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PROJECT REPORT. PROGRESSIVE TOOL. PROJECT MEMBERS. DINESHAN.N (LEADER) -TTC PRAMODHA LEONARLD -GNTC DEENADAYALAN.S -VTC MAHESH.G -ONTC. COMPONENT DRAWING. ASSEMBLY DRAWING. PART DRAWING. PART DRAWING. PART DRAWING. PART DRAWING. PART DRAWING.

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Project report

PROJECTREPORT

PROGRESSIVETOOL


Project members
PROJECT MEMBERS

  • DINESHAN.N (LEADER) -TTC

  • PRAMODHA LEONARLD -GNTC

  • DEENADAYALAN.S -VTC

  • MAHESH.G -ONTC









Scope of the project
SCOPE OF THE PROJECT

As part of the faculty training program, to get hands on experience on design, planning, processing and inspection.


Process planning
PROCESS PLANNING

Without a proper planning things will never give a good result, so we started our project with a well organized planning.

Our planning includes

  • Macro planning

  • Micro planning


Macro planning
MACRO PLANNING

This planning enables us to get a clear idea about the process execution of the project from the beginning to the end.

Generally it is called as milestone planning.


Micro planning
MICRO PLANNING

This planning enables us to know about the element wise process and progress on each element

OPERATIONS PLANNED.

  • Milling

  • Turning

  • Grinding

  • Cylindrical grinding

  • Wire cutting

  • Bench work


Distribution of work
DISTRIBUTION OF WORK

To make our work easy and to get individual responsibility we distributed our work as follows:

Mr. Dineshan. N

  • Top plate

  • Bottom plate

  • Guide pillars

    4 Guide bushes


Distribution of work1
DISTRIBUTION OF WORK

Mr.Pramodha Leonarld

  • Punch holder

  • Blanking punch

  • Shank

  • Finger stopper


Distribution of work2
DISTRIBUTION OF WORK

Mr. Deenadayalan. S

  • Stripper plate

  • Piercing punch

  • Spacers

  • End stopper


Distribution of work3
DISTRIBUTION OF WORK

Mr. Mahesh. G

  • Die plate

  • Extension table

  • Piloting punch

  • Back plate


Manufacturing process
MANUFACTURING PROCESS

Element wise machining was carried out according to the micro planning with respect to the macro planning ie,

Thickness and reference grinding of all the plates were completed at the beginning

With respect to the reference sides tooling holes were made in all the plates.


Manufacturing process1
MANUFACTURING PROCESS

With respect to the tooling hole die set boring was carried out.

Based on the bore dimension guide pillars & guide bushes were ground to the required dimension.

Die set assembly was done according to the procedure.


Manufacturing process2
MANUFACTURING PROCESS

With respect to the tooling hole,H7 holes for piercing, piloting & wire entry hole for blank profile of punch holder, stripper plate & die plate was done.

Blank profile wire cutting was done in all the above mentioned plates.

Remaining relief holes were done in the drilling machine.

Blanking punch was made by profile milling on the CNC machine.


Manufacturing process3
MANUFACTURING PROCESS

Piercing and piloting punches were ground according to the requirement.

Element wise inspection was carried out after the machining and report was made.

Assembly was carried out according to the procedure.


Tooltrail
TOOLTRAIL

  • T0 TOOL trail was carried out on 2/2/2010 as per the macro plan.

  • Component dimension was found ok as per the drawing dimension

  • T1 Trial was conducted on 5/2/2010

    and the component was given to inspection dept- for final inspection and found it correct.


Inspection
INSPECTION

  • Element wise Inspection was carried out for each part after the operation.

  • Necessary Change was made to proceed to the other operation by considering the inspection reports.

  • Note:- Inspection was carried out from the machine itself before it was

    unclamped from the bed by our self.


Things gone right tgr
THINGS GONE RIGHT(TGR)

  • On time completion of die set assembly with required function

  • Manufacture of elements well within the requirement

  • On time completion of final assembly with proper functioning of the elements

  • On time submission of the sample


Things gone wrong tgw
THINGS GONE WRONG (TGW)

  • Hole in the top plate for fitting the bush is slightly deviated as per the drawing.

  • Spacer width is 0.8less according to the drawing so strip width is increased as per that.

  • A slight Fixed stopper mark is found on the strip after trials due to the pitch difference in the fixed stopper position.


Tangible gains
TANGIBLE GAINS

  • Macro planning

  • Micro planning

  • Follow up of the process

  • Man & machine management

  • Exposure on inspection

  • Trial & Trouble shooting


Intangible gains
INTANGIBLE GAINS

  • Team work

  • Leadership

  • Time consciousness

  • Communication skill

  • Presentation skill


Individual benefits
INDIVIDUAL BENEFITS

Dineshan.N

1)Learned more about the implementation of macro & micro planning

2)Got good team work

3)Support from all staff

4)Gained good knowledge about the working procedure of tool room

5)Gained good knowledge about the tool design theory and production


Individual benefits1
INDIVIDUAL BENEFITS

R.Premodha leonarld

1)Exposure on tooling.

2)Hands on experience on tool assembly.

3)Trouble shooting methods.

4)Exposure on new tooling materials, micro & macro planning.

5)Exposure on manufacturing process & inspection

6)Team work.


Individual benefits2
INDIVIDUAL BENEFITS

Deenadayalan.S

1)Exposure on micro & macro planning

2)Acquired knowledge about APQP techniques

3) Acquired knowledge about latest manufacturing process (modular tooling)

4)Latest tooling materials

5)Exposure on CNC & Wire EDM

6)Acquired knowledge about fine blanking


Individual benefits3
INDIVIDUAL BENEFITS

Mahesh.G

1)Knowledge on micro & macro planning.

2)Importance customer relationships.

3)Knowledge on modular tooling.

4)More knowledge on press tools from experienced faculties.

5)Team work.

6)Man & machine management.

7)Latest tooling materials.