TABLE OF CONTENTS

CHAPTER NO.

TITLE

PAGE NO.

ABSTRACT IN TAMIL
ABSTRACT IN ENGLISH
ACKNOWLEDGEMENT
LIST OF TABLES
LIST OF FIGURES

INTRODUCTION

1.1 INTRODUCTION

1.2 OBJECTIVE OF THE PROJECT

1.2 METHODOLOGY

1.4 INTRODUCTION TO BICYCLE SIDE STAND

1.4.1 Bracket

1.4.2 Leg rod

1.4.3 Holder

1.4.4 Bush

1.3.5 Springs and Washers

1.3.6 Rivets, Bolts and Nuts

LITERATURE REVIEW

MATERIAL AND PROCESS

3.1 BRACKET MATERIAL

3.1.1 Chemical Composition

3.1.2 Mechanical properties

3.1.3 Minimum Internal diameter of bend

10

3.1.4 Delivery condition

10

3.2 DIE MATERIAL

3.2.1 Chemical composition

11

3.2.2 Mechanical properties

11

3.3 MANUFACTURING PROCESS

11

11

3.3.1 Sheet strip cutting

13

3.3.2 Piercing, Notching and Blanking

13

3.3.3 Company identity marking

13

3.3.4 First forming

14

3.3.5 Second forming

14

3.3.6 Folding

15

3.3.7 Acid cleaning

15

3.3.8 Powder coating

15

3.3.9 Assembly

16

DESIGN CONSIDERATION AND CALCULATION

17

4.1 DESIGN CONSIDERATION

17

4.1.1 Marking

17

4.1.2 Embossing

17

4.1.3 Bending

18

4.1.4 V- Bending

18

4.1.5 Air bending

18

4.1.6 Bottoming

19

4.1.7 Wiping

20

4.1.8 Spring back

21

4.1.9 Spring back compensation

22

4.2 DESIGN CALCULATION

22

4.2.1 Force required for Identity marking

22

4.2.2 Force required for embossing

23

4.2.3 Force required for bending

23

4.3.4 Press selection and specification

24

4.3.5 Tool height

25

4.3.6 Hexagonal socket headed screw

26

4.3.8 Pillar set

28

4.3.9 Bush set

28

MODELLING OF TOOL

30

5.1 INTRODUCTION

30

5.2 COMPONENT MODEL IN SEQUENCE

30

5.2.1 Blank modelling

30

5.2.2 First forming

31

5.2.3 Second forming

31

5.3 DIE MODEL

32

5.3.1 Bottom die Model

32

5.3.2 Top die model

32

5.3.3 Modelling of supporting elements

6

32

CONCLUSION

37

6.1 Conclusion

37

6.2 Future work

37

REFERENCES

38

LIST OF FIGURES

FIGURE NO

TITLE

PAGE NO.

1.1

Proposed methodology

1.2

Bracket

1.3

Leg rod

1.4

Holder

1.5

Bush

2.1

3D model of forming tool developed in solid Works 2003

3.1

Process flow chart

12

3.2

Sheet strip

13

3.3

Blank

13

3.4

Marking

14

3.5

First forming

14

3.6

Second forming

15

3.7

Folding

15

3.8

Powder cleaning

16

3.9

Assembly

16

4.1

Air bending

19

4.2

Bottoming

20

4.3

Wiping

20

4.4

Illustration of spring back

21

4.5

Shut height of press

25

4.6

Hexagonal socket headed screw

27

4.7

Die set parameters

28

5.1

3D Model of blank

30

5.2

First forming

31

5.3

Second forming

31

5.4

Bottom die Model

33

5.5

Bottom die Model

33

5.6

Location of the blank on the bottom die

33

5.6

Assembly of supporting elements in tool set

35

5.7

Assembly of the die set

36

LIST FO TABLES

TABLE NO.

TITILE

PAGE NO.

3.1

Chemical composition of bracket

3.2

Minimum Internal diameter of bend

10

3.3

Chemical composition of die material

11

4.1

Spring back angle compensation

22

4.2

Press specification

24

4.3

Die set parameter specification

27

CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
This work deals with the design analysis and process simulation of a sheet metal
component with multiple bends is a product supplied by SVL ENTERPRISES. SVL is a
medium scale Industry located in Thiruvallur. SVL is vendor of TI cycles of India having
more than 15 years the company tie up with the TI cycles. Some of the components made
in the plants are

Bicycle side stands for TI cycles

Bicycle carriers for TI cycles

Channels for TI metal forming

Crank case plating for Caterpillar.

Due to the unavailability of labour at sufficient levels and increase in the

production rate, adaptation of new technology is important for growth. In this work it
proposed to combine three process in the sequence of manufacturing into a single stage
process by the application of CAE tools. This not only increases the production rate but
also reduces the cost and time of production of the component.
1.2 1.2 OBJECTIVE OF THE PROJECT

To design the complete die set for combining three individual steps of
operation in single stage.

To develop the solid model of die sets and components by CAE tools.

To simulate the process and perform stress analysis of the component.

To analyse the die to determine the stress in the critical sections.

To giving proper component model to the industry for manufacture.

1.3 METHODOLOGY
The tool design starts from the need and problem description. Then the
understanding of the problem leads to the literature and design criteria needed to
incorporate. Based on this the design and model of the component is generated using
CAE tools. Evaluation of the critical regions and the remedies will be done in the
simulation stages. Fig. 1.1 shows the methodology adopted in the design of tools.

Problem description

Litrature survey

Data collection

Design of tools

Modeling using CAE

Analysis of the tool

Process simulation of the component

Evaluate the areas to redesign

design layout of tool

Fig.1.1 Proposed methodology
2

1.4 1.4 BICYCLE SIDE STAND

Bicycle side stands are used to park the bicycle in an easy manner. Various
bicycle companies has different types of side stand designs. Some of the designs are Lady
bird splash, Captain DX, AXN 26, AXN 24, Utima 24, Ultima 26 and Herculus dirt rider.
These have difference in their cut length of leg rod, bracket notch area and blank hole
position. The various component of the bicycle side stand are

Bracket

Springs

Leg rod

Washers

Holder

Rivets

Bush

Bolts & nuts

1.4.1 BRACKET
Bracket is a component which connects the side stand leg rod with the bicycle
frame with the help of bolt and nuts. It is not a straight component but an angled one.
This angle helps to make easy contact between the land surfaces to the side stand.
Embossing recess helps to increase the stiffness of bend and gives strength to the bracket.
A rivet hole is provided to connect the bracket with the leg rod through rivet connections.
Fig. 1.2 shows the bracket which is to be produced using the designed die.

Fig.1.2 Bracket
1.4.2 LEG ROD
Leg rod shown in the Fig.1.3 is an important and basic component in the side
stand. Initially using the wire drawing machine, the rod in the form of coil is drawn as a
3

uniform diameter and cut to the specified length. One end of the rod is flattened to make
the hole and another end of the rod is boot. Boot is molded using injection molding
machine. In some types of stand a cup with a hole is welded with the rod to form boot.
For placing the washer and spring arrangements a notch impression is generated on the
rod.

Fig.1.3 Leg rod

1.4.3 HOLDER
Holder shown in the Fig.1.4 is used to make the assembly of the spring with the
leg rod. This is made up of Polypropylene Co Polymer (PPCP) black plastic material in the
injection molding machine. It has good environmental impact and good strength to
withstand the spring impact.

Fig.1.4 Holder
1.4.4 BUSH
The bush shown in Fig.1.5 provide support to the holder with the bracket end. It is
also made up of PPCP black plastic material.

Fig.1.5 Bush
1.3.5 SPRINGS AND WASHERS
Springs are used to make release the stand from the original position. The spring
is placed on the rod notch with the help of washer and it is also covered by the holder.
The company outsources the component from an external supplier (Aleef Springs
Marketing Agency).
Washer is used to constrain the spring in the rod through the rod notch provided.
The company make the washer in this branch itself. The sheet strips with the proper
length are cut from the coil. Using punch and die first inside hole is pierced and then
outer surface is pierced.
1.3.6 RIVETS, BOLTS AND NUTS
Rivet, bolts and nuts all these are out sourced by the company from their external
supplier. Rivets are used to connect the bracket with the leg rod assembly through
pressing using hand press. Bolts and nuts are used to connect the bracket with the bicycle
frame.

CHAPTER 2
LITERATURE REVIEW

Annigeri et al. (2014) discussed the design, development and structural analysis
of a forming tool for a side panel of automobile. The design starts from the design
requirements, then force needed to achieve the forming and embossing operations were
calculated by using the standard formulae. Based on the total force and press availability
the press was selected. Using SOLIDWORKS 2013 the modelling of tool and die were
generated as per the drawings. Then ANSYS 5.4 was used to analyze the tool stress and
deformation. The model was free meshed using isoparametric SOLID92 3-D 10node
tetrahedral structural solid. It was observed that the design of forming tool is safe as the
von-misses stress is well within the compressive strength of the material for both punch
and die. The deflection of both punch and die are well within the allowable deflection of
0.05 mm and hence it was conclude that the design of both forming punch and die was
safe. The reduction in web thickness of punch and die by 30% did not interfere with the
allowable stress and deflection values of punch and die. This has led to a weight
reduction of 4.2 kg. Fig. 2.1 shows the 3D model of forming tool.

Fig 2.1 3D model of forming tool developed in solid Works 2003

6

Madake et al. (2013) reported on developed sheet-metal component with a

forming die using CAE software tools (Hyper form) for design validation and
improvement. Punch and die to form the cup was designed and the various dimensions,
blank holding force, force required to perform the operations were calculated.
HYPERFORM is used analyze the stress. The operating condition involving the
magnitude of blank holding pressure is varied and the results analyzed. Suitable blank
holding pressure (5Ton) is recommended for a defect-free component. The results
obtained by mathematical treatment and the results obtained through the use of software
(analytical) agree reasonably well.
Sheng et al. (2007) worked on FEM analysis and design of bulb shield
progressive draw die. The progressive tools was used to produce bulb shields include
complex deep draw operations. The component was modeled and analyzed using FEM
code DYNAFORM 5.2. An FEM simulation based analysis and design method for the
draw operations is proposed in this study. Based on the analysis on the second draw
punch radius effect on Von Mises stress which represented the material work hardening
tendency, an improved design was suggested. The resultant progressive die has been
manufactured and is running successfully in production. With the aid of FEM simulation,
forming problems can be visually identified. Furthermore, utilization of these simulations
to predict forming and cosmetic problems at the part design phase offers significant
advantages.
Chan et al. (2004) reported on Finite element analysis of spring-back of Vbending sheet metal forming processes. This paper presents a study of spring-back in the
V-bending metal forming process with one clamped end and one free end. Different die
punch parameters such as punch radius, punch angle and die-lip radius are varied to study
their effect on spring-back. Also, the effect of the punch displacement on spring-back is
investigated. The H-convergence test is done to justify the number of elements used.
Patran is used to model the nodes of the sheet metal and rigid surfaces of the die, pad and
punch. Abaqus/Standard is used to simulate the punching process. The results are
analyzed using Abaqus/CAE. The analysis shows that spring-back angle of the valley
region decreases with increment of punch radius and punch angle. Therefore, there is an
optimum punch radius to achieve minimum spring-back
7

Mastanamma et al. (2012) reported on Design and Analysis of Progressive Tool

for a sheet metal component with multiple holes. The progressive tool with its
supplementary elements were designed in Pro-E. Using ANSYS, tool was analyses ny
applying suitable boundary conditions. The results were compared with the theoretical
calculations and verified.

So for from the literature all the design has been started from the design
requirement and need. For the sheet metal bending spring back is the important criteria to
make the bend to be accurate. This literature gives the methodology of the project and
importance

of

application

of

CAE

tools

in

design

and

analysis.

CHAPTER 3
MATERIAL AND PROCESS
3.1 BRACKET MATERIAL
The bracket material is specified by the TI cycle component drawings. According
to that IS 1079: 2069 sheet material is selected.
3.1.1 Chemical Composition
Table 3.1 gives the chemical composition of the material of the bracket. From this
HR3 grade is selected based on the drawing instructions.
Table 3.1 Chemical composition of bracket material
Quality

Constituent

S.No
Designation

Old
designation

Name

Microalloy

HR0

New

Ordinary

0.25 1.70

0.05

0.045

ii

HR1

Commercial

0.15 0.60

0.05

0.035

iii

HR2

Drawing

0.10 0.45 0.040 0.035

iv

HR3

DD

Deep Drawing

0.08 0.40 0.035 0.030

HR4

EDD

Extra Deep
Drawing

0.08 0.35 0.030 0.030

Vi

HR5

New

Micro-Alloyed
dual Phase

3.1.2 Mechanical properties

Density of the material is 7850 kg / mm3
Tensile strength = 300 N / mm2
Percentage of elongation = 23%
9

0.16

Mn

1.6

0.020 0.020

0.2

3.1.3 Minimum Internal diameter of bend

The minimum bend radius is the radius below which a component should not be
bent. Table 3.2 gives the minimum internal diameter of the bend for the material. From
that for HR3 material chose the bending radius as close as possible
Table 3.2 Minimum Internal diameter of bend
S.No

Grade

Internal Diameter of Bend

HR1

2t

ii

HR2

iii

HR3

Close

iv

HR4

Close

Note wheret is the thickness of work piece

3.1.4 Delivery condition
The material may be supplied in any one (or, in combination) of the following conditions
a) Hot rolled,
b) Annealed,
c) Normalized, and
d) Descaled
From the supplier the company purchase the sheet as straight strips. This avoids
the extra cost and time of straightening and cutting of sheets from the coil.

10

3.2 DIE MATERIAL

According to IS 4957: 1999 standard, high carbon high chromium steels (HCHC).
D2 (Common name) is the popular choice of the tool makers material. The material
should have

Good wear resistance

High toughness

High dimensional stability

3.2.1 Chemical composition

Table 3.3 shows the chemical composition of the die material which as a high
percentage of chromium.
Table 3.3 Chemical composition of die material
Constituent

Carbon

Chromium

Manganese

Vanadium

Molybdenum

Percentage

1.55%

12.00%

0.45%

0.80%

0.85%

3.2.2 Mechanical properties

Density= 7700 kg / mm3

Rockwell hardness = 65

Poisons ratio = 0.27-0.3

Elastic modulus = 190 210 GPa.

Ultimate tensile strength = 260 390 GPa

3.3 MANUFACTURING PROCESS

Simple work flow from the sheet strip to the bracket assembly is
illustrated in the flow chart shown in fig.3.1

11

Sheet strip cutting from

the sheet coils

Piercing, Notching and

Blanking

First forming
(one bending and two
embossing)

Company identity
Marking

Second forming
(two bending and two
embossing)

Folding
(Channel bending)

Powder coating
(Powder spraying and
heating)

Surface preperation
(Acid and water
dipping)

Assembly

Fig3.1 Process flow chart

12

3.3.1 Sheet strip cutting:

The company purchases the sheets in strip condition as shown in fig.3.2.

Fig 3.2 Sheet strip

3.3.2 Piercing, Notching and Blanking

A progressive tool is used to make the piercing, notching and blanking operation
from the sheet strips. In the progressive tool first the holes are pierced and the center
notch operation is done finally the component blanked out as shown in fig. 3.3.

Fig 3.3 Blank

3.3.3 Company identity marking

Company identity marking is done using a hand press. The identity denotes that
the company name and the year and month of manufacturing as shown in fig.3.4.

13

Fig. 3.4 Marking

3.3.4 First forming
Fig 3.5 shows the component after first forming. During this operation two
embossing and a v-bending operation is done in a single stroke. Locating pins are used to
place the component in the die. The company has employed a 20 ton capacity
mechanically operated press to do this work.

Fig.3.5 First forming

3.3.5 Second forming
After the first forming another side of the blank is formed in this stage. During
this two v-bending operations and two embossing operations are done. Currently a 20 ton
capacity mechanically operated press is used for this forming. Fig 3.6 shows the final
component after second forming operation.

14

Fig.3.6 Second forming

3.3.6 Folding
It is a form of channel bending. A die with suitable recess used to place the
component. A rectangular tool is used to make the folding as shown in fig.3.7.

Fig. 3.7 Folding

3.3.7 Acid cleaning:
To remove the dust and impurity layer around the material acid cleaning followed
by the water rinsing is done. During this stage the color change predicts the impurity
removal rate.
3.3.8 Powder coating
After the cleaning the powder coating sprayers and systems are used to spray
black powder around the component. Then the powder coated component is heated in the
oven at 1900C. At this temperature the powder melts and sticks with the component as
shown in figure 3.8
15

Fig. 3.8 Powder cleaning

3.3.9 Assembly
In the assembly as shown in fig. 3.9 all the parts of side stand are assembled with
the Bracket through rigid connections.

Fig. 3.9 Assembly

16

CHAPTER 4
DESIGN CONSIDERATION AND CALCULATION
1.5 4.1 DESIGN CONSIDERATION
4.1.1 Marking
Marking of company identity is done by the coining operation. Coining is a form
of precision stamping in which a work piece is subjected to a sufficiently high stress to
induce plastic flow on the surface of the material. Coining is a cold working process that
uses a great deal of force to plastically deform a work piece, so it conforms to a die. It can
be done using a gear driven press, a mechanical press, or more commonly, a hydraulically
actuated press. In this process any of the male or female die has an impression and the
other one is flat. During this operation the load applied to the component is to be limited.
Because the load should not cut or damage the component.
4.1.2 Embossing
Embossing is a process for producing raised or sunken designs or relief in sheet
metal. This process can be made by means of matched male and female roller dies, or by
passing sheet or a strip of metal between rolls of the desired pattern. Embossing process
has these characteristics

The ability to form ductile metals.

Use in medium to high production runs.

The ability to maintain the same metal thickness before and after embossing.

The ability to produce unlimited patterns, depending on the roll dies.

The ability to reproduce product with no variation.

Provide the stiffness to the component

Increase the bending strength

17

4.1.3 Bending:
Sheet metal bending is the plastic deformation of the work over an axis, creating a
change in the part's geometry. This produces a V-shape, U-shape, or channel shape along
a straight axis in ductile materials, most commonly sheet metal. The bending is used in
the to produce an angled component, sheet profile, shipbuilding, apparatus manufacturing
and common household things
4.1.4 V- Bending:
In V- bending either the male and female die or any both of them must have the V
shape. In this top die forces the component in to the bottom die.
4.1.5 Air bending:
This bending method forms material by upper or top V-die into the material,
forcing it into a bottom die, which is mounted on the press. The punch forms the bend so
that the distance between the punch and the side wall of the V is greater than the material
thickness (T).Either a V-shaped or square opening may be used in the bottom die as
shown in fig.4.1. A set of top and bottom dies are made for each product or part produced
on the press. As it requires less bend force, air bending tends to use smaller tools than
other methods.
Some of the newer bottom tools are adjustable, so, by using a single set of top and
bottom tools and varying press-stroke depth, different profiles and products can be
produced. Different materials and thicknesses can be bent in varying bend angles, adding
the advantage of flexibility to air bending. There are also fewer tool changes, thus gives
higher productivity.
A disadvantage of air bending is that, because the sheet does not stay in full
contact with the dies, it is not as precise as some other methods, and stroke depth must be
kept very accurate. Variations in the thickness of the material and wear on the tools can
result in defects in parts produced. Air bending's angle accuracy is approximately 0.5
deg. Angle accuracy is ensured by applying a value to the width of the V opening,
ranging from 6 T (T- material thickness) for sheets to 3 mm thick to 12 T for sheets more

18

than 10 mm thick. Spring back depends on material properties, influencing the resulting
bend angle.

Fig. 4.1 Air bending

4.1.6 Bottoming:
In bottoming, the sheet is forced against the V opening in the bottom tool as
shown in fig. 4.2. U-shaped openings cannot be used. Space is left between the sheet and
the bottom of the V opening. The optimum width of the V opening is 6 T for sheets about
3 mm thick, up to about 12 T for 12 mm thick sheets. The bending radius must be at least
0.8 T to 2 T for sheet steel. Larger bend radius require about the same force as larger radii
in air bending, however, smaller radii require greater force up to five times as much than
air bending. Advantages of bottoming include greater accuracy and less springback. A
disadvantage is that a different tool set is needed for each bend angle, sheet thickness, and
material.

19

Fig. 4.2 Bottoming

4.1.7 Wiping:
In wiping, the longest end of the sheet is clamped, then the tool moves up and
down, bending the sheet around the bend profile as shown in fig.4.3. Though faster than
folding, wiping has a higher risk of producing scratches or otherwise damaging the sheet,
because the tool is moving over the sheet surface. The risk increases if sharp angles are
being produced. Wiping on press brakes involves special tools. This method will
typically bottom or coin the material to set the edge to help overcome springback. In this
bending method, the radius of the bottom die determines the final bending radius.

Fig. 4.3 Wiping

20

4.1.8 Spring back:

Spring back is the geometric change made to a part at the end of the forming
process when the part has been released from the forces of the forming tool. Upon
completion of sheet metal forming, deep-drawn and stretch-drawn parts spring back and
thereby affect the dimensional accuracy of a finished part. The final form of a part is
changed by spring back, which makes it difficult to produce the part. This is due to the
plastic-elastic forming of a work piece, at the end of a bending process.
When bending is done, the elastic stresses causes the material to spring back
towards its original position, so the sheet must be over-bent to achieve the proper bend
angle. In Fig.4.4, the final bend angle after springback (af) is smaller than the bend angle
before springback (ai), and the final bend radius after springback (Rf) is larger than the
bend radius before springback (Ri).It is difficult to predict springback because many
variables affect it, such as material properties, tool geometry, sheet thickness, and punch
stroke. As a rule, however, the smaller the punch radius, the smaller the springback, and
the greater the bending angle, the greater the springback.

Fig 4.4 Illustration of spring back

The spring back has to be compensated to achieve an accurate result. Usually that
is realized by over-bending the material correspondent to the height of the spring back.
That means for the practical side of the bending process, the bending former enters

21

deeper into the bending prism. In the case of complex tools the spring back has to be
already considered in the construction phase. Therefore complex software simulations are
used. Frequently this is not enough to deliver the desired results. In such cases practical
experiments are done, using the trial-and-error plus experience method to correct the tool.
The spring back angle also depends upon the bend angle and the material
properties. A spring back is compensated by two ways
1.

Over bending the sheet to get the proper bent angle.

2.

Bottoming or squeezing the material at the bend line.

In bottoming this the metal gets squeezed in the bottom die. This reduces the spring back
by holding the metal at the bottom of the die.
4.1.9 Spring back compensation
In this work embossing gives the additional stiffness to the bend angle and it
reduces the spring back of the material. Based on the internal bending radius and tensile
strength of the spring back angle is selected from the table 4.1[10]
For tensile strength 300 N / mm2 and Bending radius below the thickness of the sheet
Table 4.1 Spring back angle compensation
Bend angle

90

60

30

Spring back angle

4.7

3.1

1.6

1.6 4.2 DESIGN CALCULATION

4.2.1 Force required for Identity marking
Coining force = Perimeter x Depth of impression x Tensile strength
Avg. perimeter = 120 mm (calculating by measuring the outside length of the letters)
Force = 120 x 0.5 x 300
= 18,000 N

22

4.2.2 Force required for embossing

Embossing Force = Perimeter (P) x Average embossing depth (D) x Tensile strength (S)
During first forming:
For small embossing, Force = P x D x S
= 42 x 3 x 300
= 37,900 N
For long embossing, Force = P x D x S
= 58 x 6 x 300
= 1,04,400 N

During second forming:

For small embossing, Force = P x D x S
=38 x 2 x 300
= 22,800 N
For long embossing,

Force = P x D x S
= 56 x 3 x 300
= 50,400 N

4.2.3 Force required for bending

The V- bending force is calculated using the standard formula[9]
Force

klst 2
w

k = Bending factor = 1.33

s = ultimate tensile strength
l = length of bend
t = thickness
w = die opening = 8t
23

Force

33 x 42 x 300 x 2.5 2
8 x 2.5

= 5236.8 N
= 5237 N
Here V- bending takes place in three places. So, three times of the bending force is
required.
Total force = 18000 + 37900 + 104400 + 22800 + 50400 +5237 x 3
= 249211 N
= 25 tons (approximately)
4.3.4 Press selection and specification:
25 ton force is required to for the component. Considering the safety and
availability, the press of 30 tons is selected. The specifications are given in the table 4.2.
Table 4.2 Press specifications
Capacity

30 tons

Type

C Frame

Table size

450 x 500

Shut height

275 mm

Stroke length

75 mm

Ram Adjustment

30 mm

Strokes per minute

65

Power required

3 H.P

24

Gross weight

19000 N

Capacity of press - The maximum amount of force produced by the press during its
operation.
C type Frame - The base and the head are connected through the C type frame.
Shut height - For a press, this is the distance from the top of the bed to the bottom of the
slide with the stroke down and adjustment up[7]. In general, it is the maximum die height
that can be accommodated for normal operation, taking the bolster plate into
consideration as shown in fig.4.5.
Stroke length - It is the distance travelled by the ram during the half stroke of the press
without considering the ram adjustment.

.
Fig 4.5 Shut height of press
4.3.5 Tool height
Max. Tool height = Shut height adjustment

25

= 275 10
= 265 mm
Min. Tool height = Max. Tool height - Ram Adjustment
= 265 -30
= 235 mm
Optimum tool height = Min. Tool height + regrind allowance
= 235 + 15
=250 mm
4.3.6 Hexagonal socket headed screw:
It is used to connect the bottom plate and top plate with the die sets.
Material Specification: ASTM A574M / DIN ENISO4762-alloy steel
Hardness: RC 38 43
Max. Permissible stress on the threads: 120 N / mm2
No of Screws: 8

Permissible stress

Load on the screw

Load on the single screw

Area of the bolt on the crest

Total load
No. of screws
250 x 102
8 x 1.5

20.83 x 103 N

p
d 2
4

d c2

20.83 x 10 3 x 4
120 x

26

 = 14.86 mm
Major diameter of thread D = dc / 0.8
= 18 mm (approximately)
M18 Screw is selected
According to IS 2269: 1967 and the various dimensions of the screw are selected. Based
on PSG design data book[6] the various dimensions are shown in the fig. 4.6.

Fig. 4.6 Hexagonal socket headed screw

4.3.7 Die set
Standard die sets are selected from manufacturers catalogue[8] based on the size
of the table and availability. Fig. 4.7 gives the various dimensional parameters used in the
die sets and table 4.3 provides dimensions accordingly.

27

Fig 4.7 Die set parameters

A

A1

C1

C2

315

200

171

50

50

225

45

Table 4.3 Die set parameter dimensions

4.3.8 Pillar set
Corresponding to the die set, the pillar set of 30 mm diameter should be recommended by
the manufacturers catalogue[8].
Pillar length = Tool height Regrind allowance (two sides)
= 250 40
= 210 mm
4.3.9 Bush set
Corresponding to the die set, the bush set of 55 mm outer diameter and 30 mm inside
diameter has to be recommended[8].
Pillar length = (stroke length + Regrind allowance) + (Bolt thickness Base allowance)
28

= (75 + 15) + (50 -20) = 90 + 30

= 120 mm

29

CHAPTER 5
MODELLING OF TOOL
5.1 INTRODUCTION
Computer aided Engineering (CAE) makes the component drawing and drafting
easy. Now with the help of CAE complete study of component with their proper function,
even with the optimized condition is possible before the component has to be
manufactured. Using the CREO v2.0 CAE software package the component and the tools
were modeled and assembled. CREO platform helps easily for this work. As there is
separate module called CREO- Sheet metal specially constructed for sheet metal works.
5.2 COMPONENT MODEL IN SEQUENCE:
Component is modeled based on the drawing specified by the TI cycles of India
using the CREO. The various views of the drawings should be thoroughly understood
then only integration of those details with the software package is possible.
5.2.1 Blank modelling:
Blank is modeled based on the dimensions. Initially component is generated as a
solid part modelling. After the various operations are done the component is converted as
a sheet metal as shown in fig.5.1.

Fig.5.1 3D Model of blank

30

5.2.2 First forming

During this operation two embossing and a v-bending operation are done in a
single stroke. For the convenience of modeling the component has to be modeled without
embossing. In the software environment the bend line, bent surface (top) and the bend
angle of 300 are the data to be provided to make the component bent in the sheet metal
module. The component after first forming is shown in fig.5.2.

Fig. 5.2 First forming

5.2.3 Second forming
After the first forming the other side of the blank is formed in this stage. During
this stage two v-bending operations and two embossing operations are done. In this two
bending operations, first a 900 bent is provided adjacent to the center notch and a 600 bent
is provided 4 mm after the 900 bent as shown in fig. 5.3.

Fig 5.3 Second forming

31

5.3 DIE MODEL

5.3.1 Bottom die Model
Before the die has to be modeled the component placement is an important
criteria, as this decides the top and bottom die profile. In this work integration of identity
marking tool places an important role. Fig.5.4 shows the 3-D view of the solid model of
bottom die.
The marking tool must be a replaceable one. It should be changed every month.
So due to the gravity issue it should be placed on the bottom die.
It should contain the locating pins to place the component in a bottom die. The
placement is based on the recess provided on the component. It constrains the component
on the die. Fig 5.5 shows the location of the blank on the bottom die.
5.3.2 Top die model
The top die has an opposite impression of the bottom die. Additionally it is also
provided with a recess for the locating pin movement. The fig. 5.6 shows the solid model
of Top die.
5.3.3 Modelling of supporting elements
Supporting elements are the one which make the die as a tool. Based on the
dimensions are calculated on the chapter 4, the models are created in the CREO solid
model environment. The solid models of the various elements such as top plate, bottom
plate, pillars, bushes, and hexagonal socket headed screw are shown in the fig.5.6
Fig. 5.7 shows the complete assembly of the die set.

32

Locating pins
Provision for identity
marking tool

Fig. 5.4 Bottom die Model

Recess for locating pins

Fig. 5.6 Top die model

33

Bottom die

Locating pins

Blank

Fig.5.5 Location of blank on the bottom die

34

Top plate
Hexagonal
socket
headed screws
Bush

Pillar

Bottom plate

Fig. 5.7 Assembly of supporting elements in tool set

35

Fig 5.8 Assembly of the die set

36

CHAPTER 6
CONCLUSION
6.1 CONCLUSION

The study of the processes and problem involved in the manufacturing of the
sheet metal component with multiple bends (bracket) have been carried out.

The individual steps of operation of the component have been modeled separately
using the CREO sheet metal environment.

Total force required for the component, material selection and press selection
have been carried out.

A suitable die for the component with the various forming processes has been
designed along with the supporting elements such as top plate, bottom plate, bush,
pillar, and hexagonal socket headed screw and modeled.

The profile of the die was taken as the impression from the component. Provision
for marking tool is given on the bottom die.

Locating pins have been provided to place the component in the die.

6.2 FUTURE WORK

So far the die model has been created without considering the embossing aspect.
The second phase of this project will focus on designing the die model taking into
consideration embossing also

Designed die has to be analysed to determine the stress and critical sections.

Process simulation of the component will be carried out. Simulating the process
of the component will give the better idea and improve understanding of the
formability of the component.

37

REFERENCES
1. Ulhas K Annigeri , Y P Deepthi, Raghavendra ravi kiran, Design, development and analysis
of forming tool for Side panel of an automobile, Proceedings of IRF International
Conference, 2014, Pondicherry, India, ISBN: 978-93-82702-71-9.
2. Amit D. Madake, Vinayak R. Naik, Mr. Swapnil S. Kulkarni. Development of a Sheet-Metal
Component with a Forming Die Using CAE Software Tools (Hyper form) For Design
Validation and Improvement. International Journal of Modern Engineering Research, Vol. 3,
Issue. 3, May.-June. 2013, pp-1787-1791.
3. Z.Q. Sheng, R. Taylor, M. Strazzanti. FEM analysis and design bulb shield progressive
draw die, Journal of Materials Processing Technology, 2007, 5864.
4. W.M. Chan, H.I. Chew, H.P. Lee, B.T. Cheok, Finite element analysis of spring-back of
V-bending Sheet metal forming processes, Journal of Materials Processing Technology,
2004, pp-1524
5. Ch.Mastanamma , K.Prasada Rao,

M.Venkateswara Rao, Design and Analysis of

Progressive Tool, International Journal of Engineering Research & Technology,2012,vol 1,

issue 6,
6. PSG college of technology, Design data book, Karpagam publications, Coimbatore, ISBN13: 9780000306906
7. Ivana Suchy Handbook of Die Design, second edition, McGrew-Hill publication, 2006,
ISBN 0-07-146271-6
8. AWP die set standard manufacturers catalogue from the www.awprecision.com
9. Donaldson Tool design second edition, McGrew-Hill publication, 1995, ISBN
9780070992740.
10. P.H Joshi, Press tools- Design and construction. Third edition, wheeler publication,2001.
11. CREO v2.0 student edition CAE software package.

38