Progressive Die Research Articles

Soft Sensors for Property-Controlled Multi-Stage Press Hardening of 22MnB5

In multi-stage press hardening, the product properties are determined by the thermo-mechanical history during the sequence of heat treatment and forming steps. To measure these properties and finally to control them by feedback, two soft sensors are developed in this work. The press hardening of 22MnB5 sheet material in a progressive die, where the material is first rapidly austenitized, then pre-cooled, stretch-formed, and finally die bent, serves as the framework for the development of these sensors. To provide feedback on the temporal and spatial temperature distribution, a soft sensor based on a model derived from the Dynamic mode decomposition (DMD) is presented. The model is extended to a parametric DMD and combined with a Kalman filter to estimate the temperature (-distribution) as a function of all process-relevant control variables. The soft sensor can estimate the temperature distribution based on local thermocouple measurements with an error of less than 10 °C during the process-relevant time steps. For the online prediction of the final microstructure, an artificial neural network (ANN)-based microstructure soft sensor is developed. As part of this, a transferable framework for deriving input parameters for the ANN based on the process route in multi-stage press hardening is presented, along with a method for developing a training database using a 1-element model implemented with LS-Dyna and utilizing the material model Mat248 (PHS_BMW). The developed ANN-based microstructure soft sensor can predict the final microstructure for specific regions of the formed and hardened sheet in a time span of far less than 1 s with a maximum deviation of a phase fraction of 1.8 % to a reference simulation.

Design of Multi-Station Progressive Die for Mounting Bracket of Automobile Front Bumper Spotlight

The mounting bracket of the front bumper spotlight of the automobile is mainly produced by the method of wire cutting and processing. This method is difficult to achieve mass production and the performance becomes poor after processing. In order to improve this phenomenon, this paper adopts the method of sheet metal stamping to form it. The main tasks include the determination of the process plan, the simulation of Dynaform 5.9, the design of the layout, the calculation of the punching force, the bending force and the design of a set of 7-station progressive die. This design has certain practical guiding significance for the processing of the same type of products.

Multistage Deep-Drawing with Alternating Blank Draw-in for Springback Reduction in Transfer and Progressive Dies

Cold formed sheet metal parts made of advanced high-strength steels (AHSS) offer a high potential for a lightweight, durable and economic design. However, manufacturing dedicated, high-strength parts with cold forming technologies such as conventional deep-drawing often results in unacceptable shape deviations due to elastic springback after unloading the part from the forming tools. Therefore, various springback compensation methods have been established to ensure dimensional quality of such sheet metal parts. At the Institute for Metal Forming Technology (IFU Stuttgart), deep-drawing with alternating blank draw-in was developed in this context as a new approach to reduce springback and enhance cold forming of AHSS sheet metal parts. Presented work provides numerical sensitivity analysis as well as experimental studies about this new forming method. The asymmetric and alternating blank draw-in, which is changed within a multistage forming process sequence, results in an alternated bending over tool radii and leads to a beneficial stress superposition in the part wall area with reduced springback phenomena. Compared to conventional deep-drawn sheet metal components, springback of a benchmark part geometry could thus be reduced over 75 % by a three-stage forming process with an optimized blank draw-in kinematic.

FEA Approach for Wear and Damage Prediction of Tools for the Progressive Die Stamping of Steel Washers

In progressive die stamping processes, maintenance activities caused by tool damage, and wear represent economic losses for companies. An effective predictive maintenance strategy can only be implemented if maintenance data coming from the operations are correlated to specific process-related information. As a part of a more general data-based predictive maintenance strategy, the main causes of tool damage and wear in a progressive die stamping factory that produces automotive metal washers have been identified by means of FEA simulations. In this study, the progressive die stamping of a dented conical washer is simulated with Transvalor FORGE FEA software by implementing the process parameters used in a real case. In this study, two indicators called FEAwear and FEAdamage are proposed for prediction of die wear and damage for tools with high risk of failure. For validating the accuracy of the FEA simulations, dimension and geometry comparisons are performed between FEA and real washer, and then real and FEA maximum press force comparison is performed. In the end, FEA simulations demonstrated their accuracy in predicting the stamping force of the press and the final part quality, and proposed FEA damage and wear indicators accurately predicted the most critical tools and stations, as confirmed by the real maintenance data. Finally, the simulations also correctly detected potential damage zones of the tools.

A Review on Design of Progressive Tool Dies

A Review on Design of Progressive Tool Dies

Simulation of Dynamic Effects in Progressive Die Operation and Control

The demand from the automotive industry for increasingly complex sheet metal components and higher throughput in progressive die operations has led to the increased integration of sensors and control-systems in the sheet metal forming process. However, current control-systems used in sheet metal forming are often limited to measuring the state of the tooling during the forming process, neglecting the dynamic effects of the strip during its transfer between tooling operations. Developing a control strategy that accounts for the strip dynamics requires knowledge of how various process parameters influence the strip behaviour during both the transfer and forming stages. FE element models can accurately model the behaviour of sheet metal, but by themselves cannot identify a robust control strategy. Machine learning can solve this issue by constructing a probabilistic representation for the data generated from FE simulations to be used to identify a control strategy for sheet metal forming. The goal of this work is to conduct a parametric study on a progressive die FE model and evaluate the influence of various input parameters. The data collected from this FEM study will be used to construct a neural network model that will inform a control strategy for a progressive die.

Project-Based Learning for the Design of Progressive Dies Supporting Tools

<p class="Abstract">In the oil and gas industry, manufacturing processes covered a variety of fields including pipe fittings production. Generally, this process involves a press machine utilized as a shape forming using punch-dies sets as mold profiles. The common problem found with the dies is the dimension of dies is not ergonomics to be handled manually by operators. Additionally, the support of dies tends to experience buckling upon receiving a pressure load of 15 MPa. Hence, alternative and practical designs are required, which have low deflection values and high fatigue resistance rates. Additionally, the designs are expected to be safe and economical. In this study, two alternative designs of punch-dies support are proposed. Subsequently, the FEA simulation was carried out for pipe fittings of 8 inches with ASME B16.9 standard size for WF Beam A36 Steel to compare the two proposed designs. The results show that alternative design 2 has a lower deflection value of 0.181 mm, a higher Factor of Safety of 3.21, and a higher cycle time of 358569 cycles than alternative design 1. Nevertheless, alternative design 2 has a higher production cost of 220 USD compared to alternative design 2. Therefore, this study shows that alternative design 2 has better performance while alternative design 1 is more economical.</p>

Modelling, Analysis and Development of Progressive Die for Seat Rail

Progressive dies are highly used in batch productions where product variety is low. The progressive die is also called follow on die. It performs series of basic sheet metal operations. There are two or more stations and work piece is gradually shaped to final product through passing each of these stations. The ‘progression’ (advance or pitch) is linear travel of the strip stock at each press stroke and it is equal to the infestation distance. In the present paper an attempt is made to develop a new progressive die, which used in making seat rail of an automotive four-wheeler vehicle of Toyota, to optimize the use of material. So, the cost of progressive die reduces without losing its quality. For modelling CATIA and for analysis ANSYS are used.

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 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 Progressive Die for an Industrial Component

Design and Analysis of Progressive Die for an Industrial Component

Design of Progressive Die Sequence by Considering the Effect of Friction, Temperature and Contact Pressure

Progressive and transfer dies are used for forming of sheet metal parts in large quantities. For a given part, the design of progressive die sequence involves the selection of the number of forming stages as well as the determination of the punch and die dimensions at each stage. This design activity is largely experience-based and requires prototyping involving several trial and error operations. In some cases, empirical data and the experience based design procedure can be combined with Finite Element Method (FEM) based analysis to reduce time and cost. Often, when using FEM in progressive die design, friction and its effect upon temperatures is not adequately considered. However, at each forming station the plastic deformation and the tribological conditions influence the material flow as well as the temperatures and pressures at the tool/workpiece interface. The performance of the lubricant and coolant, used in progressive die forming, is affected significantly by interface pressure and temperatures. Therefore, a progressive process and die design methodology should include the consideration of metal flow as well as temperatures and pressures. Heat transfer coefficient, friction, plastic deformation, forming speed at each forming stage, time for part transfer from one stage to the next, and the ability of the used lubricant to cool the dies, have considerable effect upon a successful stamping. This paper describes a method for designing a progressive die sequence for forming axisymmetric sheet metal parts. The methodology for process sequence design combines experience based empirical data obtained through previous designs, design rules and numerical simulations including plastic deformation and friction. The initial experience-based design was refined using FEM and the thinning of the material in each successive drawing stage was calculated. The thermo-mechanical model was obtained using a constant friction coefficient along the tool/workpiece contact zone. Finally, the tool/workpiece interface temperature and the normal pressures were estimated in order that the lubricant can be selected based on these process conditions. The design predictions, made by using empirical data and FEM, were compared with experimental data.

Research on Progressive Die Design System Based on Rule-engine

This paper describes a knowledge-based progressive die design system integrated with rule engine technology. Firstly, the basic framework of the progressive die design main modules based on the knowledge engineering is constructed. Second, the author studies the key technologies of the design system. Finally, the system has been put into practice. The dynamic design process of the die base module is demonstrated, which verifies the feasibility and intelligence of the system.

To Priority the Success Factors in the Design of Progressive Die by DFSS Methodology

To Priority the Success Factors in the Design of Progressive Die by DFSS Methodology

Burr-free cutting edges by notch-shear cutting

Shear cutting is used to separate a sheet metal into two parts. During the cutting process, the material is deformed by two moving parts until its formability is exhausted. When a material is sheared, a burr deformation can often be observed on the cutting edge. Due to different disturbing effects, the burr must often be deburred before the next process of machining.The objective of the paper is the production of sheets without a burr under industrial boundary conditions. Therefore a progressive die is built in order to perform the necessary experiments. In addition to the experiments the simulation tool Abaqus is used to reduce the number of experiments to a suitable minimum. Adjusting a notching with a cutting process a burr-free cutting edge should occur. The notching results in a local change of formability on the blank sheet. Subsequently, the sheet metal is cutted in a normal shear process at the same position of the sheet metal where the notch at first was pressed into the bottom of the sheet. Due to the lowered deformability at this part of the sheet, the cutting edges of the sheet metal cannot build up any burr.Therefore, the impact of different parameters on the cutting edge is analyzed to create a notch geometry as well as shear cutting parameters without burr deformation, furthermore continuous strokes are performed to show the impact of this new cutting process for industrial applications on the tool material. Additionally to the burr free cutting edge, the new method shows less wear than the normal shear cutting.

Improvement of Productivity in Metal Stamping Process of Ethiopian Industries Through Introducing CAD/CAM Based Press Tools

Metal stamping is a sheet metal manufacturing process in which products are made using press machine and press tools. Currently sheet metal stamping process is practiced in Ethiopian metal industries in large amount but, mostly they use the technology which has been introduced to the companies 50 years back. This results in larger loss in material, economy and machines. These paper work asses the loss in the existing manufacturing process and provides a better way which conforms to the modern technology. In the existing metal stamping process of our country’s metal industries large press machines are used with separate single operation press tools. But, in modern technology a progressive dies are used in which all the operations are integrated in one progressive press tool and all the operations are done successively. In this paper work a progressive press tool is designed using logopress 3 die design software for a part called receiver body which is produced in Gafat armament industry. In the existing system the part is produced after passing through 22 separate working stations, 48 parts are made per day and it costs 102 birr per part. But in the newly designed progressive press tool the part is produced in one progressive die, 7200 parts are produced per day and it costs 12.23 birr per part. Therefore, introducing modern progressive press tools using computer aided design/computer aided manufacturing software’s could make a huge difference in Ethiopian metal industries.

複数部品による金属プレス順送金型内での組立技術

複数部品による金属プレス順送金型内での組立技術

드로잉 가공에서 다이패드의 독립형과 일체형 구조가 제품 두께에 미치는 영향에 관한 연구

Using a progressive die of the multi-stage drawing product, It was experiments for the Influence of the Products Roundness on the die pad process Safety die model, obstacle countermeasure research safety die design When the die pad is independent structure, Sidewall thickness of the inside 2stage, 3stage, 4stage of the product is thicker, the thickness of the inside 1stage and the bottom is thinner. it was become unstable beacuse the inside 1stage related to the Products Roundness is thinner. When the die pad is Integrated structure, Sidewall thickness of the inside 1stage, 2stage of the product is thicker, and Sidewall 3stage and 4stage was a thin. it was become unstable beacuse the inside 3stage related to the Products Roundness is thinner. Therefore, The appropriate combination of and integrated independent is required for each process.

슈퍼커패시터 양산화를 위한 하이브리드 복합금형 개발

ABSTRACT In this study, a high-speed procedure to be used in composite molding technology is developed for theproduction of a hybrid supercapacitor in a progressive and revolutionary current in a production system, asare the related operating conditions. Mold parts with solid modeling, the ease of programming of future moldproduct designs, tolerance management, and pre-explode tests by the building of a progressive die designsystem using Cimatron_E10 Die Design Software for the strip layout are done. The capacity of thesuper-hybrid composite mold design will save time and money through its verification of the manufacture ofmolds. We plan to apply this to future related products for production cost savings of more than 30%achieved by considering the components of the production costs, labor, and material costs of production ascompared to conventional production methods.Key Words : Hybrid Composite Die(하이브리드복합금형),Progressive Die(프로그래시브금형),Supercapacitor(슈퍼커패시터) # Corresponding Author : hhkwon@daejin.ac.krTel:+82-31-539-1972, Fax: +82-31-539-1970

Fully coupled numerical analysis of high frequency induction heating and warm sheet metal forming

The present study aims to develop a warm forming process for an aluminum alloy sheet to reduce weight of an electric housing part. Considering that the target product is produced through a series of metal forming processes using a progressive die, high frequency induction heating is proposed to heat a specific drawing punch locally and rapidly, out of a series performed using a progressive die. To validate the effect of the induction heating on the formability improvement of aluminum alloys, a fully coupled numerical simulation is proposed: (i) finite element (FE) analyses for the multi‐stage deep drawing processes are performed to predict formability at each stage; (ii) electrostatic‐thermal coupled FE analysis is performed to predict the temperature rise of the drawing punch; and (iii) thermo‐mechanical coupled analysis is conducted to investigate the effect of induction heating on the formability change. Through the proposed coupled simulation, it is proven that the drawing punch can be efficiently heated without a significant increase in cycle time, and the corresponding drawing process using aluminum alloys can be successfully performed without forming failure.