Design and finite element analysis of micro

punch CNC machine modeling for medical

devices
Cite as: AIP Conference Proceedings 1941, 020021 (2018); https://doi.org/10.1063/1.5028079
Published Online: 28 March 2018

Sigiet Haryo Pranoto and Muslim Mahardika

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AIP Conference Proceedings 1941, 020021 (2018); https://doi.org/10.1063/1.5028079 1941, 020021

© 2018 Author(s).
 Design and Finite Element Analysis of Micro Punch CNC
Machine modeling for Medical Devices
Sigiet Haryo Pranoto and Muslim Mahardikaa)

Department of Mechanical and Industrial Engineering, Faculty of Engineering,

Universitas Gadjah Mada, Jl. Grafika No.02, Yogyakarta, 55281, Indonesia
a)
Corresponding author: muslim_mahardika@ugm.ac.id

Abstract. Research on micromanufacturing has been conducted. Miniaturization and weight reduction of various
industrial products continue to be developed, machines with high accuracy and good quality of machining results are
needed recently. This research includes design and simulation of Micro Punch CNC Machine using Abaqus with
pneumatic system. This article concern of modeling simulation of punching miniplate titanium with 0.6 MPa of pressure
and 500 μm of thickness. This study explaining von misses stress, safety factor and displacement analysis while the
machine had the load of punching. The result gives the reaction forced of punching is 0.5 MPa on punch tip and
maximum displacement is 3.237 x 10-1 mm. The safety factor is over than 12, and considered it safe for manufacturing
process.

INTRODUCTION

The development of science and technology encourages the creation of new product with good quality,
especially in micro machining technology1–3. Miniaturization and weight reduction of various industrial products
continue to be developed, machines with high accuracy and good quality of machining results are needed recently4.
Metal forming technology has the potential for application in the manufacturing of micro scale parts considering its
process simplicity and high production capability. For this reason, various micro forming processes such us micro
forging5. Shearing process had been observed by some researchers for a variety of material or workpiece and tool
conditions to improve quality. Quality of the punched edge during punching process is evaluated based on part
characteristic and dimensional accuracy. to accommodate the high precission machine6.
Based on several experiments, optimations of manufacturing processes and parameters control are known to
have direct impact on production and operation. The most important tools for manufacturing processes optimization
are the design machine and finite element method (FEM)7. In this study, a new prototype of micro punching system
was developed, our goal is to develop which can make micro hole and miniplate profile for implant in medical
devices in diameter of 170 μm and 500 μm of thickness. Based on the several experimental studies by FEM,
clearance has the most influenced in affecting by accuracy of the punching process. In the simulation found if the
rollover and shear edge increases and the fracture edge decreases with decrease of the clearance value 8. When the
clearance value is decrease, smooth sheared punch force will increase. When the clearance value is increase, rollover
will increase but smooth sheared value will decrease.
In addition, improve the working speed can reduce production costs and energy consumption. High speed
blanking will improve the product quality of the punched edge, burr and rollover. Increasing the punch velocity in
production process will reduce production cost and energy consumption9. In this research, FEM supports the design
of Micro Punch CNC Machine before manufacturing process.

Engineering International Conference (EIC2017)

AIP Conf. Proc. 1941, 020021-1–020021-7; https://doi.org/10.1063/1.5028079
Published by AIP Publishing. 978-0-7354-1633-8/$30.00

020021-1
 RESEARCH METHODOLOGY

Micro Punch CNC Machine

This research studied about design and simulation before manufacturing process. One of the products developed
is Micro Punch CNC Machine. Micro Punch CNC Machine is a combination of press dies technology and CNC
(Computer Numerically Controlled) as shown in Fig. 1. Micro Punch CNC Machine can produce a product with
uniform quality with minimum machining time. The mechanism of process is blanking process. The blanking
process on micro punch has several advantages, besides it can produce a uniform punched edge quality and size
products its method give lower cost in a mass production. The principle of mechanism micro punch is using
penetration between punch and die.

(a) (b)
FIGURE 1. (a) Design Micro Punch CNC Machine, (b) Cylinder pneumatic punch

Mechanical properties of titanium grade 1

On this research, the reasearcher using pure titatium sheet material with 500 μm of thickness as the material to
form miniplate for medical devices. Physical and mechanical properties of titanium are shown in tables 1 below.

Table 1. Mechanical Properties of Titanium10

Mechanical Properties Value
UNS Number R50250
Nominal Composition 99,5 %
Ultimate Tensile Strength 330 MPa
Yield Strength 240 MPa
Elongation 30 %
Reduction in area 55 %

The form of the miniplate can be seen on the Fig. 2 below. (Scale 1:2)

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 FIGURE 2. Miniplate model

Design Analysis using ABAQUS

Abaqus in FEA (Finite element analysis) is divided into 3 categories: 1. Abaqus standard be used for general
analytical, 2. Abaqus Explicit be used for a analytical dynamic structure, 3. Abaqus CAE be used for complex
analytical for modeling, analysis, monitoring and visualizing simulation. In this research, Abaqus CAE is used for
analysis. Stress analysis, safety factor and displacement had been studied in this research. The step of the simulation
on Abaqus can be seen on the Fig. 3.

FIGURE 3. Step for FEM analysis on Abaqus11

The advantages of using abaqus its can quickly and efficiently create, edit, monitor, diagnose and visualize
advanced Abaqus Analyses. Results visualization in a consistent, easy to use environment that is simple to learn for
new users, yet highly productive for experienced users. Abaqus has many compability with CAD software, such as
CATIA V5, SolidWorks, Inventor, and Pro/ENGINEER enable synchronization of CAD and CAE assemblies and
enable rapid model updates with no loss of user-defined analysis features. But, the disadvantages of using Abaqus is
usually need the high performance for PC/laptop hardware.

Shearing force

Shearing force is the total force required by the machine to punch a particular hole based on the material
thickness, type and hole shape. Calculating the punching force is important for checkhing whether the machine has
enough durability to do the job without damaging the machine itself. In general, shear strength of the plate are
around 60%-80% from the tensile strength material. Punching force on the shearing process of the miniplate can be
calculated as follows:

P = π Dd τu t (for the hole shape) (1)

P = π τu L t (for the other shape) (2)

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Where,
τu : shear strength of the material (MPa)
Dd : Die’s diameter (mm)
L : Length of the shear (mm)
T : thickness (mm)

Force in the Micro Punch CNC Machine be produced by the mass of stepper motor multiply by the force of
gravity (9810mm/s2) for each axis X, Y, and Z. we known the mass of stepper motor is 0,001 ton. So, the force is

F = m.g (3)
F = 1 kg x 9.8 m/s2
F = 9.8 N
Where,
m : mass of the stepper motor (kg)
g : gravity (m/s2)

In according the type of load by motor stepper is 9.8 N for each axis, so we need to describe the type of load in
abaqus is distributed load.

Pressure

Pressure in the Micro Punch CNC Machine be produced by reaction force from action force that requires for
punching process divide cross sectional area of punch. Pressure can be determined by
P = F/A (4)
P = F/ (π.r2)

Von mises stress

Von mises strees be obtained from FEA simulation while Micro Punch CNC Machine works. Von mises stress can
be failure if the value of von mises stress is higher than strength of the material. Von mises stress is used to know
the safety factor of micro punch CNC machine. The value of safety factor is obtained from the yield strength
material divide by maximum von mises stress.

Strain and displacement

Strain is the ratio of displacement by initial length of material. Strain is obtained from punching force and resulting
on machine displacement. A safe displacement is if the displacement is lower than the clearance between punch and
die.

RESULT AND DISCUSSION

Stress Analysis

The simulation is conducted on part that have direct contact from material punching. The punching force is 0.6
MPa (for punching titanium) with 500 μm of thickness. On the Fig. 4 shown the strees distribution on cyclinder
pneumatic without punching force.

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 FIGURE 4. Von Mises Stress simulation without punching force

FIGURE 5. Von Mises Stress simulation With punching force

On the Fig. 5. we got the maximum stress distribution is 5.256 x 10-1 mm. It means that the maximum stress was
around 0.5 MPa and the location is on the punch tip. This is caused by action and reaction forced of punching.
Because of the punching force is 0.6 MPa as action forced and the punch tip will give the reaction forced response to
make equilibrium equation, so it gives around 0.5 MPa. In general that this part is safe to be used for punching
titanium with 0.6 MPa of pressure.

Displacement

The simulation is conducted on part that have direct contact from material punching. On the Fig. 6 shown the
displacement on the cylinder pneumatic without punching force.

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 FIGURE 6. Displacement without punching

FIGURE 7. Displacement with punching force

On the Fig. 7 we got the displacement value of the part is around 3.237 x 10-5 mm. it means that the maximum
displacement was around 0.00003237 mm, nearly to zero. So, the displacement was very small caused by punching
force. It can be explained that the geometry has not changed by the small displacement. In general, because of the
part geometry is the same before/after punching so the accuracy of the micro punch CNC machine can be
maintained precisely.

Safety Factor

In according to the Fig. 8 we got the result of safety factor for the micro punch CNC machine. Almost the
construction colour of the machine is blue and higher than 12. It means that the machine construction is safe for
manufacturing process because the minimum value of the safety factor in general is 1.

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 FIGURE 8. Safety factor simulation of micro punch CNC machine

CONCLUSION

The model presented for micro punch CNC machine of stress distribution and displacement on punch tip were
implemented in Abaqus finite element analysis. The work focused on the experimental analysis of the stress and
displacement on punch tip. The maximum stress is around 0.5256 MPa on punch tip and maximal displacement at
punch tip is 3.237 x 10-5 mm (0.00003237mm). Abaqus FEA can predict accurately before manufacturing process.
The estimation are helpful in proper set of process parameters and necessary to obtain the safe construction of micro
punch CNC machine.

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