Design of punch and die for taper roller bearing cage for multi pocketing

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –

6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 2, March - April (2013) © IAEME

367

DESIGN OF PUNCH AND DIE FOR TAPER ROLLER BEARING

CAGE FOR MULTI POCKETING

Mr. M. V. ARDESHANA1, Mr. N. L. MEHTA

2

1M.E.[CAD/CAM] Student, Department of Mechanical Engineering, B. H. Gardi College of

Engineering & Technology, Rajkot, Gujarat, India 2Asst. Prof. Department of Mechanical Engineering, B. H. Gardi College of Engineering &

Technology, Rajkot, Gujarat, India

ABSTRACT

Taper roller bearing is widely used in the different industries. So there is need to

demand for the taper roller bearing. It has four components outer race, inner race cage and

roller. The main function of Cage is to maintain rolling element at a uniform pitch, so load is

never applied directly to the cage. Cage is manufactured by three ways pressed cage, machine

cage, and molded cage. But mostly cage is manufactured by power press. In manufacturing of

cage pocketing operation is required as per the number of pockets. In existing situation single

pocket is produced in a single stroke of power press. So it has to go for the number of stroke

as equal to number of pocket so production time is more for cage manufacturing. In proposed

method of manufacturing for cage multi pocketing is performed in a single stroke of power

press. Due to that production time for cage is reduced and productivity is increased. Keywords: Cage, Die, Multi Pocketing, Punch, Taper Roller Bearing

1. INTRODUCTION

The main function of the roller bearing cage is to avoid direct contact between the

rolling elements. At the roller bearings, the cage realizes also the guidance of rollers and at

the roller bearings with separable rings the cage retains the rolling elements. [1]

Cages function to maintain rolling elements at a uniform pitch so load is never applied

directly to the cage and to prevent the rolling elements from falling out when handling the

bearing.

INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING

AND TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)

ISSN 0976 – 6359 (Online)

Volume 4, Issue 2, March - April (2013), pp. 367-372

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368

2. EXISTING METHOD OF CAGE MANUFACTURING

Pressed cages are usually made of steel, but sometimes of brass, too. They are lighter

than machined metal cages. [2] Prone type cage and taper roller bearing cage are

manufactured by power press operation.

Machined cages of metal and textile laminated phenolic resin are made from tubes of

steel, light metal or textile laminated phenolic resin, or cast brass rings. Machined cages are

also used where lip guidance of the cage is required. Riveted cage and Prong cage are

manufactured by Machine operation.

Moulded cages of polyamide are produced by injection moulding and are used in

many large-series bearings. Injection moulding has made it possible to realize cage designs

with an especially high load carrying capacity. Angular contact ball bearing cage are

manufactured by Moulding operation.

Cage Drawing:

Fig.1. TRB Cage 32211

This is the Cage drawing as shown in Fig. In Existing Situation cage is manufactured

by Power press. In this cage total no. of pocket is 19. Right now single pocket required single

stroke of press so 19 pockets requires 19 stroke per a single cage manufacturing. Indexing

mechanism is also required for maintaining proper distance between the two pockets.

Production time for a single cage is more. So productivity is less. Production of cage is 6,

00,000 piece per month in a company. To increase the productivity it has to increase the

production. Therefore it is required to reduce the production time for a single cage

manufacturing. It has to improve the manufacturing process. [2]

3. PROPOSED METHOD OF CAGE MANUFACTURING

In propose method of cage manufacturing all 19 pockets produce in a single stroke of

a power press. So it can also reduce the production time for the cage. [2] And it can also

increase the productivity. Same way there is no need to go for the indexing in cage for

producing a pocket. For making all pocket in a single stroke multi pocketing assembly is

required. Assembly contains the punch, die, punch retainer, centre pin, die plate, retainer ring.



369

3.1. Design of punch and die Here, in this case Blanking Shape is shown in fig.

Figure.2. Blanked shape

P= Perimeter of pocket=57.8 mm, S=Shear strength = 4000 psi= 275.79 N/mm2

T= Thickness of strip = 1.8 mm Force = 28693.19 N (1)

1 tonne =9806.65 N, So, 28693.19 N = 2.9 tone for 1 pocket.

But we have to create 19 pockets in single punching operation. [3]

For 19 pocket = 19 2.9 = 55.1 tone press capacity required.

The clearance is a function of the kind, thickness and temper of the work material,

harder materials requiring larger clearance than soft materials, the exception being

aluminium.

Punch size A1 = 10.95 mm, Punch size A2 = 9.95 mm, Punch height = 18.40 mm

3.2. Design of Die The minimum thickness of the die block depends upon the strength required to resist

the cutting forces, and it will depend upon the type and thickness of the material being cut.

Die thickness=19 mm for blanking perimeter 75 mm

Die thickness=25 mm for blanking perimeter 75 to 250mm

Die thickness=31 mm for blanking perimeter >250 mm

Or die block thickness can be taken as T= cm, F is in tones.

So, in this case blanking perimeter is 58 mm so die thickness should be 15 mm.

Die size A1 = 11.25 mm, Die size A2 = 10.25 mm, Die Height = 18.70 mm

3.3. Design of Punch Retainer/Holder The main function of punch retainer is to hold the punch. Punch is rest in the slot of

punch retainer. Punch holder – dimension of the punch holder should be at least 5 mm larger

than the punch. Punch holder thickness 25 to 75mm. Punch retainer thickness is 30 mm in

this die assembly. It has to rest 19 punches so 19 slots available in the punch retainer.

3.4. Design of Retainer Ring

Retainer ring is mounted on the punch retainer. Retainer ring thickness is 25 mm.

above the retainer ring it has to provide the constant pressure by bellow or spring. So all

punches are together with each other.

3.5. Design of center pin Center pin is fixed with the ram. Center pin is moving inside the punch.So as per

constrain center pin outside diameter is 84 mm and below portion diameter is 46 mm. Height



370

of center pin is 80 mm. It has outside taper for the proper mating between the outside of

center pin and inside of punch.

Fig.3. Model of Punch

Fig.4. Model of Die

Fig.5. Model of Punch Retainer

Fig.6. Model of Die plate

Fig.7. Model of Centre Pin

Fig.8. Model of Retainer ring

Fig.9. Multi pocketing Assembly

Fig.10. Multi pocketing Assembly

Punch Retainer

Punch

Die Plate

Die

Retainer

Ring

Center

Pin



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4. ANALYSIS OF PUNCH

Allowable stress = yield strength/ factor of safety

(2)

Factor of safety = 1.5, σ = 2200/1.5 = 1466.66 N/mm2

Static structural analysis of Punch:

Fig.11. Displacement of punch is 0.05 mm

Fig.12. Stress analysis of punch

Table.4. Result and Discussion

Sr. No. Allowable stress Von mises stress

1 1466.66 N/ mm2 205 N/mm

2

From the above analysis we can get the stress developed in the punch is less than the design

allowable stress so the design is safe design.

5. CONCLUSION

The proposed manufacturing method for cage based on the multi pocketing process.

The result for the analysis indicates the safe design for the punch. Multi pocketing assembly

include the design for punch, die, punch retainer, retainer ring and centre pin. The main

aspect of the multi pocketing is to reduce the production time for the cage but as a by product

it can also increase the productivity.

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