PRODUCTION OF METAL-BASED IMPLANTS FOR CYRO-FACIAL INJURIES (BLUEPRINTS)

The main objective of this project is to propose a design for a progressive die
for the production of metal based implants for Cyro-facial injuries. The bulk of the
work would be to produce the detailed design drawings or blueprints for each
progressive die components and to suggest the appropriate process plans for the
fabrication of the respective progressive die components. The main concentration is
put in producing the blueprint~ of a progressive die to produce the I-shaped metal
implants. Throughout the first semester, literature reviews are done to gain knowledge
about the working principle of the progressive die and how to design the various die
components needed in the progressive die. Other than that, literature reviews are also
done to gain information about the minimum tolerances, clearances and angular relief
that need to be applied to each die components to ensure the quality of the progressive
die and also the metal implants that will be produced by the progressive die. The basic
step in producing a progressive die is to produce the blank layout. There are many
ways in laying out the scrap strip. However, for this particular project, the blanks are
laid out by adopting the narrow-run, one-pass layout. To optimize the usage of the
material strip while ensuring the quality of the produced implants, minimum bridge
allowances are applied between blanks and between blanks and edges of the strip.
After calculation, the blanking force needed to cut the blank from the strip is
33707.52 N and since the press capacities are usua:lly in tons, a press of more than
3. 789 tons should be chosen to produce this particular metal implants. Other than that,
it is also found that, a total of 63 metal implants can be produced from a 1 m material
strip. On the other hand, in designing the die components, care had been taken in
assigning the correct clearances, angular relief, allowances and tolerances for each
part of the die components. This is to ensure the success of the particular progressive
die. In general, the material selected for the implants are titanium and stainless steel
strips while for the die components, are tool steels, mild steel and cast steel. The main
processes involved for fabricating the die components are Wire EDM and milling.