Press Tool Design Research Articles

Motorcycle wheel rim press tool design

In motor vehicles, especially motorcycles, sometimes there are a lot of problems with the wheel rim in the event of an accident, or hit by a pothole that causes the wheel rim to be dented. In this case, we design a motorcycle wheel rim press tool as shown in Figure 2.1. The things that must be considered for a tool design in material selection are hardness, strength, fragility. The types of materials used are carbon steel, alloy steel, hollow steel, U iron, axle iron, angle iron, plate iron. In general, there are several grades of iron, including JIS G3101 SS400, ASTMA 36; BS 4360; DIN 17 100JIS G 3101; JIS 3106; SNI 07 2054, which has a different maximum tensile strength or stress by using formulas, for example the calculation of shafts, levers, weld strength and selection of hydraulic jacks. Supporting instruments in the process of working on the wheel rim press tool are machine tools and other measuring tools. To obtain truly satisfactory results from a tool, we are required to observe and look for alternatives and as carefully as possible in order to achieve a result that meets the standard. The tool must have high efficiency, easy to operate, and uphold work safety. Based on the results of the design and testing of the design of this motorcycle wheel rim press tool, it is more efficient, fast, and precise when compared to the tools owned by David Jaya Motor's workshop. The time required is faster according to the test results, which is between 25 minutes to 40 minutes with different wheel rim damage cases, while manually at the David Jaya Motor workshop, from observing field test results it takes a minimum of 90 minutes.

Determination of the effect of thickness reduction ratio, die angle, and coefficient of friction on residual stresses in ironing process: an analysis using computer simulation

Ironing is a part of the group of metal forming processes, the process of reducing the thickness of the wall of a cup-shaped product. External load required to process metal forming, can cause residual stress. Residual stress can be beneficial or detrimental depending on the function of the product, the magnitude, and direction of the residual stress. Residual stress can act as an additional load on a given load. Residual stress can affect product quality, namely: dimensional accuracy, surface roughness, and mechanical properties. The speed of the ironing process is strongly influenced by the mechanical properties of the cup material, Thickness Reduction Ratio (TRR), and press tool design. The ironing process has a limited TRR value and if it is exceeded it results in product damage. Various studies on ironing were carried out to obtain an optimal process. In this research, stress analysis was carried out using the ANSYS software modeling simulation to obtain the occurring residual stress during the ironing process. The analysis was carried out by varying the TRR from 20 % to 30 %, the die angle from 25° to 30°, and the coefficient of friction from 0.05 to 0.15. Furthermore, processing and analysis of the stress analysis data are carried out to obtain the most dominant variables affecting the residual stress and the variable value that produces the lowest residual stress. Stress analysis was carried out on AA1100 aluminum cups with an outer diameter of 37 mm, a height of 20 mm, and a wall thickness of 2 mm. The results show that TRR and coefficient of friction are the most dominant variables affecting residual stress, while die angle has no significant effect. The lowest residual stress occurs at TRR 30 % and coefficient of friction 0.15

Design & analysis of progressive die using SOLIDWORKS

Productivity in the press tool shop is always the main stream especially in the case of products which needs more than one operation. To improve the productivity, modern day press tool shops are using the progressive dies. These dies are generally preferable to performs operations in series. The present study aims to reveal the design and analysis of various parts on the progressive die such as blanking die & punch; piercing die & punch. For this, an attempt has made to design the progressive die for strips of Aluminium (4032-T6) of 1 mm thickness. The study includes the discussion on material of the strips, press tool design procedure and the mathematical calculations. For the designing and analysis purpose, the SOLIDWORKS software is used. Besides, the study reveals the maximum value of the stress and displacement on such parts.

Study method accordance for presstool design learning between POLINES and PT Mekar Armada Jaya in the framework of link & match

PT Mekar Armada Jaya, located in Cibitung, Bekasi, West Java, is a national-scale industry engaged in manufacturing various vehicle parts, especially those made of steel sheets. The process of making various parts of this vehicle requires a press tool. This company designs, makes, studies, and develops all the required press tools, therefore human resources (HR) are needed who have the competency to design and make presstools. Based on this, PT Mekar Armada Jaya held a partnership to produce the intended HR needs, namely graduates of the D3 Mechanical Engineering study program who were ready to work both at this company and at other similar companies. Along with the link between the Semarang State Polytechnic and PT Mekar Armada Jaya above, it is necessary to study the alignment of methods and learning strategies for the presstool design. The results of this study are in the form of design learning methods that will be carried out in the D3 Mechanical Engineering study program and learning handouts for the topic of presstool design.

Modelling and Analysis of a Progressive Cam Tool for Blade Fuse Holder: A Case Study

Sheet metal segments delivered from press working find wide applications in the territories going from telephonic gadgets to space stations. To design a progressive tool for sheet metal components according to the given details is a testing assignment. This article covers design and modelling of a progressive cam press tool for the component blade fuse holder, which is used in the Printed circuit boards of cars. Few very essential basics of press tools are briefly mentioned. The design and modelling process begins with the careful examination of the component geometry and material specifications. The tool development and modelling of the tool carried out by modelling software Solid Works are provided in detail. Points of interest and detriments of progressive tools over stage tools are additionally spotlighted.

Analisa Proses Drawing Pada Pembentukan Asbak Dengan Kuping Berbentuk Alur

The design of the press tool is one of the practice courses that teach the skill in designing tool forming and cutting the product from the plate. The quality of the design is determined by the ability to apply the design procedure. Competence is widely applied in the design of drawing prints with a certain level of product complexity. Practice activity of designing drawing drawing of students of Engineering Design Program of Mechanical Polytechnic of State of Bangka Belitung done conventionally, where only using drawing table or computerized depiction software then printed on drawing paper. This results in frequent errors in student design drawings. To overcome these problems required drawing prints that can form a specific product such as ashtrays, with the aim of producing a construction drawing print that can be applied and utilized in the teaching of press tool design. The method of making this tool consists of data collection, concept making, tool design, machining & testing. Based on the results of trials that have been done, carried out on 10 blank by using a lubricant in the form of vegetable oil. Of the 10 experiments the formation showed that the central pool of ashtrays can be perfectly formed, while 4 pieces of the grooves on the ear of the ashtray have not been formed well where there are still folds or curves that are not regular.

Study and Analysis of Press Tool Design

Study and Analysis of Press Tool Design

An Application Traditional and Nontraditional Approach on Lock Industry for Optimization of Cutting Layout

Engineering becomes more advanced and the business in the industrial world becomes more competitive. The method of implementing optimization technique is essential. The nesting of two dimensional shapes for the press tool design is general optimization problem. In mass production industries; the small inefficiencies will have the huge wastage. This is also known as two-dimensional Cutting Stock Problem (CSP). The aim is to minimize wastage there by increasing the profit by means of arranging the parts into the master sheet. The parts are to be arranged in the sheet in a acceptable position. It needs a various algorithm for placing the parts into the sheets like Heuristic, Meta heuristic, Bottom left heuristics etc.

Design and Analysis of Press Tool to Produce Radiator Stay Bracket

Design and Analysis of Press Tool to Produce Radiator Stay Bracket

Design and Analysis of Blanking and Bending Press Tool to Produce Anchor Bracket Component

Design and Analysis of Blanking and Bending Press Tool to Produce Anchor Bracket Component

Control System for Electro-hydraulic Synchronization on RBPT

In industrial manufacturing systems, situations are often encounters in which motion with two, three or more hydraulic cylinder actuators need to be synchronized. The need for the design of a reconfigurable bending press tool (RBPT) control system prompted the research in the development of an automatic and synchronized system, suitable for press tool operations. The system had to de designed to be versatile in raising and thrusting of multi- cylinders with odd numbers. This paper describes the concept of the design of the control system that will allow the controlling of pressure, flow and synchronous cylinder movements, accompanied by position readings measured by position sensors. The system will work simultaneously; with a maximum assembled of units working together, typically in a number that fits the operation's needs. The aim of the proposed controller is to develop a position control system that incorporates features of a modular controller interfacing with position sensors and detecting the position of the hydraulic cylinder rod through commercially-of-the-shelf (COTS) components.

Applications of Artificial Neural Network to Sheet Metal Work - A Review

Design of sheet metal components and press tools demands a high level of knowledge and industrial experience on the part of designers. Recently, various artificial intelligence (AI) techniques are being used in sheet metal work to reduce complexity; minimize the dependency on human expertise and time taken in design of parts and dies as well as to improve the design efficiency. Artificial neural network (ANN) technique is one of the most powerful tools for solving engineering design problems and minimizing errors in experimental data. This paper describes a comprehensive review of applications of ANN technique to sheet metal work. Major published research work in the domain area is summarized in tabular form. Based on the critical review of available literature, further research scope is identified. The present literature review reveals that there is stern need to apply ANN technique to press tool design and to predict tool life in sheet metal industries.

Efficient Method of Producing Oval Punching holes on Sheet Metal

As method for punching in oval shapes is not readily available, press tool for punching in oval shapes is required in various industries according to their applications. There are press tools for punching in circular shape, but when shapes other than circular shape are desired, they have to design according to dimensions required by industry. As application for oval shape punching differs from industry to industry because dimensions required by industries differ from each other. As some industries require more than one oval shaped hole that is to be done in single stroke for reducing the time required for production, there is need to design such press tool which can perform such operation. Hence to have fast production of required oval size holes, there is need to develop a press tool assembly which can make accurate oval holes on metal sheets. For designing such assembly, it is very necessary to study every aspect of existing design of press tool so that changes required can be easily define. Comparison of existing design with the proposed enables us to find correct way of design.

An intelligent system for selection of die-set of metal stamping press tool

Die-set selection is an important activity in the process of press tool design. Traditional methods of optimal selection of the die-set involve numerous calculations and decisions based on experience and practice codes. This paper describes an intelligent system for selection of die-set of metal stamping press tool. A production rule based expert system approach has been utilized to develop an intelligent die-set selection system (IDSS) to assists die designers. This system comprises of two modules, namely DIESETSEL for selection of type of die-set and DSDIM for determination of its dimensions. The system IDSS is coded in AutoLISP language and loaded into the prompt area of AutoCAD. This arrangement facilitates interfacing of design with drafting and can be operated on a PC/AT. For consultation, the system generates friendly prompts eliciting from the user data pertaining to the job at hand. The system output includes recommendations on the kind of die-set and its appropriate dimensions suitable for the job. Illustrative examples demonstrate the usefulness of the proposed system. The knowledge base of the proposed system can be modified depending upon the capabilities of a specific shop floor and advances in new technology. The low cost of the system makes it affordable to planners working in small and medium-sized enterprises.

Automated Design of Progressive Dies

This paper describes the structure and operation of a prototype intelligent system for progressive die design and manufacturing. The system is developed using X Window ‘C’ programs to create an interface linking the CAD (computer aided design) package, AutoCAD and the expert system shell, Kappa. AutoCAD is used for the input of the piece part geometry, creating the temporary drawings and final design drawings of the tool parts and assembly while Kappa is used to create the knowledge base, the databases of the standard tool parts and the menu system for entering design data. Purpose-built ‘C’ programs are also used for some numerically intensive computations, for example calculating the best material utilization. The system knowledge is based on a structured analysis of present press tool design techniques.

Feature-based design of progressive press tools

This paper outlines two approaches for the development of a feature-based system which is used to support the detailed design of progressive press tools. The first approach is based on applying a coding technique to characterize the workpiece geometric features. This feature description is subsequently used to propose the type and layout of the press tool punches required to produce the part. The second approach uses design constraints as the bases for selecting the punches and dies. The approaches have been implemented on an IBM PC in C and integrated with a prototype low-cost CAD system for press tool design.

CAPTD: A Low-Cost Integrated Computer Aided Design System for Press Tool Design

This paper describes the structure and operation of a low-cost computer aided design system for press tool design (CAPTD). The system is a collection of integrated industry standard microcomputer packages and purpose-built programs. The packages include AutoCad 11, for the input of workpiece geometry and the output of the press tool part and assembly drawings, and dBase IV for the decision support, the selection of press tool components and generating output reports. A purpose built ‘C’ program is also developed for the layout and nesting of the workpiece. The system is driven by a set of press tool design rules implemented in both the dBase IV and ‘C’ programming languages. The system is developed to run on 80386SX or higher based IBM-compatible microcomputers.

New approaches for the nesting of two-dimensional shapes for press tool design

In this paper two approaches to the automatic pairwise clustering of two-dimensional shapes for press tool design are discussed. The first is based on extracting the edge information in the form of edge arrays, which are manipulated to obtain the optimum pairing; while the second applies the non-deterministic concepts of genetic algorithms. The results of applying both approaches are also presented.

Development of CAE System for Auto-Body Panel Forming Die Design by Using 2-D and 3-D FEM

A integrated CAE system for auto-body press tool design is discussed. The CAE system is required to predict forming detects by computer simulation and to save time and cost needed for tool design. This system consists of five models. The first module is CAD which describes tool geometry; the second module is data bases which provide experimental data: the third module is a pre-processor generating a finite element mesh in the sheet metal, the forth module is two elasto-plastic FE codes to simulate sheet metal forming processes: and the last module is the post-processor which displays the calculated results by computer graphics. Two elasto-plastic FE cods. ITAS and ROBUST, are introduced in the FE module. ITAS uses 2-D solid elements to simulate 2-D bending deformation, while ROBUST employs a membrane model to simulate fully 3-D sheet metal forming processes.

I. Developments in Industry. Computer-aided press-tool design

The engineering design spectrum ranges from completely routine to purely subjective. If computer programs can be written to perform the routine functions this will leave the designer free to concentrate completely on the subjective and creative aspects of his task. Additionally the computer can become a master base of information—allowing a system linking the various functions of design and manufacture to be established. Such an integrated system would use programs to aid the various design phases and to produce tapes to control numerically controlled (n. c.) machine tools in the manufacturing stage. An important consideration in the design and implementation of such a system however is that in practice it would build up gradually and each component part would have to be integrated into the conventional system. Thus though such things as traditional engineering drawings may be obsolete, or drastically changed in form, in the total system they would still have to be produced by the programs during the long integration period.