation time, it is prominent to use more than one operation in a single stroke of press
and increase productivity. It can be possible by using the progressive die in which the metal sheets can be
formed, cut & bends in one stroke of the press. It is recommended especially for products on which multiple
actions are planned on metal parts in progression. Besides the contribution of the progressive die to
productivity, these dies have limitations also. In the present study, the designed die has a blanking die and
punch mounted permanently on the die plates. If one part gets damaged during operation, it will cause all the
further operations. In the future, the detachable die design will be done to reduce the chances of failure of the
entire die.

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International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
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[3] B. Evangeline Design of Progressive Press Tool for Stator Lamination using Pro/Engineer. International
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[4] Harshal A chavan Design and analysis of progressive tool for an automobile components. IOP Conf:
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[5] Sandeep P.V. Design and Analysis of Progressive Tool for Photo Frame Hook IJIST-Vol 3 Issue 6, June
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[6] Ghugul Design of Progressive Press Tool for Mobile Stand IRJET – Vol 08 issue -08.
[7] S. Kumar Automation of strip-layout design for sheet metal work on progressive die Journal of
materials processing technology 1 9 5 ( 2 0 0 8 ) 94–100
[8] Khosa Design and Manafacturing of Progressive Press Tool International journal of Advances in
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[9] The past, The present and the Future-Computer Integrated Manafacturing vol-2 – R.U. Auyers W.
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[10] Tool Engineering Parameters – Indian society of Tool Engineers, (C.I.T.D.), and Hyderabad.
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[12] Feliks Stachowicz “Determination of the Hole-flangeability for thin Sheets” Acta Mechanica Slovaca 22
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[13] Khaidar Kaderov, Sergey Kireev1, Marina Korchagina1, and Aleksey Lebedev “Determination of
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