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Prediction of punching life span for phosphor bronze stamping operation

Muin Hashim, Mohd Fadzil (2007) Prediction of punching life span for phosphor bronze stamping operation. Masters thesis, Universiti Tun Hussein Onn Malaysia.

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Predictions of punching life span for stamping process is critical since affect the quality of product, the production rate and cause waste in time and cost. The punch need to be sharpened correctly after a number of punches since its dimensional accuracy will deteriorate and cause inaccuracy in the dimensions of the product and thus do not satisfy the quality requirements. One of the method that are normally used to determine the point where re-sharpening should be carried out is through estimating the number of shots or unit kshots that will produce products that are dimensionally inaccurate and the occurrence of burr on the product. The research was carried out to overcome this problem. The punch that was used is made of Cementite Tungsten Carbide and the work piece is Phosphor Bronze Strip. The relative hardness is about 6.3. The stamping process is a progressive stamping process carried out in a well known electronic factory. The profile of the wear of the punch is measured and the error in product dimension is identified. The increase presence of burr is also studied and identified for every 4000 product. The end of punch life span is determined when there is a dimensional inaccuracy on the product and the product is rejected. This research found that at this point punch is rounded, wear is present and cracks occurred at the cutting edge of the tool. As a result of this research, relation between the punch wear and kshots are found to be proportionate and this enable an algorithm to be formulated. Simulation model is built to enable more accurate algorithm is developed. The simulation model used 'Constraint Cubic Spline algorithm'. The researcher is able to forecast a more accurately the kshots that relates to punch wear and thus save products dimensional inaccuracy and product rejects. An improved sharpening process is also possible and this provide accurate rcsharpening work. The accuracy of the sharpening prediction also reduce burr and have enhance the efficiency of the resharpening process. In conclusion, the algorithm has improved productivity and save cost to the company.

Item Type: Thesis (Masters)
Subjects: T Technology > TS Manufactures > TS155-194 Production management. Operations management
Depositing User: M.Iqbal Zainal A
Date Deposited: 19 Apr 2011 06:56
Last Modified: 15 Jan 2020 03:18
URI: http://eprints.uthm.edu.my/id/eprint/1000
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