Design and Fabrication of Die and Punch Components for the Piercing-Coining Process of AA 1100-O Aluminum Plate

Abstract

The preparation of aluminium workpieces for anodizing at Jakarta State Polytechnic is currently performed manually using a hacksaw and metal file, resulting in a production time of more than 60 min/workpiece. This study focuses on the design and fabrication of punch and die components for an existing die machine by applying the Quality Function Deployment (QFD). User needs were identified through observation, interviews, and questionnaires, and subsequently translated into engineering specifications using the House of Quality (HoQ). Based on the design analysis, a die clearance of 0.21 mm and a required pressing force of 3 tons were determined. The fabricated punch and die components were then evaluated through trial production of aluminium specimens. The experimental result demonstrated that the developed tooling was successfully integrated into the die system and produced workpieces with consistent dimensions and satisfactory accuracy. In addition, the proposed system substantially improved production efficiency, increasing the production capacity from approximately one workpiece/hour using the conventional manual process to 240 workpieces/hour, assuming continuous machine operation without downtime. The proposed approach demonstrates the potential of integrating industrial press tooling into vocational laboratory applications to improve the efficiency and consistency of practical workpiece preparation. Furthermore, this approach can serve as a scalable model for implementing low-cost manufacturing technologies in vocational education.