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Design and Analysis of a Press Tool for Retainer used in Lower Door Hinge of
Automobile

Conference Paper · January 2017

DOI: 10.21647/ICCTEST/2017/48972

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 Proc. of Int. Conf. on Current Trends in Eng., Science and Technology, ICCTEST

Design and Analysis of a Press Tool for Retainer used

in Lower Door Hinge of Automobile
Dharshan B G1*, Ananthapadmanabham K C2 and Hareesha N G3
1,2
Don Bosco Institute of Technology/Mechanical Department, Bengaluru, India
Email: dharshubg@gmail.com, kcananth2000@yahoo.co.in
3
Dayananda Sagar College of Engineering/Aeronautical Engg Department, Bengaluru, India
Email: hareeshang@gmail.com

Abstract—The scope of the work is to design and analysis of a press tool for component
retainer which should meet the production requirement of 100,000 components for an
automobile. To achieve this press tool is designed for producing a component in a single
stroke in two stages and to optimize production rate and manufacturing cost. Based on
features in the component, compound die is designed which can perform blanking and
piecing operation in first stage followed by bending operation in the second stage. The
structural analysis was carried out for the forming die and punches which shows that both
the deflections and the stresses are well within the limits.

Index Terms— Retainer, press tool, die sets, blanking die, piercing punch, forming die and
punch.

I. INTRODUCTION
Press tools is most widely used for a component which is fabricated in sheet metal may vary from a tiny item
in a wrist watch to a large aircraft part with complex shapes, manually it is very difficult to manufacture a
sheet metal components which is having complex shapes and having dimensional importance in its
applications.Now a day’s practice is to produce most of the sheet parts of any shape by using specially
designed press tools and other combination of operations. The design of press tools and its manufacturing
procedure are highly specialized and knowledge intensive in nature stampings are parts cut and formed from
sheet metal. This sheet metal stampings have now replaced many components which were earlier cast or
machined. Material economy and the resultant reduction in weight and cost, high productivity, use of
unskilled labour and high degree of possible precision have rendered press work indispensable for many
mass produced goods, such examples can be found in automobiles, aircraft, house hold articles, electronic
and electrical appliances and others.This work covers the design and analysis of a press tool die set for the
manufacture of a hot rolled sheet component “retainer”, aimed at high productivity. A new tool with mass
productivity and precise component are the primary requirements. To accomplish this through careful
examination of the sheet metal component sample (3D solid model), geometric profiles, material
Specification was the first step. Design exercise involves analysis of product, materials, processes, resources-
equipment, quality, productivity and costs to design the tooling and develop the plan for its fabrication.

Grenze ID: 02.ICCTEST.2017.1.45

© Grenze Scientific Society, 2017
II. METHODOLOGY
A. Component Details
The component “retainer” under consideration is a rectangular component of uniform thickness 1.4mm and
size 92mm x 60mm. The component requires blanking of rectangular piece of size 103mm x 60mm, two
pierced hole of Φ9mm and forming of the sheet to a depth of 13mm throughout the width of the component.
As per the customer requirement gang stage tool is designed. Isometric view of the component is shown in
Figure 1.

Figure 1. Component drawing

B. Materials used in press tool

Steels play an important role in manufacturing press tools. Because tool life is governed by the steel used,
development and economical operation of the press tool is based on choice of materials. Steels used must be
of suitable compositions and produced under best possible mill conditions. Appropriate heat treatment is also
an important factor in determining tool operation. Tool materials must satisfy the Structural soundness and
uniformity, Good machinability, sufficient strength and hardness to resist deformation in service, sufficient
toughness to resist cleavage and erecting, Wear resistance and resistance to softening effect of heat.
 Mild steel.
 Water hardened tool steel (case hardened steel)
 Oil hardened tool steel (OHNS)
 High carbon high chromium tool steel (HCHCR)
C. Die set and Die construction
The die set is one of the basic tools of the stamping industry. It consists of a lower shoe and an upper shoe,
together with guide posts and bushings by means of which the shoes are aligned.The bottom bolster supports
the bottom half of the press tool consisting die block, front guide plate, rear guide plate, stripper plate, finger
stop etc., They are fastened to the bottom bolster by means of socket head screw and dowels ensures
alignment.The top bolster accommodates punches, punch plate, punch back plate etc. They are fastened by
socket head screw and aligned by dowels.The top half and bottom half of the press tool are again aligned by
guide pillar and guide bush with a fit H7/h6. The guide bush OD is having interference fit with top bolster
H7/ P6. The exploded view of die set is shown in Figure 2.

TABLE I. E LEMENTS OF A DIE SET

SN Description Material Hardness
1 Bottom Bolster Mild Steel --
2 Top Bolster Mild Steel --
3 Guide pillar OHNS HRC 55-57
4 Guide Bush OHNS HRC 55-57

Figure 2. Exploded view of die set

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D. Compound and Forming Dies
The term Compound die is applied to dies in which two or more cutting operations are performed, typically
piercing and blanking are performed in the same single station and completed during the same single press
cycle. The action of the piercing punch-die functions must be directionally opposed to the action of the
blanking punch die functions. If the piercing punches do not act in the opposite direction with respect to the
blanking punch, the die cannot be classified as a compound die.
Forming dies, often considered in the same class with bending dies, are classified as tools that form or bend
the blank along a curved axis instead of a straight axis. There is very little stretching or compression of the
material. The internal movement or the plastic flow of the material is localized and has little or no effect on
the total area or thickness of the material. The operations classified as forming are bending, drawing,
embossing, curling, beading, twisting, spinning and hole flanging. Compound and forming dies are shown
Figure 3 and Press tool in closed condition shown in Figure 4.

Figure 3. Compound and forming dies Figure 4. Press tool in closed condition

III. TOOL DESIGN

In this section step by step approach to the design of press tools based on experience, empiricism and
expertise as applied to “Retainer” and various design calculations are given below:
A. Component details
Material : Hot rolled steel
Supply Condition : Soft
Thickness of strip : 1.4mm
Type of feed : Manual
B. Strip layout and material utilization
This is forming tool the development length can be calculated using the formulae.
Development length (DL) = L1 + BA1 + L2 + BA2 + L3
Bend Allowance (BA) = A/180 (IR + KT)
Where A = Angle between length (L1) & length (L2)
IR = Internal radius
K = Constant (1/3 for IR < 2t)
T = thickness of strip
Development length=103mm
The strip layout is shown in fig (4.2). The percentage area of material utilization for the strip layout is
computed from the following formula.
Width of strip = Width of component + 2 (thickness) x 2
= 60+2 (1.4) x 2
= 66 mm
Length of strip = Length of component + 2 (thickness) x 2
= 103 + 2 (1.4) x 2
= 109 mm
Percentage material utilization = Area of blank x number of rows x 100

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 Strip width x length
= 6180 x 1 x 100
66 x 109
= 85.9
C. Clearance between punch and die
The clearance between punch and die for effective shearing is calculated by formulae
C = 0.005 x t x 3Fs
= 0.005 x 1.4 x 3 30
= 0.04 mm/ side
D. Calculation of total Shear force
Shear Force = Shear Area x shear stress
FS = (Length of cut x thickness) x Shear stress
FS = L x t x fS x n
Where FS = Shear force in Kgf
L = Length of cut in mm
t = Thickness of component in mm
fS = Shear stress in Kg/mm2
n = Number of holes
i) Force for piercing two holes ( 9mm)
FSh1 = dt x fS x n
=  x 9 x 1.4 x 30 x 2
= 2375.04 Kgf
ii) Force for blanking
FSh2 = L x t x fS
= 2 (103 + 60) x 1.4 x 30
= 13692 Kgf
iii) Force for forming
FSh3 = 1.2 SU x w x t2
L
SU = ultimate tensile strength in kg/mm2
w = width of forming in mm
t = thickness of component in mm
l = forming span
FSh3 = 1.2 x 40 x 29 x 1.4 x 1.4
13
= 209.8 Kgf
Total force = FSh1 + FSh2 +FSh3
= 2375.04 + 13692 + 209.8
= 16276.04 Kgf
E. Press Capacity Selection
The press should be capable of delivering approximately 30% greater than total shear force required by tool
 Press capacity required = Total shear force x 100
70
= 16276.04 x 100
70
= 23.2 tonnes
F. Design of die block
i) Thickness of die block
TD = 3Total shear force
= 3 30
= 32 mm

276
Thickness of die block should be more to accommodate the shut height of the tool; hence thickness of the die
block is taken as 45 mm
ii) Width of die block = Strip width + 2 (thickness of die block)
= 60 + 2 (35)
= 130 mm
iii) Length of die block = Strip length + 2 (thickness of die block)
= 103 + 2 (35)
= 173 mm
Die Block dimensions = 45 x 130 x 173 mm
Corresponding to the standard die block, Standard die set is selected from center pillar die set.
G. Design of piercing punch
Pierced hole is internal feature of component. Piercing punch controls the size and clearance is applied to die.
Therefore,
a) Punch diameter = 9mm
b) Die aperture for  9m hole = 9 + 2C
= 9 + 2 x 0.04
= 9.08 mm
c) Punch Length = Shut height – Die thickness – Sum of die set -Bolster thickness – Punch plate
thickness
= 262 – 70 – 130 – 6
= 56 mm
H. Design of Blanking Punch
In Blanking operation, die controls the size and clearance is applied to punch.
a) Length of the punch = Length of punch – 2C
= 103 – 2 x 0.04
= 102.92 mm
b) Width of the punch = Width of punch – 2C
= 60 – 2 x 0.04
= 59.92 mm
I. Design of Forming Punch and Forming Die
While designing forming punch and forming die the gap between punch and die is t + 10%t is taken. This
10% of t is provided to accommodate the variation in thickness of the component so that it does not damage
the component.
i) Forming punch
Thickness of forming punch = Shut height – Die thickness – Sum of Die Set -Bolster
thickness
– Punch plate thickness
= 262 - 70 - 130 - 15
= 47 mm
Length of the forming punch = 123 mm
Width of the forming punch = 70 mm
ii) Forming die
Thickness of forming die = Shut height – punch thickness – sum of die set -
Bolster thickness – forming punch thickness
= 262 – 47 – 130 – 15
= 70 mm
Length of forming die = 123 mm
Width of forming die = 70 mm

277
J. Land and DraftLand
After few thousand of operations the cutting edges of punch as well as the die block aperture becomes blunt ,
this results in burr on the component, hence die block surface are grinded by about 0.2 mm to get the sharp
cutting edges.
A land of 3 to 5 mm is recommended for the die block.
Draft: The Sheared press components in die block apply horizontal force on the die block and do not fall
freely. The amount of horizontal force applied per shear pieces that are stacked in die block is about 10% of
the shear force. The slender punches like small piercing punches, notching punches and other delicate
punches break causing tool lay down. Therefore, 1/4° to 1/2° draft is provided for the entire shearing
aperture.

IV. RESULTS AND DISCUSSIONS

In the formation of nearly any engineering design project, some type of analysis is required. The analysis
may involve stress-strain calculation or any dynamic behaviour of the system being designed. The computer
can be used to aid in this analysis work. Probably the most powerful analysis feature of a CAD system is the
finite element method. With this technique, the object is divided into a large number of finite elements which
form an interconnecting network of concentrated nodes. By using a computer with significant computational
capabilities, the entire object can be analysed for stress-strain and other characteristics by calculating the
behaviour of each node. By determining the interrelating behaviour of all the nodes in the system, the
behaviour of the entire object can be assured. The output of the finite element analysis is often best presented
by the system for easy visualization by the user. For example, in stress - strain analysis of an object, the
output may be shown in the form of a deflected shape superimposed over the unstressed object.
A typical analysis has three distinct steps.
 Build the model
 Apply loads and obtain the solutions
 Review the results.
A. Build the model
ANSYS uses pre-processor to define the element type to be used, the element real constants, the material
property and to create the model geometry.CAD model and corresponding meshing of Forming die and
punch are shown in Figure 5 through Figure 8.

Figure 5. Forming Die Figure 6. Forming Punch

Figure 7. Meshed model of Forming Die Figure 8. Meshed model of Forming Punch

278
B. Loading and solution
The main goal of the finite element analysis is to examine how the structure response to the loading
condition, specifying the proper loading condition, is therefore, key step to the analysis. The word load in
ANSYS terminology includes the boundary condition and the externally or internally applied force
functions.Loads are divided into six categories like DOF constraints, force loads, surface loads, Inertia loads,
and coupled filed loads.In the solution phase of the analysis, the computer takes over and solves the
simultaneous equations that the finite element method generates.The results of the solutions are:
1. Nodal degree of freedom values, which forms the primary solution.
2. The derived values, which forms the element solution. The element solution is usually calculated by
elements integration points.
C. Review of results
Stress analysis is the most important step in finite element analysis. Two post processors are available to
review the results. Post processor-1allows reviewing the results over the entire structure at any load step. Post
processor-2 allows reviewing the variation of the particular result item at the specific point in the model with
respect to the time, frequency or some other result item.Structural Analysis for forming die and forming
punch are carried out for determining the deflections and stresses. Figure 9 and 10 shows the deformation in
forming die and punch. Figure 11 and 12 shows the von misses stresses in forming die and punch. It was
found that stresses were within the limits.

Figure 9. Deformation of Forming Die Figure 10. Deformation of Forming Punch

Figure 11. Von misses Stresses in Forming Die Figure 12. Von misses Stresses in Forming Punch

V. CONCLUSIONS
Design and analysis of press tool for hot rolled steel components of retainer has been accomplished. Several
important aspects in the design of tooling for the manufacture of various elements of the press tools based
upon critical examination of the geometry of the component. To optimize production rate and manufacturing
costs compound tool is been designed. The structural analysis on form punch and dies gives deflection 0.005
mm and stresses 5.22 kg/ mm2

279
 ACKNOWLEDGMENT
The authors express their thanks to HOD and staff of Mechanical Engineering Department, to the Principal of
DBIT and to the Management of Wayanamac Education Trust, Bangalore, for the support and
encouragement during this design and analysis of injection mold tool.

REFERENCES
[1] JR Paquin, R E Crowley, “ Die Design Fundamentals “, industrial Press Inc., 1996
[2] Fank W Wilson, Philip D Harvey, ” Die Design Handbook “, McGraw Hill, 1991
[3] Eugene Ostergaard, “ Basic Die Making “, McGraw Hill, 1986
[4] Dr.JohnG.Nee, “ Fundamentals Of Tool Design “, Society of Manufacturing Engineers, Fourth Edition, 1998
[5] Prakash H. Joshi, “ Press tools Design & Constructions “, Wheeler Publishing, 1999
[6] Ismail H S; Chen S T; Hun KKB , “ Feature based design of progressive press tool “,2000
[7] Wang F; Chang L, “Determination of the bending sequence in the progressive die design “, 1996.
[8] David A Smith, “ Fundamentals of Press working “, Society of Manufacturing Engg,1999
[9] Konnerth U, “A Hydraulic high speedtryout press for the simulation of Mechanical forming processes”, Journal of
Metal processing Technology, April-2001.

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