Design Project: Blanking Die Set for Stainless Steel Sheet

ENGT 5253
ADVANCED MATERIALS AND DESIGN
ASSIGNMENT: DESIGN PROJECT (30%)

1 BACKGROUND INFORMATION
Blanking is a cold forming process. It is a shearing process in which a die and a punch
are used to modify a thin and flexible material such as paper textile, plastic film1. The
punched-out piece is called a blank. The characteristics of a blanking process include:
a) Ability to produce economical metals
b) There is removal of workpiece material as the punch enters the die.
c) Ability to produce holes
Soft materials such as aluminum, brass, bronze, mild steel, stainless steel. Aluminum is
the most blanked material.
However, the blanking has some disadvantages such as
a) Residual cracks are generated along the cracked edges.
b) There is hardening of the workpiece along the blanked edges.
c) There is excess burr and roll-over when clearance is excess.
d) Only soft materials can be blanked.
2 PROBLEM STATEMENT
We are supposed to use a Computer Aided Design (CAD) software to design a blanking
die set to blank two letters of your name from stainless Steel sheet. A 3-D model was
supposed to be constructed on a CAD software. Engineering drawings were also
supposed to be drafted with the CAD software. Appropriate materials were supposed to
be selected. Then surface treatments were to be specified to enhance the performance of
the die set. A stress analysis (FEA) was supposed to be done on the model assemblies2.
DESIGN CONSTRAINTS AND SPECIFICATIONS
The material to be blanked is stainless Steel of thickness 2mm. Each die is used to blank
or outline one letter from your word. There were no constraints to the style used as any
artistic style was accepted. The size of the letter was supposed to be in the range of (30 –
50) mm width and (40-70) mm height as shown below.
3 DESIGN APPROACH
1 M Boryga & P Kołodziej, "Use of structural synthesis of mechanisms for dynamic simulation in Autodesk
Inventor", in Mechanik, , 2019, 140-143.
2 J Kostka et al., "Stress Analysis of a Rotating Body by Means of Photostress Method and Using Solidworks
Programme", in American Journal of Mechanical Engineering, vol. 2, 2014, 226-230.

Two letters from my name S and U were chosen as for the dies. Having known which
letters to use, 3-D models were constructed on Solidworks CAD software. The
appropriate materials3 were then selected on granta CES software after which drafting of
Engineering drawings was done on Solidworks software. A Finite Element Analysis
(FEA) was done to determine the stresses4.
4 DESIGN PROCESS
4.1 3-D MODELS
Having known the letters (S and U) the dies were modelled on Solidworks. A sheet of
dimensions 100 mm x 60 mm was also designed to help in the visualization of the die set.
(DUE TO THE FILE TYPE, THE CAD 3-D MODELS FILES WERE NOT INCLUDED
HERE BUT WERE PROVIDED IN ANOTHER FOLDER).
4.2 ENGINEERING DRAWINGS
Drafting of Engineering drawings was done on Solidworks. Drawings of S-assembly and
U-assembly were made.
These engineering drawings are provided next page.
3 J Kostka et al., "Stress Analysis of a Rotating Body by Means of Photostress Method and Using Solidworks
Programme", in American Journal of Mechanical Engineering, vol. 2, 2014, 226-230.
4 schulergroup.com, "Screw presses with direct drives", in Schulergroup.com, , 2019,
<https://www.schulergroup.com/major/download_center/broschueren_forging/download_forging/
forging_broschuere_spindelpressen_direktantrieb_e.pdf> [accessed 20 March 2019].

4 3 2 1
F F
E E
D D
C
100.00
C
B
ITEM NO. PART NUMBER DESC RIPTION MATERIAL QTY.
B
1 s Plain C arbon Steel 1
2 sheet stainless steel 1
3 s2 Plain carbon steel 1
UNLESS OTHERWISE SPECIFIED: DIMENSIONS
ARE IN MILLIMETERS SURFAC E FINISH:
TO LERANC ES:
LINEAR:
ANGULAR:
FINISH: DEBURR AND
BREAK SHARP
EDGES
DO NOT SC ALE DRAWING REVISION
A NAME SIGNATURE DATE TITLE:
ADRAWN
C HK'D
APPV'D

5 M Malik, M Przytocka & M Karpiuk, "Model based definition in SOLIDWORKS®", in Mechanik, , 2019, 67-69.

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