Design and development of progressive tool

for mold tag

Cite as: AIP Conference Proceedings 2316, 030015 (2021); https://doi.org/10.1063/5.0038385
Published Online: 16 February 2021

V. Deepak, O. Abhilash, Y. P. Ravitej, Veerachari, and L. Abhinandan

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AIP Conference Proceedings 2316, 030015 (2021); https://doi.org/10.1063/5.0038385 2316, 030015

© 2021 Author(s).
 Design and Development of Progressive Tool for Mold Tag

9Deepak,D 2$bhilash,1<3Ravitej,1Veerachari and /Abhinandan

1
Dept. of Mechanical (ngineering, Dayananda Sagar University, Bangalore,QGLD
2
Dept. of Mechanical (ngineering, NTTF, Peenya, Bangalore,QGLD
a)
Corresponding author: deepv239@gmail.com

Abstract. A progressive tool carries out a sequence of basic sheet metal operations like blanking, piercing, notching, coining,
bending etc. at multiple stations during each stroke of press in order to produce a final component. The challenging part of the
project was to design a progressive tool for mold tag because of the complexity involved in it. The objective of the project is to
design a progressive tool for mold tag to meet the customer specification, analyse the punches to determine the stress induced
using ANSYS workbench and validate the results with theoretical calculations, fabricate and trial run the designed progressive
tool for the component. The methodology of the project includes detailed study of component drawing and generation of blank
development & strip layout using AutoCAD software. Based on the strip layout design various forces are calculated. Total force
is used for the design of elements of progressive tool. The design of progressive tool includes 2D drawing and 3D modelling. The
2D drawing is carried out by AutoCAD software and 3D modelling by Autodesk Fusion 360 software. After the modelling of
different punches and dies, the FEM analysis is performed on punches and dies using ANSYS workbench to determine whether
the stress and strain are within the allowable limits. It is followed by the manufacturing and assembly of elements of progressive
tool. Finally, the tool is fabricated to produce mold tag component.

Keywords: Progressive tool, ANSYS workbench, Autodesk Fusion 360, mold tag, strip layout

INTRODUCTION
Many a times, manufacturing of a component requires multiple operations like cutting or non-cutting or both. If
these components are produced using single stage tools, it results in problems like more production time, number of
labors, additional presses, consumption of power which in turn results in increase of cost of the component. The
problems which are mentioned above can be solved by a type of press tool called progressive tool. Progressive Tool
consists of two or more stations and in each station more than a one operation is performed. In the Progressive Tool
the strip must move from first to the final station to produce the required component. The components which are
produced from Progressive Tool will have burr on both upper and lower surface.

Some of the advantages of progressive tool are high accuracy, less material handling time and reduction in labor
cost. When compared to single operation tools, the Progressive tool has shorter operation time. Another advantage
of Progressive tool is the scraps which are produced during the operations is less compared with other tools.

Advanced Trends in Mechanical and Aerospace Engineering

AIP Conf. Proc. 2316, 030015-1–030015-10; https://doi.org/10.1063/5.0038385
Published by AIP Publishing. 978-0-7354-4059-3/$30.00

030015-1
 L,7(5$785(6859(<
V Bram Armunanto et al [6] conducted a study to determine whether the circularity or clearance of the punch and
die affects the circularity of the product during punching. To examine that testing has been carried out using
different punches having different diameter and circularity conditions. The clearance of the punch, die and the
product was measured using coordinate measuring machine. After multiple rounds of testing it was concluded that
the circularity of the punch and die is always lesser than the circularity of the product. Manoj Balakrishnan et al [4]
presented with development of progressive tool for blanking a sheet metal component. In this paper firstly the strip
layout was drawn and based on strip layout various forces were calculated. The 2D and 3D design of all the parts of
the progressive tool were drawn and finally a progressive tool for blanking of the component was developed.

R.Singh et al [13] focused on experts system which automatically generates a design of Strip layout for the
progressing tool. The expert system which was based on artificial intelligence consisted of six models. The six
models gave the outputs and these output files were used in AutoCAD which generated the 2D strip layout design
with appropriate dimensions, number of stages and effective economic factor. Michael P.Pereira et al [7] focused on
the importance of the shape of die corner radius on the wear behavior during sheet metal working. In this paper,
several experiments were conducted with different die corner radius and the experiment shows that a small change
in the shape of the die corner radius from the ideal profile can notably decreased the life of the tool, this effect
normally occurs during the manufacturing of the dies. So tool workers should be more careful about manufacturing
and maintenance of the dies.

G.Straffelini et al [8] conducted a study on bettering a wear resistance of the tool for stamping process. In this paper,
the inspection was branched into two stages. The first stage includes the determination of wear of tool using SEM.
The second stage includes betterment of tool wear using PVD coating with AlCrN layer and manufacturing of tools
with hard metal. Experiments showed significant improvement in wear resistance of tool. Eduardo Umaras et al [10]
studied the parameters that effect the dimensional as well as exactitude of the stamping process. The factors which
influenced the dimensional of the stamping process are clearance between the punch & die and cutting speed. In this
paper, the cutting speed as well as tool wear and its control was also studied.

Vitoslav Bratus et al [12] conducted a study on cutting edge geometry. In this paper, the cutting edge which was a
round shape was used for both experimental and numerical studies. If the round shaped punch was used, then the
circularity was not so good .For that several FEM Analysis was done and finally it was concluded that by using non-
round shape punch, better circularity is achieved which is ten times lower than normal value. Sung Bo Sim at al [5]
focused on developing a multi forming die which has a cut off type feeding system. Initially the strip layout
simulation was done by DEFORM Programming. A carrier was made on the centre axis of the strip because of U-
bending in the part. Since the centre axis type carrier was used in the strip layout design there will be no wastage of
material in the strip which in turn increases the economic factor of strip layout.

METHODOLOGY
Figure 1 presents the methodology adopted for the project. The methodology of the project includes detailed study
of component drawing and generation of blank development & strip layout using AutoCAD software. Based on the
strip layout design, various forces were calculated. Total force was used for the design of elements of progressive
tool. The design of progressive tool includes 2D drawing and 3D modeling. The 2D drawing was carried out by
AutoCAD software and 3D modeling using Autodesk Fusion 360 software. After the modeling of different punches
and dies, FEM analysis was performed on punches and dies using ANSYS workbench to determine whether the
stress and strain are within the allowable limits. It was followed by the manufacturing and assembly of elements of
progressive tool. Finally, the tool was fabricated to produce mold tag component.

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 FIGURE 1. Project Methodology

Progressive Tool Design

The design of progressive tool is one of the important steps in the design process. Traditional methods of designing
a progressive tool involve number of calculations and decision making based on experience. The component details
are given in Table1. The component details will be based on the customer requirement and on its final application of
the component along with other variables like burr direction, direction bending and secondary operations. These are
design variables will influence the strip layout, which is building block of press tool design.

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 TABLE . COMPONENT DETAILS

Details Specification

Material Al 6016-T6

Thickness of the sheet 0.9 mm

Shear strength 207 MPa

Tensile strength 280 MPa

Few details of strip layout and press required are given in Table 2

TABLE . PRESS TOOL DESIGN DETAILS

Description Details

Strip width 29mm

Pitch 11.5mm

Blank Area 212.12mm

Economic Factor 63.6%

Total force or Tonnage required 2.5T

FIGURE 2. 3D assembly view of top half of progressive tool.

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FIGURE 3. 3D assembly view of bottom half of progressive tool.

FIGURE 4. 3D assembly view of progressive tool.

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 RESULTS AND DISCUSSION

Structural Analysis of Punches

The objective of carrying out structural analysis on punches is to determine the stress, strain and deformation
induced in punches because of the load applied. The tool elements are made from D2 steel, but less hardened top
and bottom plates are made from mild steel. Since we are concentrating on critical elements, the specification is
given below table.

TABLE  CHEMICAL COMPOSITION OF D2 STEEL

Chemical composition C Mn Si Cr Mo V

Percentage 1.5 0.3 0.3 12 0.75 0.9

TABLE . MECHANICAL PROPERTIES OF D2 STEEL

Description Details

Density 7700 Kg/m3

Young’s modulus 2.1GPa

Hardness 62 HRC

Poison’s ratio 0.3

Compressive yield strength 1650MPa

The ANSYS software was used to determine the deflection and stresses induced in punches, the images of analysis
results are given below. The 3D modelling of the punches is done using Autodesk Fusion 360 software which is then
imported to ANSYS workbench to perform the analysis. Punch profiles are obtained from AutoCAD design
drawings.

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 Structural Analysis of piercing punch

FIGURE 5. Piercing punch drawing

TABLE . DETAILS OF PIERCING PUNCH

Description Details

Type of element Tetrahedron

Size of element 1mm

Load applied 1441.71N

Number of nodes 7118

Number of elements 3827

Equivalent Von-Mises stress

FIGURE 6. Equivalent Von-Mises stress of piercing punch

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 Equivalent Von-Mises strain

FIGURE 7. Equivalent Von-Mises strain of piercing punch

Total deformation

FIGURE 8. Total deformation of piercing punch

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 Validation of Analysis results

TABLE . VALIDATION OF RESULTS OBTAINED FROM ANALYSIS AND THEORETICAL

CALCULATION

No Description Analysis Result Theoretical result % Error

1 Piloting punch Stress 353.38 MPa 372.25 MPa 4.91

Strain 0.00176 0.00183 3.85

2 Piercing punch Stress 212.58 MPa 203.99 MPa 4.27

Strain 0.00101 0.000971 4.41

3 Blanking Punch Stress 46.0 MPa 43.05 MPa 4.79

Strain 0.000221 0.000205 4.87

4 Die plate Stress 8.88 MPa 8.77 MPa 1.25

Strain 0.0000457 0.0000417 4.69

From the table it can be seen that the values of stress and strain of all the punches are within the allowable limits.
The error between the analysis value and the theoretical value is less than 5% which means that design of all the
punches are safe.

CONCLUSIONS
A progressive tool was designed, analyzed and fabricated to produce mold tag component. The following
conclusions arrived at:

1. Design of progressive tool was performed using AutoCAD and Autodesk Fusion 360.
2. FEM analysis was performed by ANSYS and compared with theoretical calculations. The results
obtained were within the allowable limits.
3. Stresses induced in the punches due to the cutting force acting on them are within the compressive yield
strength limits. Hence design is safe.
4. The analysis results are compared with theoretical calculations and the results deviation was found to be
within 5%.

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 REFERENCES
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