Design of combined tool for production of metal holders for wire and hose ties in RASCO sweepers

Tema ovog diplomskog rada je projektiranje i konstrukcija kombiniranog alata za izradu metalnih držača vezica RASCO čistilica. Alat pripada u grupu kombiniranih štanci za obradu metala deformiranjem. Pod nazivom štance podrazumijeva se velika grupa specijalnih alata koji služe za obradu metala ili nemetala pomoću rezanja ili oblikovanja bez odvojene čestice. Štance su tipičan alat za velikoserijsku i masovnu proizvodnju. Upotrebom odgovarajućih materijala, pravilnom toplinskom obradom reznih dijelova alata i pravilnim radom može se jednim alatom izraditi serija od više stotina tisuća komada. Posluživanje alata je jednostavno, vrijeme izrade jednog izratka je vrlo kratko te iznosi sedam do deset puta manje nego pri obradi skidanjem čestica. Kombinirani alati osim postupka rezanja uključuju i postupke trajne deformacije. Oni su konstrukcijski riješeni tako da se i složeniji izradci mogu dobiti u jednom hodu alata. Cijena izrade takvih alata je visoka i zbog toga se primjenjuju samo za velike serije ili za izratke s velikim zahtjevom na točnost. U ovom radu su opisane tehnike štancanja, svi procesi oblikovanja te je objašnjena podjela štanci prema njihovoj konstrukciji i namjeni. Pozornost se posvetila materijalu koji se oblikuje i stroju na koji se alat postavlja. Detaljno su opisani svi dijelovi kombiniranog alata i dat je opis proizvoda po fazama proizvodnje. Proveden je proračun rezne zračnosti, sila probijanja, odrezivanja i savijanja metalnih držača vezica. Na kraju rada su kvantitativno prikazane sile oblikovanja, a u tehničkoj dokumentaciji prikazani su radionički i sklopni crteži.The topic of this thesis is Design of combined tool for production of metal holders for wire and hose ties in RASCO sweepers. The tool belongs to the group of progressive stamping dies for metal forming processes. The name progressive stamping die implies a large group of special tools used to process metals or non – metals by cutting or metal forming. Progressive stamping dies are a typical tool for large – scale and mass production. Using the right materials, proper heat treatment of cutting parts of the tool and proper operation, a batch of hundreds of thousands of pieces can be made using one tool. The operation of the tool is simple, the production of one workpiece is very short, and is seven to ten times shorter compared to machining processes. Combined tools, in addition to the cutting process, also include permanent deformation procedures. They are structurally solved so that more complex workpieces can be obtained in one step of the tool. The cost of producing such tools is high and therefore they are only applicable to large batches or workpieces with a high accuracy requirement. This paper describes die – stamping techniques, all shaping processes, and explains the division of progressive stamping dies according to their construction and purpose. Attention has been devoted to the material shape and the machine in which the tool was placed. All parts of the combined tool are described in detail and a description of the product in its production stages are given. The calculation of the cutting gap, force of punching, cutting and bending of metal holders for wire and hose ties was carried out. At the end of the paper, the shaping forces are presented quantitatively, and the workshop and assembly drawings are shown in the technical documentation