Abstract
Metal stamping is a sheet metal manufacturing process in which products are made using press machine and press tools. Currently sheet metal stamping process is practiced in Ethiopian metal industries in large amount but, mostly they use the technology which has been introduced to the companies 50 years back. This results in larger loss in material, economy and machines. These paper work asses the loss in the existing manufacturing process and provides a better way which conforms to the modern technology. In the existing metal stamping process of our country’s metal industries large press machines are used with separate single operation press tools. But, in modern technology a progressive dies are used in which all the operations are integrated in one progressive press tool and all the operations are done successively. In this paper work a progressive press tool is designed using logopress 3 die design software for a part called receiver body which is produced in Gafat armament industry. In the existing system the part is produced after passing through 22 separate working stations, 48 parts are made per day and it costs 102 birr per part. But in the newly designed progressive press tool the part is produced in one progressive die, 7200 parts are produced per day and it costs 12.23 birr per part. Therefore, introducing modern progressive press tools using computer aided design/computer aided manufacturing software’s could make a huge difference in Ethiopian metal industries.
Highlights
Metal stamping die is an ideal tool that can produce large quantities of parts that are consistent in appearance, quality and dimensional accuracy
48 parts are made per day 7200 parts are made per day Following fundamental principles and procedure in the progressive die designing area, every possible effort has been made in designing a progressive die that meets the functional requirements
Powerful and important engineering software’s such as logopress 3, Solidworks 2012 simulation Xpress module and Camworks 2012 have been used for designing and simulation, analysis and machining code generation respectively
Summary
Metal stamping die is an ideal tool that can produce large quantities of parts that are consistent in appearance, quality and dimensional accuracy. Because heat is generated from friction during the cutting and forming process, stamped parts often exit the dies very hot. A stamping die is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a desired shape or profile. The decision to produce a part progressively is usually determined by two factors: the volume of production and the complexity of the part These two factors are instrumental in the design and construction of the tooling. Kassahun Nigussie Asfew and Wassihun Yimer Amdie: Improvement of Productivity in Metal Stamping Process of Ethiopian Industries Through Introducing CAD/CAM Based Press Tools to produce consistent-quality parts. Excess material equal to one to two material thicknesses per side is required for trimming This method typically produces minimal scrap. [10]
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