Scribd
Upload
537 views13 pages

Tool Room

1) The document discusses various tool room countermeasures to prevent frequent tool breakage and wear. It describes issues like piercing punch breakage, die backplate breakage, and knife wear being addressed by modifications like adding radii, increasing thickness, and applying coatings. 2) Conversions of machines are described to make better use of capacity, like converting a D08N o-ring machine to a D08E model and a 4C bush extrusion machine to a D08E model. Modifications like adding pin guides and changing carriers are mentioned. 3) Other countermeasures included adding fork support during pin assembly, providing entry steps to bush pilots to improve alignment, and implementing a gauge plate to more easily

Uploaded by

Subramanya Seeta Ram Prasad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
537 views13 pages

Tool Room

1) The document discusses various tool room countermeasures to prevent frequent tool breakage and wear. It describes issues like piercing punch breakage, die backplate breakage, and knife wear being addressed by modifications like adding radii, increasing thickness, and applying coatings. 2) Conversions of machines are described to make better use of capacity, like converting a D08N o-ring machine to a D08E model and a 4C bush extrusion machine to a D08E model. Modifications like adding pin guides and changing carriers are mentioned. 3) Other countermeasures included adding fork support during pin assembly, providing entry steps to bush pilots to improve alignment, and implementing a gauge plate to more easily

Uploaded by

Subramanya Seeta Ram Prasad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 13

TOOL ROOM

THEME : To Prevent frequent brakeage of piercing


punches

Before

AFTER

Breaking at
this point

PHYSICAL PHENOMENON : frequent breakage of piercing punches in 08E HMSI OP


(20 Occ / month).

Analysis :

Countermeasure : -

W1: piercing punch breakage


W2:.load on shank area
W3: sharp corner at shank taper area.
W4: weak at sharp corner.

By providing smooth radius at shank


taper area so that punch is
strengthened.

THEME : To Prevent breakage of die back up plate

Before

101/102 DIE BACK PLATE 30mm


THICKNESS

AFTER

101/102 DIE BACK PLATE 40mm


THICKNESS

PHYSICAL PHENOMENON : frequent breakage die back up plate in


101/102 OP (2 times)
Analysis :

Countermeasure : -

W1: die back up plate breakage

By increasing the thickness of die back


up plate from 30mm to 40mm, hence
back up plate is strengthened.

W2: not withstanding the load.


W3: less thickness

THEME : To Prevent frequent tool change due to


wear out

Before

AFTER

BUSH FORMING M/C (KBD) KNIFE NON


COATED

BUSH FORMING M/C (KBD) KNIFE ALCRONA


COATED

PHYSICAL PHENOMENON : frequent change of tool due to wear out .


(every 20kgs).
Countermeasure : Analysis :
W1: tool wear out
W2: low hardness

Knife working area is coated with


Alcrona, hence surface hardness has
increased.

THEME : To Prevent frequent TOOL CHANGE DUE


TO WEAR OUT

Before

KBD L . H & R .H TOOLS

AFTER

KBD L . H & R .H TOOLS WITH CARBIDE TIP

PHYSICAL PHENOMENON : frequent change of tool due to wear


out (500kgs ).
Analysis :
Countermeasure : W1:tool wear out.
W2:low hardness.
W3:tool material didn't support to get
high hardness.

Carbide insert brazed at working area,


hence working area got good hardness.

THEME : To prevent operator skill in clamping tool

Before

AFTER

PHYSICAL PHENOMENON : clamping tool with non standard clamps


getting loose in running causes tool break down.
Analysis :
W1:tool break down due to non
standard clamps.

Countermeasure : Provided direct clamping by providing


spacer and T clamp screw holes.

THEME : To prevent bush miss


alignment

Before

AFTER

PHYSICAL PHENOMENON : to prevent bush pilot breakage due to


miss alignment .
Analysis :
W1:bush pilot breakage.
W2:miss alignment between bush and
pilot.
W3:less clearance to align.

Countermeasure : Provided entry step to bush pilot , hence


it got 1mm per side clearance to align
bush with pilot.

CONVERSION OF D08N-O-RING
ASSEMBLY M/c to D08E MODEL
BEFORE

AFTER

As 8E Model order has increased and 8N O Ring M/C has less order M/c
has converted to 8E
ALL TRACKS
CHANGED

PIN ANVIL AND BUH


ANVIL

PIN GUIDE
ADDED

PIN CARRIER
HOLDER
CHANGED

Before

AFTER

Fork support is increased up to pin assembly stage.

Provided pin guide to assemble pin easily.

Pin carrier holder changed to use common pin carrier for all
machines .

CONVERSION Of 4C SOLID BUSH EXTRUSION


M/c to D088 MODEL PROPOSED & TAKEN TRAIL
Before

AFTER

As 4C Model order is less than M/C capacity, in order to use M/C in ideal time it is proposed to
convert it to 88 model

Before

4th PUNCH

AFTER

4th KO
PUNCH

4th DIE

4th PUNCH
HOLDER

4th KO PUNCH HOLDER


COLLET

4th PUNCH

4th KO
PUNCH

4th DIE

4th PUNCH
HOLDER

4th PUNCH HOLDER


COLLET

THEME : Difficulty in checking blanking


punches

BLANKING PUNCHS CHECKING


GUAGE PLATE

PHYSICAL PHENOMENON : difficulty in checking blanking


punches.
Analysis
:
Countermeasure : W1: difficulty in checking blanking
punches
W2: difficulty in checking profile
accurately

Implemented gauge plate to check


blanking punches easily and accurately.

Thank You

You might also like