Development Of A New Die For The Manufacturing Of Telekom Malaysia Berhad (TM) Metal Based Products

Che Mat, Abdul Azim (2016) Development Of A New Die For The Manufacturing Of Telekom Malaysia Berhad (TM) Metal Based Products. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

This study was conducted at Subsea Supplies Sdn Bhd, Sepang. Recently, Subsea Supplies Sdn Bhd has started the production of Telekom Malaysia Berhad (TM) metal-based products. There are 38 types of products which can be divided into five categories; pole accessories, GI pipes, strut pipe, stainless steel cable tie and steel pole. The purpose of this study is to design and make a new die for manufacturing of clamp pole step for iron pole. The die making started with the study of clamp pole step specification based on several documents such as bill of material (BoM) and product drawing. Then die was designed by making hand-sketching and by using Solidworks 2015 CADCAM software followed by establishment of BoM for the die. The die was made of 8 main components; base plate (upper), die holder, backup plate (upper), upper die, stopper, lower die, backup plate (lower) and base plate (lower). As overall, the die for clamp pole step consists of upper and lower base plate that housing the die, and the V-shape upper and lower die that produces the 450 degrees bending shape on flat bar. There were many processes involved in making the die components which include cutting, surface grinding, drilling, hardening, tapping and welding. The upper and lower die also underwent heat treatment to ensure the die is strong and has high resistance to extreme absorption of stamping forces. The main materials used as die components were XW41 and DH2 steel. After the die completely assembled, it was installed at 200 tons stamping machine to test its performance in producing actual product, that is clamp pole step. The dimension of the V-shape of product was inspected. The length was ranged between 140.1 to 140.5 mm which was less ± 5% variation and within TM specification. Further inspection was conducted by visual inspection to the product including on the thread to ensure good galvanization conditions and the bolt have full thread. The visual inspection was also conducted by checking whether all the accessories were fit to a dummy 61 mm iron pole. The main contribution of this study to the company was the making of new die for clamp pole step and the establishment of several important documentation particular BoM and engineering drawing.

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