Die Design Research Articles

Design and Fabrication of Drawing Die for Fly Press

Press working is defined as a non -chip removal manufacturing process by which various components are made from sheet metal. There are various types of components are produced from sheet metal operation. The main aim of this project is to "Design and fabrication of drawing die used in the fly press”. The design aspects of drawing die is accomplished in CATIA v5 and ansys 15.0 software. As coming to the manufacturing of drawing die, drawing die are manufactured in hot-chamber process which has the capacity to cast high melting point materials. The press tool leads to different operations namely blanking, drawing, trimming, bending, lancing, perforating, curling and shaving operations. Generally, drawing operation is the process of producing cylindrical objects. There is a vast use of press tools in industries like defense, textile, automobile, aircraft and food processing. The press machine is of the hand-operated fly press.

A Split Die Design for Forging of Hexagonal Bolt Head

A Split Die Design for Forging of Hexagonal Bolt Head

New Die Design Configuration for Grain Refinement by Hollow Twist Extrusion (HTE) Process

The severe plastic deformation (SPD) processes used for applying an extensive shear plastic strain in the material and consequently grain refinement and increase in the strength of materials. The strain distribution is very important and more homogenous plastic strain is desired in SPD process modifications. In this article, four different die configurations will be investigated during the hollow twist extrusion (HTE) process and the plastic strain distribution will be compared within a hollow section. The die configurations are similar slope line angle of inner and outer dies (SD), opposite slope line angle between the inner and outer dies (OD), outer die with twist zone and flat inner die (FI) and inner die with twist zone and flat outer die (FO). The Von-Mises stress, plastic strain, and material deformation are studied by using a finite element model which was developed in the ABAQUS finite element software. The results show that the FI and FO die configuration produce higher plastic strains than SD die configuration, but the strain homogeneity is not satisfactory. The plastic strain is higher and more homogenous for OD die configuration in comparison to the other die configurations. The required force for twist extrusion of the billet is almost equal for FI and FO die configuration (~ 216 kN) and increases to about 256 kN for SD die configuration (16% increase). The required force for OD die configuration increased once more to 370 kN (44.5% increase). The element distortion along the two defined paths determined the material flow during the HTE process. The flat die retards the material flow for FI and FO die configurations. A significantly material flow will happen for OD die configuration. The element distortion leads to better material mixing in OD die configuration and consequently higher magnitude and more homogenous plastic strain distribution and higher grain refinement will be obtained.

Design, Analysis and Fabrication of Safe Holder and Cam Dies in Injection Molding

Injection molding is one of the very significant methodologies in the plastic manufacturing industry. Production of any shape in the injection molding, mold with cavity must require. For this mold making three phases were involved in this project starting from design, analysis, manufacturing respectively. The objective of this project is to introduce detailed steps on design mold and using the simulation software to analyze the material flow, temperature and pressure characteristics of the product. The product designed and analyzed for this project is SAFE HOLDER and CAM. The manufacturing of mold is done by using advanced machinery such as CNC. The design and analysis of this product and mold were made by the designing analysis software CATIA V5, ANSYS 15.0, which is then stimulated by the use of Fluid Flow (Fluent) tool. This project was very useful in knowing the fluid characteristic behavior subjected to flowing inside the mold and also observed the variation of values with respect to given values at each stage. In this project, the analysis performed with taking polypropylene as a fluid from propylene polymer and steel as solid material for the die with inlet values are 230℃ temperature and 15m/s velocity.

Crystal plasticity prediction of texture evolution during helical extrusion process of aluminium alloys under three-dimensional deformation path

Accurate prediction of the texture evolution of aluminium alloys during hot extrusion process plays an important role in the die design and determination of process parameters. In this work, the deformation textures of aluminium alloys under three-dimensional deformation path are investigated numerically and experimentally. Firstly, the extrusion process of a helical profile is simulated with HyperXtrude and the deformation history under three-dimensional deformation path of the profile is extracted. Then the deformation modes in the different positions on the profile are analyzed and the velocity gradients are imported respectively into FC-Taylor, ALAMEL and ALAMEL III models to predict the extrusion deformation textures. Finally, a specially-designed helical extrusion die is manufactured and the extrusion experiment are carried out. The textures are analyzed by EBSD to verify the predicted results by three crystal plasticity models. The results show that there are significant differences in the deformation modes from the centre to surface of the extruded profile and the three crystal plasticity models differ greatly in the prediction accuracy of textures. For the deformation texture of the helical profile, the FC-Taylor model gives better prediction at the centre position and the ALAMEL-type model predicts better at the surface position of the profile.

Die design and optimization of cooling channel position for cold chamber high pressure die casting machine

A well-designed gating system for pressure die casting has always been of great importance to achieve good quality castings. However, the cooling system employed in the die and its position has found to have a significant impact on the generation of stresses in the die. High stress concentrations contribute to the erosion of cavity surface thereby affecting the tool life and casting quality. The objective of this research work is to design a die and to analyse the effect of positioning of the cooling channels on the generation of stresses on the cavity surface. In this study, a runner gate system is designed for an ADC 12 aluminium alloy component that is to be cast on a Cold Chamber High Pressure Die Casting (HPDC) machine. Stress analysis and optimization of the cooling channel positionof the die is carried out using ANSYS Workbench. Flow simulation of the optimized design is carried using MAGMA software to understand the effect of cooling channel position on the flow characteristics. The results demonstrate the impact of cooling channel position on the stresses generated in the die and prove to be valuable in designing the die. Defect inspection and testing of porosity is carried out on the castings produced with the optimized design in operation to check if they are acceptable.

Improved inverse design method for thin-wall hollow profiled polymer extrusion die based on FEM-CFD simulations

Extrusion process has excellent capability in continuous manufactures with high production volume, low cost, and steady quality for very complex cross-sectional products. However, manufacturing a proper extrusion die is challenging, but essential for qualified products, which needs to consider many influence factors in the die design. This paper shows an improved inverse design method for thin-wall hollow profiled polymer extrusion die by using computational fluid dynamics simulation. Also, the design criteria of the inverse design method for extrusion die are proposed and discussed. The simulation results show that the thickness of the die lip gap can be enlarged with the decreasing of the inlet flow rate. Additionally, it shows that the geometry profile of the die lip gap can be widened with the increasing of the length of the free jet. The analytical results have been verified by experiments and show a good agreement. It is concluded that the improved inverse design method with FEM-CFD simulations can provide better accuracy and significantly reduce the manufacturing difficulty of micro and thin-walled extrusion die.

Knowledge-based Design Method of Forging Dies based on the Stereotypes of Die Structures and the Functions of Forming Surfaces

The die design of forged products greatly affects the quality, cost, and delivery of cold- and warm-forged products. However, such design is often not easy even for experienced engineers because extensive knowledge and experience of plastic forming, forging, blanking, and punching are required. This paper proposes a general forging die design method termed GeneDie on the basis of the basic die structure and the forming surfaces configuration which are introduced as basic concepts for the support of simple but general die design. The basic die structure is the relative positional inter-relationship among the components of forging dies and is used to represent the structure of forging dies simply. Meanwhile, the forming surfaces configuration is the correspondence between functions allocated to the surfaces of forging dies and the surfaces of a forged product and used to represent the shapes of forming dies concisely. Die design plans are generated by exhaustively assuming a basic die structure and a forming surfaces configuration that satisfy design requirements and then verifying design constraints regarding formability, workability, and economy. An experimental knowledge base is implemented adopting the GeneDie method and applied to a forging process plan for an electrical connector. Experimental results show that die design plans that are functionally equivalent to those of an experienced engineer are included in the plans generated for all forming steps of the forging process plan.

FEA optimization of injection parameters in ceramic core development for investment casting of a gas turbine blade

Turbine blade/vane castings for aero-engine applications are produced through the investment casting process. In order to increase the turbine entry temperature and also to reduce the weight of individual blades, ceramic cores are used in the investment casting process to generate complex internal cooling passages. The wall thickness of hollow blades produced are critical, as a minimum wall thickness of 0.5 mm must be maintained ensuring desired strength of the high speed rotating turbine blades. The dimensional deviations in the ceramic cores due to shrinkage & warpage must be quantified before designing the tooling for the Ceramic Injection moulding. In present study, an attempt is made to quantify the shrinkage and warpage during injection molding. The quality of ceramic cores depends on the injection parameters. Predicting the shrinkage and warpage associated with the ceramic injection process helps in avoiding costly and time consuming iterations involved in die design and development. The flow process during filling, packing and cooling stages and the effect of injection molding parameters such as holding time, injection pressure (packing pressure) and flow rate on shrinkage, warpage and Von-Mises stresses on green core is studied using Moldex3D injection molding flow software. In the present study, a Taguchi based partial factorial experiment for optimization of ceramic injection parameters for injection molding of ceramic core is presented. The effect of individual parameters and their interaction is also presented.

Yield improvement in hot forging of differential spider

The main aim of the paper is to improve the yield in forging a Differential Spider. Yield is improved by varying the cross-section of the billet from Circular to RCS (Round Cornered Square) and orientation of billet. It is shown that the yield can be improved by employing a billet of RCS cross-section placing the diagonals parallel to the arms. Further improvement is made by modifying the die design in such a way that the die shape allows the material to flow into the arms of the spider, which resulted in a yield of 85%. 91% yield is obtained by completely closing the cavity in the bottom die and allowing the top die to enter into the cavity till the forging process is completed. This is achieved by providing a choke just after the flash land around the body of the spider. This paper also provides a complete die design procedure for multi-stage forging of a component. And, also shows the variation of effective-stress distribution, effective-strain distribution, temperature distribution and load with change in the equipment and billet temperature. For completely filled dies in varies cases wear depth is estimated. To estimate the metal flow and die filling a finite element method based simulation software DEFORM-3D is used.

Design and Verification of a New Test Bar Die for LPDC Process Based on Numerical Simulation

Design and Verification of a New Test Bar Die for LPDC Process Based on Numerical Simulation

A Fast Approach for Optimization of Hot Stamping Based on Machine Learning of Phase Transformation Kinetics

Hot stamping is one of the key technologies to produce lightweight components for the automotive industry. Numerical simulations are an important tool to design hot stamping tools. However, the hot stamping simulations are highly complex due to the deformation as well as heat transfer and phase transformation mechanisms taking place simultaneously. An accurate prediction of these mechanisms leads to high computational cost. Conventionally, an elastoplastic material model with temperature and strain rate dependence is used to describe the forming behavior, while austenite decomposition models are used to predict the kinetics of the phase transformation. The time spent on calculating the phase transformations can reach up to 40% of the total calculation time. To overcome these computational time issues, the current study introduces an alternative fast approach, to reduce the total calculation time of the hot stamping simulation during the die design stage. The simulation is sped up by replacing austenite decomposition models with surrogate models. A machine-learning (ML) model is used as a candidate for calculating the final phase fraction of hot-stamped parts. To train the model, various simulations models with varying degrees of deformation and cooling rates are set-up in the commercial FEM program LS-DYNA®. The ML model learns from the deformation histories and the final phase fractions to achieve the desired accuracy. For validation, the proposed approach is tested and compared with fully integrated phase transformations models. The final phase fraction and the total amount of floating operations are used as indicators to evaluate the performance of the fast approach. The results indicate that the ML model performs well in predicting the final phase fraction after hot-stamping and a significant reduction of the calculation time evaluated from the counting of floating operation FLOPS is reduced from 5713 to 12.

금형 수명을 고려한 자동차 엔진 마운트용 어댑터의 냉간 단조 금형 설계에 관한 연구

Process and die design of cold forging for the asymmetric part, engine mount adapter has been studied. Forging of the asymmetric part frequently causes die failure because of the high forging load and local stress concentration of the die. Thus, performing process design of cold forging to minimize forging load is required. Preform for the engine mount adapter was chosen based on the forging load and filling rate of forgings by the finite element analysis. In the die design, number of stress rings, interface radius, and relative interference were investigated in several cases with maximum principle stress by the finite element method. The shape of the die was determined by comparing the load changing the radius of the flange area. Also, the life of the designed die was calculated using the Goodman theory by cyclic fatigue loading. As a result, it was confirmed that the calculation life and results of the test were identical. In this study, it is verified that stress concentration and fatigue life should be considered simultaneously in the design of cold forging die for the asymmetric part.

Design and Analysis of Progressive Die for Chain Link Plate

Progressive die follows a sequence of processes in a single die at two or more stations. Design of progressive die is an essential phase in sheet metal manufacturing. Small error at any workplace causes huge manufacturing downtime due to die failure. In this analysis, current die design has low production rate when using multiple stations for sheet metalworking. Each process produced by multiple stations, which increases the loss of time. However, the choice of proper materials for sheet metal plate has become one of the vital features of progressive die design. Due to its long die life has become a requirement for lowering the cost of sheet metal mechanisms. The punch has very short life cycles. The purpose of this paper is to design a new 3D modelling of sheet metal forming die, to optimise a new chain link plate material to improve the performance of the punch component and to analyse the sheet metal punch to increase the punch lifetime cycle. The analysis was conducted by using ABAQUS/CAE to analyse the maximum and minimum stress of punch. The materials used are stainless steel, nickel plate and mild steel. The result of maximum stress obtained from ABAQUS/CAE is used in stress-lifetime prediction calculation. Based on the theory of stress-lifetime prediction, the lower the stress required to deform a material, the longer the life cycle of the punch. From this calculation, we can identify which material is the most suitable for chain link plate production.

Design and Analysis of Stage Progressive Die for a Sheet Metal Component

Stamping die industries had been a significant impact on research and development of new technology for bigger and advance. To sustain the stamping die industry under the current global situation, cost and time are most important factors that need to be focus. In this case study, the main problem of design and analysis of progressive die is cost spent for die fabrication is high, the number of station or stages is high that will affect the production time and lifespan of tool is short. This paper focused at the stages or station that will be redesign to reduce the cost for the die, station optimization to reduce time taken for stamping process and simulate the design of tools to calculate the life cycle of punch. The study is conducted through AutoCAD and Solidwork to redesign the die and strip layout optimization. Subsequently, the ABAQUS/CAE and e-fatigue are used to completed the analysis and life cycle results for punch with various design of punch edge. Theoretical analysis indicates that design of punch plays a vital role in life cycle analysis.

Design and Analysis of Punch and Die of a Micro Blanking Tool

Stamping dies one of the essential industries in engineering. The sheet metal blanking procedure is a shearing operations. In the blanking procedure the sheet metal is detached from the bulky portion of stock through the application of shearing force on the sheet. Nowadays, the increase of gadgets and smart phone is because of the 4th industrial revolution. This situation leads the demand for micro parts that will include in electronic devices. The main problem occurred in sheet metal stamping is damage to the punch after running thousands of stamping process. This paper focuses on designing a micro blanking dieset that meet the industrial demand. The study is conducted using solidworks to design the micro blanking dieset and perform analysis using FEM. The result of FEA will be calculated using e-fatigue to get the lifecycle for the punch.

Oscillating shear capillary rheometry (OSCAR) for polymer melts

Abstract Knowing the flow parameters of a polymer melt under steady state condition is required to assess the performance of the material in die and mold design. Often, however, this is not sufficient for a full understanding of the polymer processing behavior, and information on the linear and non-linear viscoelastic behavior is needed. In this paper, the non-linear viscoelastic behavior of a polymer under shear flow has been investigated by measuring the stress response when a cyclic oscillating shear rate in a capillary rheometer is applied. The time-dependent wall shear stress has been decomposed into in-phase viscous and elastic components. A model to interpret the experimental results is presented and applied to a well-characterized polystyrene and two polyethylenes with similar rheology but different molecular structure (HDPE and LLDPE). The relevant characteristics resulting from the model, such as the generalized elastic and viscous modulus under shear, are compared and discussed.

Design and Verification of Hot Pressing Die for Ceramic Matrix Composite Preform

Finite element analysis method, combined with experiments, has been employed to optimize the structure of die, which would be used to fabricate the ceramic matrix composite (CMC) preform. The contact property between bodies in dies (i.e., structure I and II designed in this paper) and analysis step were firstly defined based on the characteristics of force and heat transfer in the die. Hereafter, the stress distributions in dies and stress, pressure and temperature distributions in preforms were achieved, respectively. The outcomes demonstrate that the pressure transmission of the structure II was more efficient than that of the structure I, resulting in more even pressure on the preforms. Thus, the die II (i.e., the structure II) was utilized to fabricate the ceramic matrix composite preform. In addition, the performance of the preform II fabricated by the die II was detected through X-ray computed tomography, which indicates that the preform II has a compact and uniform internal structure. Therefore, the finite element analysis method should be regarded as a potential option for design and optimization of die.

Tool and Die Design for a Piercing Operation of Strip

The sheet-metal parts have already replaced many expensive cast, forged, and machined products in today’s practical and cost-conscious world. The factor is obviously the relative cheapness of these methods, or otherwise mass-produced parts, as well as greater control of their technical and aesthetic parameters. Press working is generally defined as a chip less manufacturing process by which various components are made from sheet metal. To produce a particular component in large quantity press tools are used. Metals having thickness less than 6mm is generally considered as strip. Metals having thickness greater than 6mm is considered as plate. In this work, According to organization need that the required strip part should have semi circular ends at both the ends. So in this work an attempt is made on to design the die for the strip to meet the actual operations requirement, materials, and calculations involved in it. The theoretical calculations for die are done and the parts are drawn with the help of software. The analysis of these parts is done on Ansys software and the results are taken.

Influences of Different Die Bearing Geometries on the Wire-Drawing Process

Metalworking is an essential process for the manufacture of machinery and equipment components. The design of the die geometry is an essential aspect of metalworking, and directly affects the resultant product’s quality and cost. As a matter of fact, a comprehensive understanding of the die bearing geometry plays a vital role in the die design process. For the specific case of wire drawing, however, few efforts have been dedicated to the study of the geometry of the bearing zone. In this regard, the present paper involves an attempt to investigate the effects of different geometries of the die bearing. For different forms of reduction as well as bearing zones, measurements are carried out for the wire-drawing process. Subsequently, by extracting the friction coefficients from the electrolytic tough pitch copper wire in cold-drawn essays, the numerical simulations are also implemented. We present the results on both the superficial and center radial tensions obtained by finite element methods. It is observed that the reduction of the friction coefficient leads to an increase in radial stress, while for a given friction coefficient, the substitution of the C-type die by the R-type one results in a decrease in the superficial radial stress of up to 93.27%, but an increase at the center of the material. Moreover, the die angle is found to play a less significant role in the resultant center radial stress, but it significantly affects the superficial radial stress. Lastly, R-type dies result in smaller superficial radial stress, with a change of up to 34.48%, but a slightly larger center radial stress up to 6.55% for different die angles. The implications of the present findings are discussed.