AAIT Internship report 2017/18

Chapter 1
Company background
The metals and engineering sector is a sector which falls under the categories of manufacturing
industry sector. This sector, the Metals and Engineering sector according to United Nation’s
International Standard Industrial classification (ISIC), is classified into two categories, namely
Basic Metals Industries and Engineering Industries.
Industries classified in the Basic Metals Industries category, including extraction of iron ore,
produce primary metal products and using these products as raw materials manufacture hot rolled,
ribbed and plain reinforcement bars, rolled tubes, wires, wire rod, galvanized sheet metals and
nails through deploying technologies such as forging, melting and milling.
Industries which fall under Engineering Industry category are also industries which utilize primary
metal products, produced by the Basic Metals Industries as raw materials (inputs), and manufacture
different kinds of equipment and tools of various profile through deploying various molding
technologies such as engraving, forging and welding.
Knowing the fact that the Basic Metals and Engineering Industries contribute in country’s overall
economic growth, the Ethiopian government took initiation/decided to establish an institute which
leads and support sub sector industries.
Particularly, as the sub sector is being considered as the primary industries to import substitution-
based industrial development, which is newly emphasized in the second GTP, establishing an
institute was an inevitable matter.
In response to this, hence, the metals industry development Institute (MIDI) is established in May
2010, pursuant to regulation no. 182/2010 of council of ministers.
Thus, we published this bilingual brochure to our stakeholders and others, to provide the necessary
information pertaining institute’s general profile and the services render by it.

1.1 Background of the Institute and its’ establishment

The bilateral assistance agreement reached between the Ethiopian government and the United
Nations Development program in 1981, lay a foundation for the establishment of the current
Institute or any of the other former supporting institutes which were called by different names and
led the sub sector.
Since the establishment of the Engineering design and tools enterprise in 1983, there was no any
organized government institute which led the country’s Metals and Engineering sub-sector. Thus,
the enterprise was established with the objective to contribute its own share to the overall economy
of the country through designing and manufacturing equipment, tools and other materials.
Lately, as the proclamation No.47/1989(E.C) caused the amalgamation of other institutes which
carried out similar activities as design and tool enterprise, the basic metals and engineering institute
was established, with pursuant to proclamation No.47/1989

1|Page
AAIT Internship report 2017/18

The main objective of the agency was product development and rendering industrial support for
sub-sectors industries
Thereafter, as the proclamation No.47/1989(E.C) caused the amalgamation of other industries
which carried out similar activities as design and tool Enterprise, the basic metals
engineering institute was established, in accordance with proclamation No.47/1989.
The main objective of the agency was product development and rendering industrial supports for
sub-sectors industries.
The agency, after spending a certain period of time, discharging the responsibilities vested upon
it, on July 2004 transformed to a new center, with the new center, with the new name, The Metals
Products Development Center(MPDC), under the pursuant to proclamation No.411/2004.
The main objectives of the Center, building up the capacity to design and manufacture technologies
that are favorable to micro and small industries and for rural development as well.
The Center, until fully handed over to the current institute ‘The Metals Industry Development
Institute’ (MIDI), on May 2010, it was administrated under the former ministry of trade and
industry.
The metals industry development institute (MIDI) is established pursuant to regulation
No.182/2010 of the council of ministers.
The objective of the Institute is to facilitate the development and transfer of metals and engineering
industries technologies and to enable the industries become competitive and beget rapid
development.

1.2 Mission
Enhancing the capacity of the metals and ensure the expansion of competitive industries through
providing research based integrated investment, marketing and manufacturing technology support
for developmental investors.

1.3 Vision
By building regionally efficient and internationally competitive light Metals and Engineering
Industries by the year 2017 E.C, laid the foundation for heavy industries development.

1.4 Objectives
The objectives of the institute shall be to facilitate the development and transfer of Metals and
Engineering Industries Technologies, and to enable the industries become competitive and be get
rapid development.

1.5 Values
1. Striving for the success of developmental investors!
2. Ever ready to learn and adapt to changes!

2|Page
AAIT Internship report 2017/18

3. Diligently working for rapid technology development and application!

4. Strive for product quality and reliability!
5. Stand firmly for environmental protection and safety!
6. Working for occupational safety and health of the industry workers!
7. Seamless coordination among the stakeholders of the sector!
8. Persistently working for women’s, children and youth full participation and benefit!

1.6 Former names of the Present Metals Industry Development Institute

(MIDI)

No. Name of the organization Duration of title Institute/organization

Head title
1
Engineering Design and tool 1975-1989 Manager
Enterprise
2
Basic Metals and Engineering May 1989-July 1996 Commissioner
Agency
3
Metals Product Development July 1996-May 2002 Center Head
Center (MPDC)
4
Metal Industry Development May 2002 up to now Director General
Institute (MIDI)
Table 1: Former names of metal industry Development Institute
Consequently, the institute, to successfully realize the goals vested up on the sub-sector in the
second Growth and transformation plan years and execute the power and duties bestowed to it by
law, it has installed and, is implemented Business Process Reengineering oriented strategic plan.
In this strategic plan, Strategic Themes which enable to render substantial support for
developmental, investors, are identified and set.
These Strategic Themes are:-
a. Promotion of Metals and Engineering Industries Investment
 Establishing complete information system which could attract local and foreign investors
to be engaged in the metals and engineering Industries;
 Facilitate the provision of infrastructure, financial and the like input support for
developmental investors to undertake investment activities.
 Strive to ensure the availability of conductive policy that enables the developmental
investors to undertake investment activity;
 Provide technical support for sub sector’s developmental investors in terms of project
preparation and implementation;

3|Page
AAIT Internship report 2017/18

 Work in collaboration with stakeholders in order to promote micro and small Enterprises
to medium scale industries,
 Through delivering integrated and sustainable support, foster investment projects that
are transforming to production stage,
 Strive to enhance national contribution of the engineering product to the strategic
developmental projects.

b. Enhancing production capacity of the metals and engineering industries

 Prepare product standards and provide quality testing services,
 Conduct benchmarking studies that are to the level of international indexes, and
implement it.
 Provide capacity building trainings which boost the performance and development of the
sub sector.
 Conduct problem solving researches for the development of the sub sector industries.
c. Expand Metals and Engineering products market share
 Provide professional support to sustain smooth functioning relationship between and
among industries towards input and output linkages, shares and twinning activities.
 Provide inclusive support and service for import substitute industries to enable them
expand their market share.
 Seeking business in foreign markets for the products of the sub-sector and also perform
similar tasks.

1.7 Organizational structure of the Metals Industry Development Institute

(MIDI)

Director General

System improvement and Planning and information

human resource directorate Management Directorate

Finance and supply

Registrar office
Directorate
Corporate
communication Audit Directorate
Directorate

Engineering
services Product Design and Metals and Engineering Marketing
Directorate Dev't Directorate Technology Dev't Directorate Directorate

Fig 1: Organizational structure

4|Page
AAIT Internship report 2017/18

The institute is organized by a director general, four general processes and five support processes.
The core processes include: Engineering Services Directorate, Metals and Engineering
Technology Development Directorate, Product design and Development, and marketing
Directorate.

1.8 Services and supports delivered by the foregoing core processes

I. Engineering services
1. Process and disseminate information for users.
2. Prepare project file study.
3. Conduct prefeasibility study.
4. Support and follow up investment activities of ongoing project.
5. Provide support on design and construction plan.
6. Provide technology selection.
7. Provide support on plant erection.
8. Provide support on commissioning.
II. Metals and Engineering Technology Development Services
1. Set product standards to ensure that the Metals and Engineering Industries are
manufacturing internationally accredited products.
2. Established international management and quality systems with in industries.
3. Provide product quality testing services using Non-Destructive test (NDT) technique.
4. Execute international best practices which make the Metals and Engineering sector
competitive.
5. Build up the capacity of the Metals and Engineering human resources with sustainable
trainings.
III. Product Design and Development Service
1. Conduct researches and studies on technologies that are identified to be developed locally.
2. Enhance product design and manufacturing capacity.
3. Deliver or transfer developed products to industries.
4. Provide technical support for those manufacturing industries which are prioritized and most
especially produce export goods.
5. Identify products which are going to be developed by foreign consultants, evaluate them,
enter into contracts and transfer accordingly.
6. Generate research (product development), policy and strategic ideas and implement them.
IV. Marketing Service
1. Identify import products and ensure their sustainability to be produced locally.
2. Establish modern transaction management system.
3. Promote subsector’s product and deliver inputs and outputs linkages support,
4. Searching international market for products of the sub-sector.
5. Establish marketing system that encourages local manufacturers.
6. Set a work system and prepare a manual for safe disposal of local metals scraps and worn
out metal products.

5|Page
AAIT Internship report 2017/18

1.9 Project Description and Prefeasibility studies

Metals Industry Development Institute (MIDI) was issued powers and duties by Council Ministers
of Federal Democratic Republic of Ethiopia. Among the powers and duties issued to MIDI in this
regulation is, preparing and disseminating project profiles that may be helpful in expanding
investments in Metals and Engineering Industries; and conduct feasibility studies for those
investors desiring to engage in the sector, is the one.
Hence, the following preliminary project ideas, Project Description and Project profiles have been
identified and studied between the years 2005-2007 E.C.
List preliminary project Ideas identified in 2005 E.C
 Alloy steel manufacturing plant.
 Railway truck manufacturing plant
 Manufacturing of die blocks and high speed steel.
Group of Engineering:
 Manufacturing of fabricated metal products, except machinery and equipment (16
types of project ideas)
 Manufacturing of machinery and equipment (24 types of project ideas)
 Manufacturing of office, accounting and computing machinery (2 types of project
ideas.)
 Manufacturing of electrical machinery and apparatus (6 types of project ideas.)
 Manufacturing of radio, television and communication equipment and apparatus (3
types of project ideas.)
 Manufacturing of medical, precision and optical instruments, watches and clocks (4
types of project ideas.)
 Manufacturing of motor vehicles, trailers and semi-trailers (5 types of project ideas.)
 Manufacturing of other transport equipment (4 types of project ideas.)
 Others (2 types of project ideas.)
List preliminary project Ideas identified in 2005 E.C
 Electromechanical and other equipment (18 types of project ideas.)
 Electrical equipment (33 types of project ideas.)
 Basic Metal Industries (6 types of project ideas.)
 Manufacturing of fabricated Metal Product (2 types of project ideas.)
 Manufacturing of machinery and equipment (2 types of project ideas.)
 Manufacturing of electrical machinery (4 types of project ideas.)
 Manufacturing of electrical equipment’s (16 types of project ideas.)
 In 2007 E.C 46 project ideas are identified.
 In 2008 E.C 47 project ideas are identified.

6|Page
AAIT Internship report 2017/18

Summary of project description and prefeasibility studies

Description 2005 E.C. 2006 E.C. 2007 E.C
List of Sponge iron Manufacturing of Manufacturing of wind mill
product Manufacturing greenhouse structures water pump
description plant Manufacturing of agricultural
machineries/implements
Steel billets, slab Manufacturing of garden Manufacturing of baking oven
and bloom and sun umbrella Manufacturing of flexible
Manufacturing tubing of iron steel
plant
Structural steel Manufacturing of Manufacturing of automobile
Manufacturing mechanical power radiators
plant transmission products Manufacturing of razor blade
(safety razor)
Seamless pipe Manufacturing of alloy steel Manufacturing of air filters
Manufacturing Manufacturing plant Manufacturing of aluminium
plant can
Aluminium Manufacturing of die blocks Manufacturing of alloy steel
extrusion and high speed steel Manufacturing of copper billet
Manufacturing or ingot from scrap
plant
Aluminium foil Metal forging, pressing, Manufacturing of coated
Manufacturing stamping and roll forming electrodes for electric arc
plant industry welding
Manufacturing of spark plugs
Ball bearings Manufacturing of hand tools Manufacturing of electro
Manufacturing thermic tea or coffee maker
plant (electric drip coffee maker)
Manufacturing of electrical
hand drill
Electric motors, Manufacturing of wheel Manufacturing of microwave
generators and barrows, luggage trucks, oven
transformers hand carts Manufacturing of copper clad
Manufacturing laminate
plant Manufacturing of aluminium
billet or ingot from scrap
Submersible Manufacturing of sewing Manufacturing of automatic
pump machine circuit breaker
Manufacturing Manufacturing of ball bearing
plant
Link chain Manufacturing of milk Manufacturing of cash register
Manufacturing processing machinery machine
plant Manufacturing of filament
lights/light bulbs

7|Page
AAIT Internship report 2017/18

Manufacturing of staplers Manufacturing of fire

and punchers extinguishers
Non-threaded Manufacturing of metallic Manufacturing of flash lights
mechanical households/office furniture Manufacturing of flywheel and
fasteners pulleys
Manufacturing Manufacturing of generator
plant
Manufacturing of hand Manufacturing of windmill
pump water pump
Seamless pipe Manufacturing of agricultural
Manufacturing industry machineries/implements
Manufacturing of Manufacturing of baking oven
mechanical power
transmission products
Manufacturing of animal Manufacturing of flexible
and hand driven cart tubing of iron steel
Manufacturing of windmill
water pump
Manufacturing of Manufacturing of automobile
agricultural radiators
machineries/implements
Manufacturing of baking Manufacturing of razor blade
oven (safety razor)
Manufacturing of flexible Manufacturing of air filters
tubing of iron steel
Manufacturing of Manufacturing of aluminium
automobile radiators can
Manufacturing of razor Manufacturing of alloy steel
blade (safety razor)
Manufacturing of air filters Manufacturing of copper billet
or ingot from scrap
Manufacturing of Manufacturing of coated
aluminium can electrodes for electric arc
welding
Manufacturing of alloy steel Manufacturing of spark plugs
Manufacturing of copper
billet or ingot from scrap
Manufacturing of coated
electrodes for electric arc
welding
Manufacturing of spark
plugs

Table 2: Project description and prefeasibility studies

8|Page
AAIT Internship report 2017/18

Chapter 2
Overall internship experience
My way to MIDI, the hosting company, was really unique. I have been finding several companies
that I thought one can accept me as an intern. But it turns out to be disappointing. Many of them
are not interested to receive a student as an intern. They say we have already accepted enough
interns, all the spaces are occupied and many more reasons. However we finally submitted our
academical information that includes the hierarchy of choice which the school provided since we
did not get a hosting company. I put Aphia flour factory first. The school placed me in this
company as I filled in the first place. Unfortunately, Aphia flour factory was located very far from
my residence and it was a place where we could not gain much experience. Therefore, we requested
the school to change the hosting company, Aphia flour factory. But it seemed we had no hope of
getting another hosting company. So we decided to find a hosting company that would accept us
as an intern in the shortest time possible. I tried to find some additional places. But their response
was the same as the former ones. Finally I went to MIDI where I submitted the internship inquiry
letter once. I thought they have refused to accept me as an intern since they remained silent with
no response. Yet when I found out why they did not reply, there was a fault while transferring the
letter we submitted. One of the office workers mistakenly handed in the list of our names as
‘students to work as interns by the year 2010 E.C.’. Soon they realized that they did make a
mistake. Later they apologized and accepted me as their intern.
In a little while, I went to the school to inform the hosting company that accepted me. But despite
my expectation the UIL office forbade that we should start working at the company where the
school placed us. I tried to explain the existing problems if I would work in Aphia flour factory
and what benefit I could gain if I work in MIDI. But it was a hopeless effort. The next day I decided
to start working at Aphia flour factory because I had no choice. Unexpectedly, one of the workers
in MIDI insisted to the dean of school of mechanical and industrial that I should work at MIDI.
The dean then called the UIL officer and told him I should work at MIDI. Later the UIL officer
called and asked me some information about my academical status. He also told me that I can work
at MIDI. In the afternoon praising my God I went to MIDI and thanked the lady that enabled me
to work at their company. I met her colleagues that work as product design and development
engineers. There were two interns from AAIT. This made me very easy to communicate with the
members of the department and also other personnel.
All three of us were assigned to work as a design engineer in the PDD department. This department
is the section of the company where customers directly interact with the engineers. Different
customers have different desires. They may need a new design, need to manufacture a damaged
product again or seek another solution. Then this department discuss on the existing circumstances
and propose a solution. If a design is to be made, they have to transfer it to the senior and lead
engineer. After their approval, the design gets back to the PDD department and one member of the
department goes down to the workshop and explain how the design is developed. Finally the
workers inside the workshop develop the design and it is given to the customer.

9|Page
AAIT Internship report 2017/18

The institute also conducts projects on agricultural areas. Some of the engineers in this department
make projects on different titles.
My role in the institute was to conduct a project. But before making the project my workmates as
well as I were given a training which is solid works software.
For almost a month we were given solid works training. Concerning this we have been doing two
types of tasks i.e. the three dimensional sketch and two dimensional sketch. First we watched a
number of tutorial videos starting from basic skills up to drawings. These tutorials were very
essential for us. They enabled us to develop our solid works skills and face to make challenging
drawings. The figures below are some of the tasks we did.

Fig 2: 2D sketch A Fig 3: 2D sketch B

Fig 4: 3D sketch A Fig 5: 3D sketch B Fig 6: 3D sketch C

I practiced sixteen analogous two dimensional sketches and twenty six three dimensional sketches.
It’s after these assignments I improved my drawing abilities on solid works. They were really
helpful during drawing my final design drawings. I also tried to make some drawings downloading
from the web. But these drawings were really challenging and tough to tackle.
Subsequently in addition to taking solid works training I started to read about die design for the
sake of designing the die. There were numerous books concerning die design. But I found the book
Paquin very interesting and easy to understand. It was also more comprehensive compilation of

10 | P a g e
AAIT Internship report 2017/18

the information contained in a series of articles that appeared in American Machinist/

Metalworking Manufacturing under the title, "Fourteen Steps to Design a Die".
For a couple of days I read about the die design introduction. I completely read the entire parts. It
included the denotation of blue prints and stampings, what a scrap strip means, what does it refer
to when we say die design, what a punch press is, parts of a die set, how someone should read part
drawings and the die set assembly.
Besides I tried to have the knowledge of press and press accessories which is another indispensable
part of die design. In the course of reading this lesson I went to the workshops to look the
appearance of the press types we read. But there was only one type of press which is the Gap-
frame press. In addition to this I found a number of dies made inside the workshop.
After reading the introduction I perceived:
The die design is a large division of tool engineering.
There are different ways of communications while working with dies.
The different parts of a die set with their functions and assembly manner.
Different types operations performed on a die.
Types of feeding a sheet metal into a die.
Types of punch presses with their accessories and where to use them.
Considerations before designing a die….etc.
Later I started to read about the material strip. It is the most important lesson of all the entire die
design. This stage of die design determines the complete appearance of the die. It should be
carefully studied and applied.
Formerly, before the determination of the strip layout I thoroughly read about property of sheet
metals as well as the two types of strip orientations that are the narrow strip run and wide strip run.
In addition I got the knowledge of the effects that occur when insufficient and excessive clearance
exist during a die operation.
Subsequently reading about the material strip I understood:
How strips are produced.
How strips are planned.
Materials from which strips are made.
Deformation of sheet materials.
Theory of cutting sheet materials.
Types of strip edges.
My next task was to have an insight about the blank. The blank determines the appearance of a
component called die block.
After reading about the blank I understood:
How to select the best method of producing a particular blank.
Different types of producing blanks.

11 | P a g e
AAIT Internship report 2017/18

The advantages of using cutoff dies over blanking dies.

Different types of operations performed post blanking.
Ways of minimizing cost in relation to methods of producing blanks.
Furthermore I tried to have the awareness of determining the shear strength, area to be cut during
piercing and blanking. Related to this I tried to see an exercise that was familiar during taking the
strength course. Also I determined the blanking force with these obtained values.
The work piece I was given to design a die was a Three bar slide as the figure below indicates. It
is used in association with belts to wrap any small webbing to a harness bar or to wrap any end
fitting into a small piece of webbing. As shown it has two similar holes and the central member is
indented. It consists of three operations namely piercing, forming and blanking. It is made of mild
steel of moderate strength. In this project it is assumed to be produced with a progressive die. All
the three operations are done lonely at one stage. Its thickness is 1mm.

Fig 7: Project work piece

A forming operation is performed on the middle bar in order to ease inserting belts past the other
bars. Different forms of these product exist in the market.
Throughout making this project I used the modest and systematic procedures provided on the book.
There are fourteen steps to design a die. I simply followed these steps one by one until the
termination.
Namely the fourteen steps are the strip lay out, die block, blanking punch, and piercing punch,
punch plate, gage with front spacer, finger stop, automatic stop, stripper plate, fasteners and die
set selection.

12 | P a g e
AAIT Internship report 2017/18

Before getting to the design procedures material for every component is selected. The selection of
die materials is an important decision in the production of precise components. Materials are
selected according to operating conditions, service lifetime and strength. Mostly a D2 (high carbon
steel) material is used for the die block and punches in order to sustain hardness since these two
components perform the shearing action and the severity is higher compared to the other parts. But
for all the remaining parts C40 and C45 material is preferred since minimal stresses are present
and lower severity with minor operation conditions exist.
The overall design progress is as follows:
2.1 Strip lay out determination
To determine the strip layout a variable called economic factor have to be calculated. Also the
dimensions from the edge of the strip to the contour of the work piece is determined.
Both orientations are tested that are the wide run and the narrow run.
The results are:
%𝑒𝑐𝑜𝑛𝑜𝑚𝑦 = 76.9% For the narrow run and

Fig 8: Narrow run strip layout

%𝑒𝑐𝑜𝑛𝑜𝑚𝑦 = 80% For the wide run.

Fig 9: Wide run strip layout

13 | P a g e
AAIT Internship report 2017/18

Therefore the wide run is preferred. It has sixty eight blanks per unit strip. The overall die operation
becomes:
Piercing Forming Blanking
The needed tonnage is also calculated in this step. Using the modulus of elasticity, density, shear
area and shear strength the value obtained becomes:
𝑇𝑜𝑛𝑛𝑎𝑔𝑒 = 6.6 𝑡𝑜𝑛
2.2 Die block design
Since the appearance of the die block is dependent on the strip lay out it inherits its features. The
important variables are the die block thickness, straight land thickness, angular relief, margin,
critical distance and clearance at the punch zone. With these obtained results the length and width
of the die block are calculated and its overall dimension is known.

Fig 10: Die block margin distance

Most results are read from tables and figures.
Below the straight land thickness there is a tapered hole which enables the blank and pierced scraps
to fall easily.
There are three stages as mentioned previously. Piercing operation mandatorily comes first in a
die operation. Then other operations can proceed as desired by the designer. As shown in the figure
below two holes are made at the front of the die block up to a certain depth. These holes are made
in order to be fastened with the screws that function for holding the front spacer with the die block.

14 | P a g e
AAIT Internship report 2017/18

Fig 11: Die block

Here the center of pressure is also found by using the weight of the scraps and the distance from
the fulcrum point to the point at which moment becomes equal.
2.3 Blanking punch design
Here I designed the blanking punch to be manufactured together with holes for the forming punch
and piercing punch i.e. the punch section is machined from the material. As usual standard
dimensions are read from tables. Since the length of the blanking punch is dependent on the length
of the piercing punch, it is designed with piercing punch section.

Fig 12: Blanking punch

15 | P a g e
AAIT Internship report 2017/18

Besides, the holes are machined in relation to the head sizes of the forming punch and the piercing
punch.
2.4 Piercing punch design
I designed the piercing punch according to standards provided on the material. Since the holes are
close to each other two piercing punches could not be designed. To solve this the two identical
piercing punches are made to be manufactured from a single material i.e. they are machined from
the same material below the press fit width.

Fig 13: Piercing punch

Length of the punch is calculated using three parameters. These parameters are the specifications
of the selected ram. The specifications of the ram are
 Shut height=146mm
 Ram adjustment=80mm
 Stroke=70mm
Based on this data the length of the punch is known.
After obtaining the length of the punch, it’s compared with the minimum and optimum tool shut
height. Fortunately it is between these results. So there is no need of finding another solution. The
press fit width is made 3mm offset from the tip width of the punch and the same holds true for the
shoulder.
Distinct from this design step, there was a pilot design. Since the holes of the blank are small and
the die is considered as a small die there is no need of designing a pilot. Additionally the forming
operation aids in the alignment of the work piece.
2.5 Gage design
In operations that have two stages, die gages locate the formerly blanked or formed part for
advanced processing operations. The gages and its related components that are the front spacer
and strip support are designed in accordance with common design standards.

16 | P a g e
AAIT Internship report 2017/18

When using hand feed system the space between the back gage and the front spacer is the width
of the blank plus 3.2mm. The thickness of the gages is also made 3.2mm. However the depth of
the formed central bar is 3.5mm. Therefore the thickness is made 3.5mm with no choice of another
solution.
Of the three types of fastening the strip support with the back gage I used the rivet fastening for
the sake of durability.

Fig 14: Riveted fastening in a gage

Front spacer design
Its length is made equal as the length of the die block that is 24mm. A relief of 1.4mm is left to
ease the starting of new strips through the die. From the common methods of making finger stops
I used the single extruded boss type with its top surface milled. So the front spacer is milled at its
bottom. Dimensions are obtained according to the slot dimensions of the finger stop with
allowances taken into consideration.
2.6 Finger stop design
Automatically all dimensions are taken from the table.
The thickness of the strip or sheet metal corresponds with this finger stop. It is labeled number one
in the table.

Fig 15: Standard finger stop

17 | P a g e
AAIT Internship report 2017/18

Two finger stops are used. The first one registers the strip at the piercing stage and the second
registers the strip at the forming stage.
A hole with 6mm diameter is bored at the arms of the finger stops in order to fasten them with the
die block. Also a return spring is used to avoid misfeeds on notched strips.

Fig 16: Spring aided finger stop

2.7 Automatic stop
This component registers the strip at the last stage of the whole process i.e. the blanking
operation. From the different types of automatic stops I selected the pin stop one.
The pin stop is selected because:-
It is easy to design.
The die is considered as a small die.
It is easy during operation.
Its cross section is:-

Fig 17: Spring loaded automatic stop

This pin is located past the blanking slot of the die block. A hole as shown in the figure is bored
which is a complementary shape with the pin. The center of the hole or the pin location is
calculated by considering the distance between the edge of the strip and the contour tip of the
blanking slot.

18 | P a g e
AAIT Internship report 2017/18

Fig 18: Automatic stop

Additionally this pin stop is aided by a spring that is located at its bottom. Its purpose is to return
the pin to the original position immediately after the operators push. Since it is tapered at the top
surface, successive operations are done easily and safely.
2.8 Stripper plate
Some measurements are obtained from tables as usual.
Stripper plate thickness=6.4mm
Notch length=9.5mm
Clearance from the die block=0.7mm

Fig 19: Stripper plate

These stripper plate, machined to receive blanking and piercing punches, is fastened in position on
top of the back gage and front spacer with four button head socket screws. Two dowels correctly
locate the stripper plate in relation to the die block and back gage. A small, short dowel locates the

19 | P a g e
AAIT Internship report 2017/18

other end of the back gage to the stripper plate. The notch is machined in the stripper edge to
provide a shelf for starting new strips through the die.
2.9 Fasteners
Three types of fasteners are used. Namely:

Socket cap screws

Dowels
Socket button-head screws
Socket cap screws are used to fasten the die holder with the die block. Socket button-head screws
secure the stripper, front spacer, back gage and the die block together. The purpose of dowels is
to bring a good alignment of the clipped parts.
The size and positions of these fasteners are calculated with the following guides:

Fig 20: relationship between plate thickness and screw

Fig 21: placement of screw

20 | P a g e
AAIT Internship report 2017/18

It is important to carefully consider screw placement when designing dies.

There is the problem of whether to make the screw size large and make the number of screws
small, or to make the screw size small and make the number of screws large.

Fig 22: placement of screw

The screws’ size:

Fig 23: dimensions related to screws

Dowel pins are used very often for the positioning of die components. A common method of using
dowel pins is to determine the position by lightly pressure fitting a dowel pin in two components.
Analogous to screws, the diameter of the dowel pin is obtained according to the size of the die
component.

21 | P a g e
AAIT Internship report 2017/18

2.10 Die set selection

The die set includes the die holder, punch holder, guide pillars, bushings and shank. These parts
are not designed but are selected from a catalogue. The independent parameter here is the
dimension of the die block. All the measurement of the other components is determined in relation
to the size of the die block.

Fig 24: Die set

For the shank a table is referred that relates the tonnage to the size of the shank.

Fig 25: Shank

Fig 26: Shank size in relation with tonnage

22 | P a g e
AAIT Internship report 2017/18

All the die set parts except the shank are referred from a catalogue.

2.11 Cost estimation

The gross cost of this three bar slide manufacturing die is estimated by the company’s cost
estimation guide.

The size of the parts is inserted in this excel sheet format:

Size of part Unit price Design

No. Part name Material Qty
Height X width X Length (birr/cm) time(Hr)
1 upper bolster C40 252X237X38 X 252 35.93 2 1
2 Lower bolster C40 279x252x38 X 279 35.93 2 1
3 Guide Pillar D2 Ø25X152 X 152 4.37 2 2
4 Back up plate D2 230X205X10 X 230 111.78 2 0
5 Forming punch D2 64X21.8X67 X 64 55.90 3 1
6 piercing punch D2 72.2X30X70 X 72.2 55.90 3 1
7 striper plate C40 151.62X127.7X6.4 X 151.62 12.48 2 1
8 Front spacer C40 151.62X30.9X4 X 151.62 12.48 2 1
9 Back gage C40 227.4X30.9x4 X 227.4 12.48 2 1
10 finger stopper C40 53X9.5X4 X 53 1.98 2 2
11 Die block D2 151.62X127.7X23.8 X 151.62 55.90 4 1
12 Bushing C40 Ø45x62 X 62 12.54 2 2
13 Automatic stop C40 Ø10x17 X 17 1.00 2 1
14 Strip support C40 77.7x30.9x4 X 77.7 12.48 2 1
15 punch plate C40 131X100X20 X 131 55.90 3 1
16 clamp C40 18X15.9X8.7 X 18 14.89 1.5 0
17 SHANK C40 Ø20X60 X 60 2.79 2 1
18 Screw C40 Ø50X91 X 90 71.83 1.5 0
19 punch plate C40 131X100X20 X 131.00 55.90 2 1
20 DOWELS C40 Ø8X33 X 33.00 1.00 0.5 1

Table 3: Input data for cost estimation

Additionally in this format there is a time input for different types of operations like milling,
cutting, turning, drilling…etc. If the part designed needs a certain machining operation, the time
needed to complete this operation is inserted hypothetically. This format also includes the
standard materials like spring and fasteners, assembly cost, testing cost….etc. From all the costs
material cost and machining cost make up most of it.

Based on this input the excel file calculates the total cost of the designed part.

The total cost of the die is:

Designed parts = 63,185 birr

Standard parts and services = 1047 birr Total cost = 64,232 birr

23 | P a g e
AAIT Internship report 2017/18

2.12 Challenges during practice

During conducting this project I confronted one big challenge. My project advisor told me to
make the die to have only two stages of operations. Therefore I primarily started to design the die
as declared. I designed the die to complete the whole manufacturing process in two stages. At the
first stage I made the piercing operation. At the second stage I made the forming and blanking
operation to be completed simultaneously.

This was the cross sectional appearance of the die block design earlier in the beginning:

Fig 27: Die block side cross section

𝑋 = 0.42𝑚𝑚

With a total length 𝐿 = 187.78𝑚𝑚

And the appearance of the blanking punch was:

Fig 28: previously used blanking punch

24 | P a g e
AAIT Internship report 2017/18

At the second stage, the blanking punch conducts the forming operation with the help of the feature
located in middle of the two pilots. This feature performs the forming operation on the central bar
of the work piece.

However this idea was not acceptable according to different written materials and the comment of
my advisors. So I sought another concepts.

In addition I also faced a couple of problems related to selecting different parameters,

standards…etc. and more things that are based on choice.

2.13 Measures taken to overcome the problem

Concerning the number of stages, I presented a review approximately at half stay in the company.
After the presentation of the review the audiences commented on my project. I took these remarks
and included them in my project. The comments are similar with the challenge I faced. It was to
minimize the number of stage.

I came up with three ideas to solve this problem. The first one is to make the forming operation
with the piercing operation.

 Piercing and forming blanking

But this idea was conflicting with the principle of forming operation. In forming operation there
must be the female part that receives the strip and make up the lower part of the work piece and a
male part that does the punching action on to the strip. It also conflicts with the principle of
piercing. During piercing the sheet metal must fully lie on the die block. Thus this idea was
rejected.

The second idea was to make the forming operation with the blanking operation. Unfortunately
this idea also conflicts with the principle of forming as well as blanking. During blanking the area
inside the contour of the work piece should be empty in order for the strip to fall downward. So
this idea was also cast-off.

The third and the accepted idea was to make the three operations all alone. This concept was
selected because there were no choice to solve the problem with two stages of operations.

Piercing Forming Blanking

This was the final decision made after dumping two concepts.

The other was the selection of different things found in this die design. I overcame this challenges
by considering other related measurements and referring extra materials. For example there were
numerous die set lists in the catalogue I referred. I selected the die set whose die holder size was
closer with the size of the die block designed. Regarding the selection of fasteners I considered the
size of parts and guides provided on the books.

25 | P a g e
AAIT Internship report 2017/18

2.14 Benefits gained from the internship

Since the company works jobs related to designs specially manufacturing design and I joined the
design stream I gained a lot of new experiences regarding design.

Concerning practical knowledges I advanced my abilities related to conducting projects.

According to the comments given to me at my progress and final presentation I improved some
practices like what things must be included and what things should not be included in a project.
Moreover I have developed my knowledge of conducting a project starting from the beginning up
to the end.

Related to theoretical knowledge I developed the perception of die design. Additionally I have
gained much knowledge about different operations performed on a die. I almost fully understood
the fourteen steps to design a die. Besides I also gained a first-hand knowledge about cost
estimation and also working it with Microsoft word excel.

I had improved my interpersonal communication skills since the day I entered the company.
Especially with the engineers inside the product design and development, I had a good relation
during my stay.

I did not gain much practical experience related to work ethics. A few of them which I am
familiarized with were punctuality and formality on working fields.

Chapter 3
Project work
3.1 Introduction
3.11 Die design
A die is a particular tool used in manufacturing industries to cut or profile a certain material mostly
by using a press machine. However the word “die” is used in two separate ways. When used in a
general sense, it means the whole press tool including all components. When used in a more narrow
sense, it refers to that component which is machined to receive the blank, as distinguished from
the part called the punch which is its differing member.
Products produced with dies range from simple paper clips to intricate parts used in advanced
technologies.
Die design is a part of tool engineering which enables us to yield numerous kinds and amounts
products with minimum amount of time possible. This large division of manufacturing involves a
couple of procedures to achieve what is desired by the consumer. A die designer first prepares
designs of dies engaged to stamp and form parts from a sheet metal. The die is designed according
to the part print which governs the design of the die essentially. After the die has been designed
then a variety of operations can be performed.

26 | P a g e
AAIT Internship report 2017/18

3.12 Parts of a die

Fig 29: Parts of a die

Die set: - is composed of few constituents namely punch shank, punch holder, bushings, guide
posts and die holder. These components establish the foundation for mounting the working parts.
Bolster plate: - is a plate that is designed to hold the die holder in place and it is attached to the
top surface of the press bed.
Guide post: - is a tough rod mounted in the die holder that fits in to a bushing in the punch holder
to guide the punch vertically during operation.
Bushings: - are hardened steel tubes that slide over the guide post and directs the die holder at the
time of operation.
Die holder: - is the lower plate of a die set and bears the foundation of the die set.
Punch holder: - is the upper plate of a die set that safeguards the punch retainer. The shank is also
mounted on it.
Punch: - is a tool typically attached to the upper portion pf the die set that shapes or creates
apertures on the sheet metal.
Ram: - is the main upper portion of the press fastened to the punch holder that cranks up and down
within the press frame.
Stripper: - is a plate designed to remove sheet metal stock from the punch as it clings away from
the die during operation.

27 | P a g e
AAIT Internship report 2017/18

Die block: - is a mass that into which holes have been machined and the strip slides over its surface.

3.13 Types of dies

A. Conventional dies
These are the most widely used type of dies in which the punch holder is attached to the ram of
the press and the die holder is fastened to the bolster plate. The punch is mounted to the punch
holder and aligned with the opening in the die block using guide pins. Stripper holds the scrap strip
so that the punch may pull out of the hole. The operation is conducted as the ram descends down
and performs the desired operation.

B. Inverted dies
The punch and die positions are interchanged due to the opening in the bolster plate is very small
to allow the finished part to pass through bolster opening. The die block is fastened to the punch
holder and the punch is fastened to the die holder. As the ram runs down the blank is sheared from
the strip. The punch is forced through the scrap strip and a spring attached to the stripper is
compressed and loaded. When the ram ascends the shedder pushes the blank out of the die opening.
The stripper forces the scrap strip off the punch.

C. Compound dies
Integrate the principles of conventional and inverted dies. A scrap strip is pierced and blanked at
one station. The piercing punch is fastened in conventional position to the punch holder. Die
opening for piercing is machined into the blanking punch. The blanking punch and blanking die
are mounted in an inverted position. Here the blanking punch is fastened to the die holder and the
blanking die opening is fastened to the punch holder.

D. Progressive dies
These types of dies perform two or more operations at separate stages every time the ram descends.
The strip is advanced through a series of that conduct one or more distinct operations. The strip
should move through each successive station to produce a complete work piece. The distance from
one station to the next must be the same. The work piece is completed when the last operation is
accomplished.

E. Combination dies
In these types of dies cutting operation is combined with non-cutting operation. The cutting
operations may include blanking, piercing, trimming, cutting off etc.… and are combined with
non-cutting operations such as bending, extruding, forming, drawing etc.…

3.14 Die operations

Die operations are frequently named after the explicit type of die that performs the operation.
Numerous operations are conducted in a die ranging from a small part to bigger part. Almost all
work pieces to be manufactured from sheet metals go through die operations.

28 | P a g e
AAIT Internship report 2017/18

Blanking: -is cutting a closed contoured part out of a scrap strip. But the desired part here is the
cut part.
Piercing: -is cutting a closed contoured part out of a scrap strip where the desired part is the
Lancing: - is a piercing operation in which the work piece is sheared and bent with one strike of
the die. The difference is, in lancing there is no scrap to handle.
Nibbling: - is a process that cuts a contour by producing a series of overlapping slits or notches.
Shaving: -is removing a chip from around the edges of a previously blanked stamping in order to
improve the edge finish or part accuracy.
Bending: -is applying a simple bend i.e. one in which the line of bend is straight to stampings.
Forming: -is applying more complex shapes of forms into work pieces. Here the line of bend is
curved instead of straight line.
Drawing: -is the process of transforming flat sheet metals into cups, shells, or other drawn shapes
by subjecting the material to severe plastic deformation.
Trimming: -is cutting away excess or unwanted irregular features from a part, they are generally
the last operation performed.
Coining: -is analogous to forming with the main difference being that a coining die may form
completely different features on either face of the blank.

3.2 Objective
The general objective of this project is to design a die that can easily manufacture a three bar slide.

3.3 Problem statement

The problem that triggered to carry out this project is the lack of easiness while inserting belts into
a three bar slide.

3.4 Mission statement

The mission of this project is to make a die that produces a three bar slide that the central bar has
been formed or bent.
Mission Statement: Three bar slide manufacturing die
Project description A manually operated die set that produces three bar slide
Benefit proposition Enables easy insert of belt since the central bar is formed or indented
other than the remaining bars
Primary market Consumers
Secondary market Casual customers
Assumptions Manually operated
Table 4: Mission statement
29 | P a g e
AAIT Internship report 2017/18

3.5 Material selection

The choice of die materials is a very substantial decision in the production of precise components.
Correct selection of die materials is imperative to get acceptable die life at reasonable cost. Die
wear is mostly influenced by the hardness of the die material and other material properties such as
toughness and ductility. Selection of proper die materials is very important for reducing the
production costs and setting narrow tolerance. In some die operations, the mechanisms by which
the dies fail are due to wear (adhesive and abrasive), plastic deformation and fatigue (mechanical
and thermal). Of all the failure mechanisms present during die operations, wear and mechanical
fatigue is found to be the most common form of failure.

The punch and die holder do not only fix the die to the press machine but also for supporting the
rigidity of the die. They also have the role of altering the die height. Usually, the materials used
are C40 or C45. There is no big difference between these two. Thus for both the punch and die
holder C45 would be a better choice.

A punch plate is used for the purpose of holding a small punch. Usually C40 or C50 are used like
that of punch and die holder without heat treatment. Since similar operation conditions exist, C40
can be selected.

Although the main purpose of a stripper is to get rid of scrap, very often it is made to have vital
secondary functions of pressing the material or guiding the tip of the punch. When removing scrap
in small scale production is important, materials such as C50 or pre-hardened steel are used which
do not require heat treatment. When materials without heat treatment are used, although they are
made to have the functions of pressing the material and guiding the punch, the plate may get
deformed when there is wrong punching. In this case the stripper does not perform any pressing
function. So C45 would be a suitable alternative.

The die block, blanking punch and piercing punch are die components where extra hardness is
needed relative to other parts. A hard material which is D2 is a good choice.
The rest parts are of lower severity and minor operation conditions exist. Therefore C40 can be
used for the remaining components.
Material selection summary

No Part name Material

1 upper bolster C40

2 Lower bolster C40
3 Guide Pillar D2
4 Forming punch D2
5 piercing punch D2
6 striper plate C40
7 Front spacer C40

30 | P a g e
AAIT Internship report 2017/18

8 Back gage C45

9 finger stopper C40
10 Die block D2
11 Bushing C40
12 Automatic stop C40
13 Strip support C45
14 punch plate C40
15 Shank C40
16 Screw C40
Table 5: Material selection summary

3.6 Design procedure and overall process

This project, as various projects, follows the fourteen steps to design a die. It starts from carefully
studying the part or the work piece and terminates with selecting standard parts.
The part to be produced with the die to be designed appears like this:

Fig 30: Project work piece

Its name is “three bar slide”. It is used to wrap any small webbing to a harness bar or to wrap any
end fitting into a small piece of webbing. As shown it has two similar holes and the central member
is indented. It consists of three operations namely piercing, forming and blanking. It is made of
mild steel of moderate strength. In this project it is assumed to be produced with a progressive die.
All the three operations are done lonely at one stage. Its thickness is 1mm.

31 | P a g e
AAIT Internship report 2017/18

3.61 The strip lay out

Before analyzing the orientation of the strip the allowance between successive blanks and distance
between the part and edge of strip must be determined.
distance between the part and edge of strip = G = 2mm
allowance between successive blanks = H = 2.4mm
Now, both the wide run and narrow run conditions are tested for their economy.
a. Narrow run
𝑎𝑟𝑒𝑎 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘 = 1518.23𝑚𝑚2 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝 = 61200𝑚𝑚2
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝 = 31
%𝑒𝑐𝑜𝑛𝑜𝑚𝑦 = (𝑎𝑟𝑒𝑎 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘 ∗ 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝)/ 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝
%𝑒𝑐𝑜𝑛𝑜𝑚𝑦 = (1518.23𝑚𝑚2 ∗ 31)/61200𝑚𝑚2
%𝑒𝑐𝑜𝑛𝑜𝑚𝑦 = 76.9%
b. Wide run
𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝 = 12900𝑚𝑚2 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘 𝑝𝑒𝑟 𝑠𝑡𝑟𝑖𝑝 = 68
%𝑒𝑐𝑜𝑛𝑜𝑚𝑦 = (1518.23𝑚𝑚2 ∗ 68)/129000𝑚𝑚2
%𝑒𝑐𝑜𝑛𝑜𝑚𝑦 = 80%
Thus, the wide run have a higher economic factor than the narrow run.
Tonnage
Properties of the work piece:
𝐸 = 210𝐺𝑝𝑎
Material: - Mild steel
𝜌 = 7860𝐾𝑔/𝑚3 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ = 344.5𝑀𝑝𝑎
𝑠ℎ𝑒𝑎𝑟 𝑎𝑟𝑒𝑎 = 156.52𝑚𝑚2
𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 = 𝑃 = 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ ∗ 𝑠ℎ𝑒𝑎𝑟 𝑎𝑟𝑒𝑎
𝑃 = 344.5𝑀𝑝𝑎 ∗ 156.52𝑚𝑚2
𝑃 = 53921.1𝑁 = 5502.2𝐾𝑔 = 5.5 𝑡𝑜𝑛
𝑆𝑡𝑟𝑖𝑝𝑝𝑒𝑟 𝑓𝑜𝑟𝑐𝑒 = 𝑃 ∗ 20%
𝑆𝑡𝑟𝑖𝑝𝑝𝑒𝑟 𝑓𝑜𝑟𝑐𝑒 = 1.1 𝑡𝑜𝑛

32 | P a g e
AAIT Internship report 2017/18

𝑇𝑜𝑛𝑛𝑎𝑔𝑒 = 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 + 𝑠𝑡𝑟𝑖𝑝𝑝𝑒𝑟 𝑓𝑜𝑟𝑐𝑒

𝑇𝑜𝑛𝑛𝑎𝑔𝑒 = 5.5 𝑡𝑜𝑛 + 1.1 𝑡𝑜𝑛
𝑇𝑜𝑛𝑛𝑎𝑔𝑒 = 6.6 𝑡𝑜𝑛

3.62 Die block design

The die block thickness, angular relief and the straight land thickness are obtained from the table
according to the strip thickness.
𝑑𝑖𝑒 𝑏𝑙𝑜𝑐𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 𝐵 = 23.8𝑚𝑚 straight land thickness = H = 3mm
𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑟𝑒𝑙𝑖𝑒𝑓 = 1°
Calculating the margin:
𝑀 = 1.2 ∗ 𝐵 = 1.2 ∗ 23.8𝑚𝑚 = 28.6𝑚𝑚
𝐶𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 𝐴 = 1.5 ∗ 𝐵 = 1.5 ∗ 23.8𝑚𝑚 = 35.7𝑚𝑚
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑎𝑡 𝑡ℎ𝑒 𝑝𝑢𝑛𝑐ℎ 𝑧𝑜𝑛𝑒 = 𝑠𝑡𝑟𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 ∗ 8% = 1𝑚𝑚 ∗ 0.08 = 0.08𝑚𝑚
𝐻𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 ‘𝑥’ 𝑑𝑢𝑒 𝑡𝑜 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑟𝑒𝑙𝑖𝑒𝑓 = 23.8𝑚𝑚 ∗ tan 1 ° = 0.42𝑚𝑚
Now length of the die block can be calculated as:

Fig 31: Die block cross section

𝐿 = 2𝐴 + 2𝑋 + 3 ∗ 26.6𝑚𝑚 + 2 ∗ 2.4𝑚𝑚 − 5.22𝑚𝑚
𝐿 = 151.62𝑚𝑚
And the width of the die block excluding fastening area will be:
𝑊 = 2𝑀 + 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑤𝑜𝑟𝑘 𝑝𝑖𝑒𝑐𝑒 = 2 ∗ 28.6𝑚𝑚 + 60.5𝑚𝑚
Leaving 10mm for the screw fasteners it becomes 127.7mm.
𝑊 = 127.7𝑚𝑚
Since a clearance is given on the die block in piercing operation, the holes will be 0.08mm offset
larger than the work piece.

33 | P a g e
AAIT Internship report 2017/18

A grinding allowance of 3mm is usually added on the thickness of the die block. Thus the gross
thickness of the die block becomes 26.8 mm.
Center of pressure is calculated with the weight of the scraps. Where the moment becomes equal
when we place a fulcrum at the center, is the location of the center of pressure.
1518.23𝑚𝑚2 ∗ (49.92𝑚𝑚 − 𝑋) = 271.2𝑚𝑚2 ∗ (2𝑋 + 16.28𝑚𝑚)
7.6𝑋 = 263.27𝑚𝑚
𝑋 = 34.6𝑚𝑚
3.63 Blanking punch design
Since the part size is small, the punch can be manufactured with the flange in order to minimize
machining operations.
As used in the design of the die block, standard dimensions are read from figures are obtained
using the thickness of the strip. However, the length of the piercing punch governs over the length
of the blanking punch.

Fig 31: Blanking punch distance

𝐹𝑙𝑎𝑛𝑔𝑒 ℎ𝑒𝑖𝑔ℎ𝑡 = 𝐵 = 20𝑚𝑚 𝑃𝑢𝑛𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ = 𝐴 = 70𝑚𝑚
In blanking operation the punch is made smaller. Therefore it will be 0.08mm offset smaller than
the work piece.
The flange has a square profile with dimension 76mm.
Punch for the forming operation is designed according to the standards of the piercing punch. The
tip punching section will have a thickness of 4.4mm as the central bar. The total length of the
punch starting from the bottom of punch holder is 2.5mm greater than the length of the piercing
punch and the press fit width is made the same as the piercing punch i.e. 35mm. The punch is
filleted at the transition of the press fit width to the piercing diameter section.

3.64 Piercing punch design

The press fit width is made 3mm offset from the tip width of the punch and the same holds true
for the shoulder.

34 | P a g e
AAIT Internship report 2017/18

Height of the shoulder is made in the range from 4.5mm up to 6mm. for convenience 5.5mm is
taken.

Fig 32: Piercing punch

Reffering at standard punches, the punch will have a length of 70mm and the press fit length would
be half of the total length i.e. 35mm.
Length of the punch:
Assuming the press to have the following specifications.
 Shut height=146mm
 Ram adjustment=80mm
 Stroke=70mm
Then the permissible length of the punch is calculated as:
𝑀𝑎𝑥. 𝑡𝑜𝑜𝑙 𝑠ℎ𝑢𝑡 ℎ𝑒𝑖𝑔ℎ𝑡 = 146𝑚𝑚 − 10𝑚𝑚 = 136𝑚𝑚
𝑆𝑐𝑟𝑒𝑤 𝑎𝑑𝑗𝑢𝑠𝑡𝑚𝑒𝑛𝑡 − 𝑟𝑒𝑔𝑟𝑖𝑛𝑑 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 = 80𝑚𝑚 − 20𝑚𝑚 = 60𝑚𝑚
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑡𝑜𝑜𝑙 𝑠ℎ𝑢𝑡 ℎ𝑒𝑖𝑔ℎ𝑡 = 136𝑚𝑚 − 80𝑚𝑚 = 66𝑚𝑚
𝑂𝑝𝑡𝑖𝑚𝑢𝑚 𝑡𝑜𝑜𝑙 𝑠ℎ𝑢𝑡 ℎ𝑒𝑖𝑔ℎ𝑡 = 66𝑚𝑚 + 20𝑚𝑚 = 86𝑚𝑚
Since the length of the punch is in this interval i.e. 70mm the calculated value is safe to use.

3.65 Punch plate

As usual some dimensions are obtained from tables

35 | P a g e
AAIT Internship report 2017/18

Fig 33: (a) Length and width distances of a blanking punch (b) Blanking punch
Dimensions A and B are read from table. Since the highest width of the piercing punch is 64mm
we have to select a larger punch plate i.e. 76.2mm and 101.6mm respectively and the thickness of
the punch plate will be 22.2mm. However these obtained dimensions are conflicting according to
this project. Therefore, a total length of 131mm and width of 90mm would fit the standards nearly.
Dimensions of the slot inherit the dimensions of the piercing punch. Since the distance between
the holes is 4.4mm the two piercing tips can be made on a single punch.

3.66 Gage design

In this part case, since a forming operation is conducted the thickness of the gages must be greater
than the total height of the part. For convenience the thickness of the gages is made 4mm
Past the die block the back gage should extend one and half of the width of the gage. Therefore
the length of the back gage becomes 227.4mm.

Fig 34: (a) Back gage (b) Strip support

Among the three types of fastening gages the riveted fastening is selected.
Width of the gage is made 30.9mm according to remaining dimensions.
𝐺𝑎𝑔𝑒 𝑤𝑖𝑑𝑡ℎ = 30.9mm
But a clearance of 1.4mm is given for the strip.

36 | P a g e
AAIT Internship report 2017/18

The strip support has length as much as half of the length of the part past the edge of the back gage.
It has the same width as the back gage. Thus its width becomes:
𝑆𝑡𝑟𝑖𝑝 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑙𝑒𝑛𝑔𝑡ℎ = 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑔𝑎𝑔𝑒 + 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝/2
𝑆𝑡𝑟𝑖𝑝 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑙𝑒𝑛𝑔𝑡ℎ = 56.2𝑚𝑚 + 64.5𝑚𝑚/2
𝑆𝑡𝑟𝑖𝑝 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑙𝑒𝑛𝑔𝑡ℎ = 88.5𝑚𝑚
Front spacer
Its length is made the same as the length of the die block that is 24mm. A relief of 1.4mm is left
to ease the starting of new strips through the die.
According to the dimensions of the finger stop, a slot machining having a depth of 2mm is done
on the front spacer where the finger stops are to be located. Therefore this becomes the final
appearance.

Fig 35: Front spacer

3.67 Finger stop design

Standard dimensions are taken from tables

Fig 36: (a) Standard finger stop (b) Finger stop

37 | P a g e
AAIT Internship report 2017/18

The number one front spacer is used in relation to the strip thickness. It has a width of 9.5mm, a
slot to go to and fro with 20.6mm length and a hole with diameter of 6mm. It is fastened by a screw
that inserted to the die block and a spring with 25mm length, 4mm pitch, 8mm diameter and 1.2mm
wire diameter.

3.68 Automatic stop

Since the die is small, a spring loaded pin stop would be a better choice. The counter bore end
position is made at the half thickness of the die block.

Fig 37: Spring loaded automatic stop

Making the diameter of the pin 8mm and the shoulder to be 2mm offset with 3mm shoulder height
would be a good estimation.

3.69 Stripper plate

According to strip thickness, as read from table, the thickness of the stripper should be 6.4mm.
It inherits the width and length of the die block except that it has a notch machined in the edge to
offer a shelf for starting new stripps through the die. The notch has 9.5mm width and equal length.

3.70 Fasteners
For the punches
Selecting the socket button head screw to fasten the stripper plate, gages and die block together,
the M8 dimensions are read from the table.
𝐻𝑒𝑎𝑑 𝑑𝑖𝑎. (𝐷) = 13𝑚𝑚 𝐻𝑒𝑎𝑑 𝑙𝑒𝑛𝑔𝑡ℎ = 8𝑚𝑚 𝑆𝑐𝑟𝑒𝑤 𝑙𝑒𝑛𝑔𝑡ℎ = 30𝑚𝑚
𝐿 = 2.75𝐷 = 2.75 ∗ 13𝑚𝑚 = 35.8𝑚𝑚 𝑑𝑜𝑤𝑒𝑙 𝑑𝑖𝑎 = 8𝑚𝑚

Fig 38: (a) Hole spacing from edge (b) Dowel hole spacing from screw hole

38 | P a g e
AAIT Internship report 2017/18

For the die block:- The fool proof method is used for easier assembly procedure. At one side the
dowel is 22mm apart from the screw and 24mm apart at the opposite side. Also socket cap screws
with identical dimension but with a different length are used.
For the finger stops:- a bolt with 6mm diameter and length of 72mm is preffered according to
related dimensions.

3.71 Die set selection

Since the dimension of the width of the die block is 177.7mm a die set that corresponds this value
is selected from a catalogue.
Die holder:
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑒𝑛𝑔𝑡ℎ = 279𝑚𝑚 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑤𝑖𝑑𝑡ℎ = 238𝑚𝑚 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 38𝑚𝑚
Punch holder:
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑒𝑛𝑔𝑡ℎ = 226.6𝑚𝑚 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑤𝑖𝑑𝑡ℎ = 205𝑚𝑚 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 32𝑚𝑚
Guide pillar
𝐷𝑖𝑎 𝑋 𝑙𝑒𝑛𝑔𝑡ℎ = 25𝑚𝑚𝑋146𝑚𝑚
Bushing: 𝐷𝑖𝑎 𝑋 𝑙𝑒𝑛𝑔𝑡ℎ = 45𝑚𝑚𝑋62𝑚𝑚
 To select the type of shank, the tonnage is reffered.
𝑇𝑜𝑛𝑛𝑎𝑔𝑒 = 6.6 𝑡𝑜𝑛
Therefore a shank with M16 thread diameter is selected.

3.72 Cost analysis

The total cost consists of material cost, machining cost, labour cost and design cost. These costs
are valued according to national standards and standard materials are assumed to be bought from
near by markets.
UNIT TOTAL
S/N DESCRIPTION Qty PRICE PRICE
[BR] [BR]
1 upper bolster 1 pcs 4,262.0 4,262.00
2 Lower bolster 1 pcs 4,379.0 4,379.00
3 Guide Pillar 2 pcs 1,616.0 3,232.00
4 Forming punch 1 pcs 3,908.0 3,908.00
5 piercing punch 1 pcs 9,042.0 9,042.00
6 striper plate 1 pcs 6,474.0 6,474.00
7 Front spacer 1 pcs 2,862.0 2,862.00
8 Back gage 1 pcs 4,408.0 4,408.00

39 | P a g e
AAIT Internship report 2017/18

9 finger stopper 2 pcs 302.0 604.00

10 Die block 1 pcs 11,359.0 11,359.00
11 Bushing 2 pcs 1,470.0 2,940.00
12 Automatic stop 1 pcs 2,388.0 2,388.00
13 Strip support 1 pcs 2,668.0 2,668.00
14 punch plate 1 pcs 4,517.0 4,517.00
15 SHANK 1 pcs 142.0 142.00

1 standard parts 1 pcs 504.0 504.00

2 used material 1 pcs 0.0 0.00
3 assembly cost 1 pcs 361.0 361.00
4 checking cost 1 pcs 182.0 182.00
Total
Amount 64,232.00

Table 6: Cost estimation

40 | P a g e
AAIT Internship report 2017/18

Chapter 4

Conclusion and recommendation

This internship project has discussed the full design procedure of a three bar slide manufacturing
die. It also mentions problems that occur when designing a certain die. Additionally it not only
states the problems but also provides the better solutions to tackle them.

In order to increase productivity and production rate the die can be designed with a two stage
progress. However, it should hold the principle of combination die which integrates cutting
operation that are blanking and piercing and the non-cutting operation, forming. In most designs
the primary operation, piercing, is done. Then the die performs the forming operation followed by
blanking. Additionally the die may be inverted since the forming operation is done downward and
the blanking operation upward according to the look I have made on the work piece.

41 | P a g e
AAIT Internship report 2017/18

Chapter 5
References
[1] Die Design Fundamentals by Paquin, First edition, 1962
[2] LEMPCO Die set engineering handbook and catalog, 2012
[3] PRESS TOOL design & construction PRAKASH H. JOSHI, First edition, 1996
[4] Handbook of Die Design, 2nd Edition, 2000
[5] Company brochure printed in 2008 E.C.

42 | P a g e
AAIT Internship report 2017/18

Chapter 6
Appendices
ISIC-----------------------------------------International standard industrial classification (1)
E.C. -----------------------------------------Ethiopian calender (1)
MIDI-----------------------------------------Metal industry development institute (1)
MPDC---------------------------------------Metal products development center (2)
NDT-----------------------------------------Non-destructive test (5)
UIL------------------------------------------University industry linkage (9)
AAIT----------------------------------------Addis ababa institute of technology (9)
PDD-----------------------------------------Product design and development (9)
2D-------------------------------------------Two dimensional (10)
3D-------------------------------------------Three dimensional (10)
i.e.-------------------------------------------That is

43 | P a g e