PREDICTION OF LIFE OF V BENDING PUNCH USING

MACHINE LEARNING
BATCH NUMBER (JMFG05)

GUIDED BY
PRESENTERS
Dr. C. RAJKUMAR
ANAND MAHATO (17UEME0011)
ASSOCIATE PROFESSOR
BISHAL K.C. (17UEME0039)
DEPARTMENT OF MECHANICAL
PRABIN KHADKA (17UEME0196)
ENGINEERING
CONTENTS
• ABSTRACT
• PROGRESS FROM FIRST REVIEW
• LITERATURE SURVEY
• PROBLEM DEFINITION
• PROJECT METHODOLOGY
• SPECIFICATIONS AND BILL OF
MATERIALS
• DETAILED DESIGN (CAD MODEL)
• CALCULATION
• ANSYS ANALYSIS
• MACHINE LEARNING MODEL
• COST OF THE PROJECT
• RESULT AND DISCUSSION
• CONCLUSION
• REFERENCES
ABSTRACT

• Determining the life of V Bending punch before failure is the main motto of this
project
• AutoCAD is used as a designer tool for designing the working model
• Finite element analysis is used to determine the maximum and minimum principal
stress to determine fatigue limit of tool
• Machine Learning Toolbox in MATLAB is used for the development of
mathematical model and life estimation of the punch
PROGRESS FROM FIRST REVIEW

• AUTOCAD is used to design CAD model of V bend punch

• In ANSYS meshing operation of the designed model has been run to various load
condition
• Maximum and minimum principal stress data has been acquired for the
estimation of fatigue limit of the punch
• Data extracted has been feed to MATLAB
• Machine Learning tool box of MATLAB is used to acquire the life of punch
LITERATURE SURVEY
Authors System Details Remark
Lin and Chang Application of a neural network machine learning Developed combination model of neural
[1995] model in the selection system of sheet metal network (NN) and expert system for
bending tooling bending operation

Kannadasan, et al., Modelling the Forming Limit Diagram for Aluminum sheet metals of various grade
[2017] Aluminum Alloy Sheets using ANN and ANFIS are analyzed using ANN

Alsamhan. A, et al., Prediction of formation force during single point Predicted the forming force in the
[2019] incremental sheet metal forming using artificial context of sheet metal forming,
intelligence techniques particularly SPIF

Sachin Salunkhe, et al., Prediction of Life of Compound Die Punch Using Life prediction of the ANN, ANFIS and
[2020] Machine Learning ML compound die

Wei Li, et al., Predicting the evolution of sheet metal surface Prediction of evolution of the surface
[2021] scratching by the technique of artificial scratching using fuzzy logic modelling
intelligence and MQPSO algorithm
PROBLEM DEFINITION

• As the successful usage of the punch in v bending operation, industrial person is

unknown about the ultimate stress of the tool
• Being unaware of the ultimate stress , tools are being break down after certain
period of usage and had to replace it
• Repairing may be the better option than the replacement of tool to some extra
working hours
• To know the repairing period of tool, study on the life of punch to the ultimate
stress is required
• So our study on the prediction of life of punch can be a breakthrough for this
problem
PROJECT METHODOLOGY

DESIGN OF PROCESSING
SELECTION OF
TOOL IN OF 3D MODEL
TOOL
AUTOCAD IN ANSYS

LIFE PREDICTION DATA FEED IN EXTRACTION

USING MACHINE MATLAB OF DATA
LEARNING TOOLBOX FROM ANSYS
SPECIFICATIONS
WORK MATERIAL
ALUMINUM ALLOY 7075
Physical properties
• Density (ρ) : 2.81 g/cc
• Mechanical properties
• Young's modulus (E) : 71.7 GPa
• Tensile strength (σt) : 572 MPa
• Poisson's ratio (ν) : 0.33
Thermal properties
• Melting temperature (Tm) : 477 °C
• Thermal conductivity (k) : 196 W/m°K
• Linear thermal expansion coefficient
(α) : 23.6*10^-6/K
• Specific heat capacity (c) : 714.8 J/kg°K
DIE MATERIAL
T8 STEEL
Physical properties
• Density (ρ) : 8.43 g/cc
Mechanical properties
• Young's modulus (E) : 200 GPa
• Tensile strength (σt) : 1158 MPa
• Poisson's ratio (ν) : 0.29
Thermal properties
• Melting temperature (Tm) : 1510 °C
• Thermal conductivity (k) : 18 W/m°K
• Linear thermal expansion coefficient
(α) : 10*10^-6/K
• Specific heat capacity (c) : 420 J/kg°K
PUNCH MATERIAL
TUNGESTEN CARBIDE
Physical Properties
• Density : 15.0 g/cc
Mechanical properties
• Young's modulus (E) : 630 GPa
• Tensile strength (σt) : 530 MPa
• Poisson's ratio (ν) : 0.22
Thermal properties
• Melting temperature (Tm) : 2000°C
• Thermal conductivity (k) : 373.15 W/m°K
• Linear thermal expansion coefficient
(α) : 4.5 *10^-6/K
• Specific heat capacity (c) : 184 J/kg°K
BILL OF MATERIALS

SN No. Description Material Source

1. Work material Aluminum Alloy 7075 Sheet metal

2. Die T8 Steel Hard Metal

3. Punch Tungsten Carbide Hard Metal

CAD MODEL

b. Side View
a. Front View

Fig. 1(a,b)V bend model

Note: All dimensions are in mm.
CALCULATIONS

Sheet metal thickness(S) = 2mm = 20.96 mm

Die opening (V) =S*8 Tensile strength for Aluminum
=2*8 Alloy 7075 (σb) = 520 Mpa
= 16 mm Plate width (L) = 200 mm
Internal radius bend (ir) = (5*V) / 32 Bending force (P) = 1.42*σb*S²*L
= (5 * 16) / 32 1000*V
= 2.5 mm = 1.42*520*4*20
Degree of bending (α) = 45° 1000*16
Minimal resting part (B) = V * 1.31 = 0.37648 Ton
= 16 * 1.31
ANSYS ANALYSIS

Fig: Maximum Principal Stress Fig: Minimum Principal Stress

MACHINE LEARNING MODEL

Fig. Sample of code of XGBoost models

COST OF THE PROJECT

As our project is based on simulation on software. So, the cost of our product is assumed and found
out from the online website. We visited different sites which sell the product which we need in our
project. We found the cost for those product as mentioned.

• Aluminium Alloy 7075 Sheet Metal

Price per kg = Rs 600 INR

• T8 Steel Die Material

Price per kg = Rs 587 INR

• Tungsten Carbide Punch Material

Price per kg = Rs 3950 INR

RESULT AND DISCUSSION
SN. Max Principal Stress Min Principal Stress Amplitude Stress (σa) Mean Stress (σm) Analytical Results Cycles ML Predicted Cycles
No.
1 -72920 -325100 126144.3 -198955.75 757245 756248
2 -72811.5 -324964.5 126130.8 -198833.75 756787 755330
3 -72703 -324829 126117.3 -198711.75 756329 754412
4 -72594.5 -324693.5 126103.8 -198589.75 755871 753494
5 -72486 -324558 126090.3 -198467.75 755413 752576
6 -72377.5 -324422.5 126076.8 -198345.75 754954 751658
7 -72269 -324287 126063.3 -198223.75 754496 750740
8 -72160.5 -324151.5 126049.8 -198101.75 754038 749822
9 -72052 -324016 126036.3 -197979.75 753580 748904
10 -71943.5 -323880.5 126022.8 -197857.75 753121 747986
11 -71835 -323745 126009.3 -197735.75 752663 747068
12 -71726.5 -323609.5 125995.8 -197613.75 752204 746150
13 -71618 -323474 125982.3 -197491.75 751745 745232
14 -71509.5 -323338.5 125968.8 -197369.75 751287 744314
15 -71401 -323203 125955.3 -197247.75 750828 743396
16 -71292.5 -323067.5 125941.8 -197125.75 750369 742478
17 -71184 -322932 125928.3 -197003.75 749910 741560
18 -71075.5 -322796.5 125914.8 -196881.75 749451 740642
19 -70967 -322661 125901.3 -196759.75 748992 739724
20 -70858.5 -322525.5 125887.8 -196637.75 748533 738806
CONCLUSION

• Project report presents an overview of the life prediction of life of v bend punch
• ML model is built for v bend punch could predict the life of the die punch in a short time
• Confidence level of the predicted ML results is approximately 99.5 percent
• Average error rate between the analytical cycles and the ML model developed is more
accurate and robust
• ML model effectively predicts the presence of a v die punch
• Increased predictive ability is demonstrated by the results of the ML system
• As a result, such a design is reliable for the life forecast of other die components such as
die block, die set, knockout bar, etc.
 REFERENCES
[1] Lin, Z. C. and Chang, D. Y., “Application of a neural network machine learning model in
the selection system of sheet metal bending tooling”, Artificial Intelligence in
Engineering, 1995, Vol.10, pp.21-37.
[2] Kannadasan, S. Senthil Kumar, A. Pandivelan, C. Sathiya Narayanan, C., “Modelling the
Forming Limit Diagram for Aluminium Alloy Sheets using ANN and ANFIS”, Applied
Mathematics & Information Sciences, Vol. 11 (5), 2017, pp 1435-1442.
[3] Alsamhan. A, Adham E. Ragab, Abdulmajeed Dabwan, Mustafa M. Nasr, Lotfi Hidri.,
“Predictionof formation force during singlepoint incremental sheet metal forming using
artificial intelligence techniques”, Plos One, 2019, doi.org/ 10.1371/journal.pone.0221341.
[4] Sachin Salunkhe,Vishal Naranje,Praneeth Vasarla,Dharmateja M., “Prediction of Life of
Compound Die Punch Using Machine Learning”, 2019 International Conference on
Computational Intelligence and Knowledge Economy (ICCIKE) December 11–12, 2019,
Amity University Dubai, UAE.
[5] Wei Li, Liangchi Zhang, Xinping Chen, Chuhan Wu, Zhenxiang Cui3 & Chao Niu
“Predicting the evolution of sheet metal surface scratching by the technique of artificial
intelligence”, January 2021 The International Journal of Advanced Manufacturing Technology
112(1):1-13 DOI:10.1007/s00170-020-06394-4.