Design and Analysis of An Industrial, Progressive Die For Cutting and Forming
Design and Analysis of An Industrial, Progressive Die For Cutting and Forming
Design and Analysis of An Industrial, Progressive Die For Cutting and Forming
Research Article
Keywords: Progressive Die, Piercing, Notching, Bending, Blanking, Finite Element Analysis
DOI: https://doi.org/10.21203/rs.3.rs-262802/v1
License: This work is licensed under a Creative Commons Attribution 4.0 International License.
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Design and analysis of an industrial, progressive die for cutting and
forming
1
University of Peloponnese, Department of Mechanical Engineering, School of Engineering
M. Alexandrou 1, GR-26334 Patras, Greece
Abstract
Nowadays, many components which were earlier cast or machined have now been
replaced by steel metal stampings. Material economy and the resultant reduction in weight
and cost, high productivity and a high degree of possible precision have made press-work
essential for many mass-produced products such as electronic appliances, utensils and car
parts. Although, laser-cut technology is widely developed and more flexible in terms of
variety of produced components, it cannot reach the extremely high productivity rates of a
progressive die. Progressive die can perform a sequence of operations, in different stations
at a single stroke of press. In this work, an innovative progressive die consists of two
stations was designed, in order to produce a complex metal part with three different
manufacturing processes. The components of the die have been calculated by mathematical
formulas and empirical data, designed with Computer Aided Design software and analyzed
by Finite Element Analysis tool.
*
Corresponding author. Tel.:+30-2610-369283, e-mail: [email protected]
1. Introduction
2. Research Objectives
The aim of this work is to design a progressive die in order to produce a complex metal
part with four different manufacturing processes, piercing, notching, blanking and bending,
with as few as possible stations. So, a two-stations die was designed with manual feeding
in which a stripper plate is also helping the operator with the guidance and alignment of the
metal sheet.
Fig. 1, present the flow chart of the manufacturing processes of the part. In Station 1, the
piercing and notching process takes place and in Station 2 the bending and the final cut of
the part.
Fig. 1 Stations of metal sheet forming
In Fig. 2a,b, show the component’s dimensions and the final part. It has 14 holes with 3mm
diameter and 7 holes with 4mm diameter. The all part has 80mm length and 70mm width.
The thickness of the material is 2mm.
(a) (b)
Fig. 2 Component’s (a) dimensions and (b) isometric view
3. Calculations
For the workpiece a 316L stainless steel, was used as shown in Table 1.
The components of the die have been calculated by mathematical formulas and empirical
data, as presented in the next sections.
A. Cutting Force
During punching operations (Fig.3) such as piercing and blanking, the cutting force
applied in the punch can be calculated using formula (1)[12,13].
𝐅𝐜 = 𝐟𝐬 × 𝐂 × 𝐭 (1)
where,
fs = shear strength of material (N/mm2)
C = cut length (mm)
t = sheet thickness (mm)
C1 = 4 × π × 7 = 87.99 mm
C2 = 3 × π × 14 = 131.88 mm
C3 = 169.18 + 4.16 + 4.00 = 177.34 mm
Ct = 𝐶1 + 𝐶2 + 𝐶3 = 397.21 𝑚𝑚
B. Bending Force
𝟐.𝟔𝟔 × 𝐟𝐭 × 𝐋 × 𝐭 𝟐
𝐅𝐛 = (2)
𝑾
where,
ft = tensile strength of material (N/mm2)
L = transverse length of bend (mm)
t = sheet thickness (mm)
W = width of channel (mm)
C. Total Force
Due to friction between various components of the die, the cutting force must be increased
by 20% [14].
F = 1.2 × Fc + Fb = 428,168 N = 43.66 tn ≈ 44 tn
where,
B = strip width (mm)
V = progression (mm)
A = part area without holes (mm2)
R = number of part rows
During the press working process of the shearing-cut and bending progressive die, the
position of the die’s pressure center has a direct impact on whether the die can work
accurately in balance.
In Fig. 4, are presented the distances from the zero point (left corner).
(∑𝐧
𝐢=𝟏 𝐅𝐦 𝐢 )× 𝐗 𝐢
𝚾= ∑𝐧
(4)
𝐢=𝟏 𝐅𝐦 𝐢
(∑𝐧
𝐢=𝟏 𝐅𝐦 𝐢 )× 𝐘𝐢
𝐘= ∑𝐧
(5)
𝐢=𝟏 𝐅𝐦 𝐢
3.4 Springback
Springback occurs when a metal is bent and then tries to return to its original shape. After
a bending operation, residual stresses will cause the sheet metal to spring back slightly.
Due to this, it is necessary to over-bend the sheet an amount to achieve the desired bend
radius and bend angle.
The springback radius can be calculated by formula (6)[15].
𝐑𝐢 𝐟𝐲 ×𝐑 𝐢 𝟑 𝐟𝐲 ×𝐑 𝐢
𝐑𝐟
= 𝟒 × ( 𝐄 ×𝐭 ) − 𝟑 × ( 𝐄 ×𝐭 ) + 𝟏 (6)
where,
Ri = initial radius (mm)
Rf = final radius (mm)
fy = material yield strength (MPa)
t = sheet thickness (mm)
E = Young’s modulus (MPa)
where,
Ri = initial radius (mm)
Rf = final radius (mm)
ai = initial angle (degrees)
t = sheet thickness (mm)
2
1.74 +
αf = 2 × 90° => α = 89.77°
2 f
1.747 +
2
The springback factor, commonly denoted by Ks, is the relation between the initial and
final angles. A springback factor of Ks = 1 means there is no springback, where a value of
0 means total springback.
The springback factor can be calculated by formula (8).
𝐚𝐟
𝐊𝐬 = (8)
𝐚𝐢
where,
af = final angle (degrees)
ai = initial angle (degrees)
89.77°
Ks = => K s = 0.997
90°
4. Die Design
The die design was made with the help of commercial software SolidWorks, in which
was also made the assembly of the die and the motion study (Fig.5a,b). Also, in Table 2,
die components and materials are presented.
(a) (b)
Fig. 5 Assembly of the die
B. Thickness
The thickness of the die block can be calculated by formula (9).
𝐁 𝟐
𝟑×𝐅 ( )
𝐓𝐫 = √ ×[ 𝐀
𝐁 𝟐
] + 𝟑 𝒎𝒎 (9)
𝐟𝐭 𝟏+( )
𝐀
where,
F = total force (N)
ft = tensile strength of die block (N/mm2)
A = active length (mm)
B = active width (mm)
70 2
3 × 428,168 Ν ) (
𝑇r = √ × [ 180 2 ] + 3 mm ≅ 18 mm
756 Ν⁄mm2 1+(
70
)
180
* 3 mm resharpening allowance
C. Margin
Margin is the solid cross-section around the die cutting edge. The fixing screws and
dowels should be placed outside the margin to prevent weakening of the die.
M = 2 × Tr = 2 × 18 = 36 mm (10)
D. Die Clearance
The intentional gap between the punch and the cutting edges, depends upon the physical
properties of the sheared material. Our material is stainless steel and the clearance is 20%
of the sheet thickness. So:
u = 20% × t = 0.2 × 2 = 0.4 mm (11)
𝐖𝐝 = 𝐁 + 𝟐 × 𝐌 + 𝟑 × 𝐝𝐤 (12)
where,
B = active width (mm)
M = margin (mm)
dk = screw head diameter (mm)
𝐋𝐝 = 𝐀 + 𝟐 × 𝐌 (13)
where,
A = active length (mm)
M = margin (mm)
The stripper plates guide the punches through the sheet and also helps the operator with
the manual feed of the strip.
where,
B = sheet width (mm)
t = sheet thickness (mm)
hin = sheet opening height (mm)
So, in our case:
1
ts = × 70 mm × +2 × 2 mm + 5 mm = 32.33 ≅ 33 mm
3
These components are made by softer steel in order to the die block and the punches do
not break or bend. Also, they are interchangeable because they are simpler and cheaper
parts.
The top plate is mounted on the press and it is standardized. Its dimensions depend on the
width and length on the die block.
The bottom plate is mounted on the bed of the press and it is also standardized. Its
dimensions depend on the width and length of the die block.
Width-Length: A x B = 450 x 365 mm
Height: C = 55 mm
Guide pillars insert diameter: E = 38 mm
The guide bushes guide the pillars so the whole assembly is perfectly straight and also
lubricate the pillars. They are standardized.
The guide pillars guide with the help of the bushes the whole die. They are press fitted on
the bottom plate. Their height depends on the height of the die. They are also standardized.
Diameter: D = 38 mm
Bottom diameter: Dbottom = 38.013 mm
Length: L = 200 mm
4.9 Punches
In this die assembly there are four kinds of punches. There two standardized circular
punches, a custom-made cutting punch and a custom-made bending punch.
First, we should calculate the critical length of the punches. Τhe lengths of the punches
are calculated from Euler’s formula (15).
𝛑𝟐 ×𝐄×𝐈
𝐋𝐜𝐫 = √𝐧 × (15)
𝐏
where,
n = factor accounting for the end conditions
E = Young’s modulus (N/mm2)
P = load (N)
I = Moment of inertia (mm4)
A. D3 piercing punch
N
√ π2 × 200,000 2 × 3.98 mm
4
Lcr = 2 × mm = 44.7 mm
7,875.12 N
B. D4 piercing punch
N
√ π2 × 200,000 2 × 12.57 mm
4
Lcr = 2 × mm = 68.7 mm
10,508.52 N
C. Notching punch
N
√ π2 × 200,000 2 × 42,420.31 mm
4
Lcr = 2 × mm = 1,088.1 mm
141,434.48 N
D. Bending-blanking punch
N
√ π2 × 200,000 × 1,755.02 mm4
Lcr = 2 × mm2 = 435.6 mm
36,507.76 N
During the production, all the punches must have the same, safe length. So, for our case
we choose 40 mm.
In conclusion according to the Fig. 6-15 and Table 3, the results of Von-Mises stress and
deformation of the most important parts of the die specifically the punches and the die, can
withstand the load of the procedure.
6. Conclusions
In this work a progressive die was developed, in order to produce a complex metal part
with four different manufacturing processes, piercing, notching blanking and bending, with
as few as possible stations.
The components of the die have been calculated by mathematical formulas and Finite
Element Analysis tools.
The proposed approach is based on real manufacturing data, in order to be easily produced.
Ethical Approval
For this type of study formal consent is not required.
Consent to Participate
Informed consent was obtained from all individual participants included in the study.
Consent to Publish
The participants have consented to the submission of the case report to the journal.
Author contribution
The manuscript was written through contributions of all authors. All authors have given
approval to the final version of the manuscript.
Funding
No funds, grants, or other support was received.
Competing Interests
There are no relevant financial or non-financial competing interests to report.
All the data (numerical, figures, diagrams, tables, etc.) used to support the findings of our
study are included within the article. Thus, data sharing regarding the aforementioned
paper is totally allowed and any reader can access the data supporting the conclusions of
the study.
ORCID iDs
Tsirkas A. Sotirios
https://orcid.org/0000-0001-7770-1321
Grammatikopoulos Spyridon
https://orcid.org/0000-0001-9787-9071
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Figures
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