Optimization of compound die piercing punches and double cutting process parameters using finite element analysis

Abstract

This article investigates different types of compound die piercing punches and double cutting operation parameters in terms of optimization using finite element technique, Taguchi method, regression analysis, and analysis of variance. The article overcomes the current knowledge gap in studying various cutting edges of piercing punches such as flat, chamfered, flat edge with concave hemisphere, and convex shaped when using the compound dies in stamping operations. The analysis of the compound die is carried out using ANSYS software. The main focus is to determine the contribution of key parameters for obtaining optimum cutting tool design. The best piercing punch is selected based on minimum burr height of the product. The values of cutting process parameters and burr heights have been analyzed using Minitab software. The results obtained indicate that the burr heights of the final product are at a minimum when the sheet metals are thicker and larger when the sheets are thinner. The chamfered and convex punches provided minimum burr heights which are as low as 0.034 mm for a typical sheet metal. This study provides a better outcome compared to the available experimental data in the literature. The investigation also designed efficient compound dies resulting in improved product quality.