Designing of Punch and Die for Blanking, Forming and ... · Designing of Punch and Die for...

International Journal of Trend in Research and Development, Volume 3(4), ISSN: 2394-9333

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IJTRD | Jul-Aug 2016 Available [email protected] 227

Designing of Punch and Die for Blanking, Forming

and Bending Press Tools to Manufacture Fuel Filter

Bracket Component Using Finite Element Method 1Chandranath.M,

2Dr G Mallesh and

3Dr. D. Ramegowda,

2Associate Professor,

3Principal

2Department of Mechanical Engineering, SJCE-Mysuru, India

1,3PG Studies, Govt tool room and training centre, Mysuru, Karnataka, India

Abstract — This paper presents Finite Element analysis

technique to design the Blanking, forming and bending press

tools punch and die for Fuel filter bracket component using

static structural analysis. Press tools are used to manufacture

sheet metal components. These sheet metal components are

widely used in Automobile and Aerospace domain. The sheet

metal components are manufactured by applying the

predetermined force or pressure. The design, manufacturing

and safety requirement needs a design based on Finite element

method. The static structural analysis is carried out to find

possibilities of failure and to design Punch and die of Press

tool. Fuel filter bracket component is a part of fuel filter

assembly unit of automobile. Sequence of operation is planned

initially and then press tool is designed and analyzed. The

analysis helps in avoiding the costly tryouts and optimizing the

design with safety and cost effectiveness. With the assistance

of structural analysis, the problem regions, causes and

solutions can be found using the Computer aided Engineering

techniques.

Index Terms — Finite Element Analysis, Blanking, Bending

and Forming

I. INTRODUCTION

Press tool device is used to produce sheet metal parts by

cutting, non-cutting and hybrid operations. Most of

Automobile and Aerospace mass production products are

manufactured by Sheet metal technology. The Blanking,

Forming and Bending are main sheet metal operations in

making components. Blanking is a cutting operation in which

punched out piece is a component. Forming is shaping the

metal to the desired contour around nonlinear axis. Bending is

shaping the metal around a straight axis. A sheet metal is

subjected to plastic deformations using press tool to confirm to

a planned shape in forming and bending operations. A sheet

metal is subjected to shearing in blanking operation. During

design process, the optimization of parameters of Punch and

Die has to be done correctly to eliminate failure and to ensure

safety. Finite Element analysis software can be used in the

design of Blanking, forming and bending punch and dies. The

structural analysis method has been established as a practical

methodology to access failure. With this methodology die

tryout may be removed and safety can be ensured and

productivity can be increased by reducing tool cost and lead-

times. The static structural analysis can be used in design of

Punch and Die.

II. COMPONENT STUDY

The name of the component is Fuel Filter Bracket. It is an

automobile component used in automobile vehicle fuel filter.

The three stages of operations Blanking, Forming and Bending

are used to produce this component.

Figure 1: Fuel filter bracket

Material: MS CR2

III. STATIC STRUCTURAL ANALYSIS OF PUNCH

AND DIE

The analysis is carried out using Catia software with CAE

application. The solid models created using Catia Software are

analysed using Catia Generative Structural Analysis work

bench. In this context only the critical functional parts which

undergo repeated stresses like Punch and die are considered for

analysis purpose. The analysis of punch and die for blanking,

forming and bending operations are analysed by applying

material properties, boundary conditions, Load and then it is

solved for results Punch and die Material used for Blanking

Press tool: High carbon high chromium Grade D2 steel

Chemical ingredients: Copper =1.55%, Silicon =0.3%,

Molybdenum =1%, Manganese =0.3%, Chromium =12%

Punch and die Material used for Forming & bending Press tool:

Oil Hardened Non Shrinking Steel

Chemical contents: C=0.85 to 1, Mn=1 to 1.4, Si=0.5, Cr=0.4

to 0.6, Ni= 0.3 W= 0.4 to 0.6, V= 0.3, Cu= 0.25, P= 0.03, S=

0.03 percentages.

Element Type: Linear tetrahedron Solid Mesh

The Global mesh size is used for larger surface areas and

smaller fine mesh is used at fillets to get correct results with

less computation time.


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Global and Fine Mesh Elements Size

A. Tool Calculations

Shear Force:

Shear Force = Length of Cut x Thickness x Shear Strength

Shear Force= 439.446 x 2 x 280

Shear Force=246089.76N

Forming Tool Force

Forming Force= Component thickness (mm) x Forming length

in X and Y axis (mm) x Ultimate tensile Strength (N/mm2)

=2 x (22.5+135) x 560

=176400N

=17.98 Tons

Pad Force = 25% of forming force

= 0.25 x 17.98

= 4.495 Tons

Total force = Forming force + Pad force

= 17.98 + 4.495

= 22.475 Tons

= 220479.75N

Bending Tool Force

Bending Force = Component thickness (mm) x Forming length

in X and Y axis (mm) x Ultimate tensile Strength (N/mm2)

= 2 x (53+61) x 560

=127680N = 13.015Tons

Pad Force = 25% of forming force

= 0.25 x 13.015

= 3.25 Tons

Total force = Forming force + Pad force

= 13.015 + 3.25

= 16.26 Tons

= 159510.6N

B. Blanking Tool Design

3D Model is created using Catia software. Blanking is a cutting

operation in which punched out piece is a component. The 3D

models of tool, punch, die and component are shown below.

Figure 2: Blanking Press Tool

Figure 3: Blanking tool Punch and Die

Figure 4: Blanking component

C. Analysis of Punch for blanking operation

Applied Load: 246089.76N

Figure 5 Punch Boundary condition

Figure 6 Blanking Punch Mesh


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Figure 7: Von Mises Stress of Blanking Punch

D. Analysis Results

Table 1: Blank Punch Von-Mises Stress results

Objective Von-Mises Stress (MPa)

Minimum 2.96

Maximum 1180

E. Analysis of Die for blanking operation


Figure 8: Blanking Die Mesh

Figure 9:Blanking Die Boundary condition

Figure 10: Von Mises Stress of Blanking Die

Analysis Results:

Table 2: Blank Die Von-Mises Stress results


Minimum 2.95

Maximum 171

F. Forming Tool Design

3D model of the Forming tool with Rear pillar press tool is

designed. The 3D Models of tool, die, punch and component

for Forming process are shown below.

Figure 11: Forming Press Tool

Figure 12: Forming tool Punch and Die

Figure 13:Forming component

G. Analysis of Punch for forming operation


The Pressure = 111.3MPa is applied based on forming Load of

220479.75N and corresponding Contact area on Punch.

Figure 14: Forming Punch Mesh


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Figure 15: Forming Punch Boundary condition

Figure 16: Von Mises Stress of Forming Punch

Analysis Results:

Table 3: Forming Punch Von-Mises Stress results


Minimum 0.797

Maximum 249

H. Analysis of Die for Forming operation


The Pressure of 113.88MPa is applied based upon forming

Load of 220479.75N and corresponding Contact area on Die.

Figure 17: Forming Die Mesh

Figure 18: Forming Die Boundary condition

Figure 19: Von Mises Stress of Forming Die

Analysis Results:

Table 4: Forming Die Von-Mises Stress results


Minimum 0.154

Maximum 193

Figure 20: Forming Press tool

I. Bending Tool Design

3D model of the Bending tool with Rear pillar press tool is

designed. The 3D models of tool, die, punch and component

for bending process is shown in Fig

Figure 21: Bending Tool

Figure 22: Bending Punch and Die


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Figure 23: Bending component

J. Analysis of Punch for Bending or flanging operation


The Pressure of 50.22MPa is applied based on flanging Load

of 159510.6N and corresponding Contact area on Punch.

Figure 24: Bending Punch Mesh

Figure 25: Bending Punch Boundary condition

Figure 26: Von Mises Stress of Bending Punch

Figure 27: Bending Press tool

Analysis Results:

Table 5 Bending Punch Von-Mises Stress results


Minimum 0.0715

Maximum 48.6

K. Analysis of Ejector for bending operation


The Pressure of 74.58MPa is applied based on Flanging Load

of 159510.6N and corresponding Contact area on Ejector.

Figure 28: Bending Ejector Mesh

Figure 29: Bending Ejector Boundary condition


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Figure 30: Von Mises Stress of Bending Ejector

Table 6: Bending Ejector Von-Mises Stress results


Minimum 0

Maximum 129

The resulting stress distribution in Punch and die components

due to Press tool forces and pressure were found using FEM

analysis. The Von-Mises stress is considered to know the

failure of components due to excess of yield stress.

IV. RESULTS AND DISCUSSION

The results in above Tables shows that Von Mises stresses

induced in Punches and dies are less than the yield stress of

material. Hence the design is safe. The components are

manufactured using blanking stage 01, forming stage 02 and

forming stage 03 press tools using the designed punches and

dies based on FEM method. All the dimensions of component

were found acceptable with safe functioning of Press tool.

References

[1] Anudeep S and N. Ramesha, “Design and Analysis of

Blanking and Bending Press Tool to Produce Anchor

Bracket Component”, International Journal of

Engineering Research & Technology (IJERT),

ISSN: 2278-0181, Vol. 4 Issue 04, April-2015.

[2] Dr D. Ramegouda and Nandish Harti, “Conceptual Design

of Blanking tool for Washer special”, National Joint

Conference On Innovation In Engineering & Technology

(NJCIET-2015), Canara Engineering College, Mangalore,

29 April 2015.

[3] Jutz-Scharkus, Westermann Tables, Revised second

edition, new age international(P) limited, publisher Year

2006.

[4] GT&TC Standard Data Hand Book.

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