Jadhav et al.

, International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

Research Paper
DIE DESIGN FOR FORMED COMPONENT USING INPUTS
FROM FEA FOR DETERMINING THE MOST SUITED VALUES
FOR THE DESIGN/ PROCESS PARAMETER
1
Sachin Ramdas Jadhav, 2Sunil Hiraman More, 3Swapnil S. Kulkarni
Address for Correspondence
1*
ME-Mechanical Design-2nd yr, 2Asst. Prof.SKN Sinhgad Institute of Technology and Science, Lonavala.
3
Director-Able Technologies India Pvt. Ltd., Pune
ABSTRACT:
Sheet metal forming problems are typical in nature since they involve geometry, boundary and material non-linearity.
Drawings part involves many parameters like punch and dies radius, clearance, lubrication, blank holding force and its
trajectories etc. So designing the tools for part drawing involves a lot of trial and error procedure. To reduce number of
costly trial error steps, the process can be simulated by using finite element packages. Even the finite element package gives
an approximation towards the solution. The dissertation work is relevant in the context of developing a cost effective die
with a lower lead time through the phase of Design, Development, Trials and Testing, Pilot lot production & Regular supply.
The Deep draw process being critical to evaluate offers higher scope for study and research while addressing the most
suitable design for the Draw Die. Sheet-metal die is an inseparable constituent of the development process of any given
automotive or consumer appliance. In most of the cases, this accounts for a high proportion in the tooling needs of the large
size and structural member in any automotive like the chassis and the BIW.
KEYWORDS: Blank holding Force, Die block, Forming Die Design, Tonnage, HYPERFORM, Punch.
INTRODUCTION appliances, submarine hulls, and air craft frames.
Deep drawing can be defined as a metal forming Based on the geometry, the volume and the material,
process in which a part is produced from a flat sheet sheet metal forming can be divided into various
metal blank by the action of a punch force onto the categories such as stamping, deep drawing, stretch
blank. The blank is pulled (drawn) into a die cavity, forming, rubber forming, and super plastic forming.
which causes the flange of the blank to compress in Among these, Stamping and deep drawing are the
the circumferential direction while material flow is most common operations. Deep drawing products in
controlled by a restraining force provided by a blank modern industries usually have a complicated shape,
holder. . Metal in the area of the die shoulder so these have to undergo several successive
undergoes a lot of stress, and will result in wrinkles if operations to obtain a final desired shape. Trimming
a blank holder is not used to control the flow of of the flange is one of those operations and that is
material into the die. Material is usually thickest in used to remove the ears i.e. to have uniform shape of
the area where the metal loses con Items often made the flange on all the sides of the final product. These
by deep drawing include cupped baking pans, like are formed due to uneven metal flow in different
muffin pans, and aluminum can cylinders. However, directions, which is primarily due to the presence of
irregular items, like fire extinguishers and enclosure the planar anisotropy in the sheet.
covers for oil filters in trucks are also made this way - II. Principle of Draw process
as is your kitchen sink! Products made by deep Deep drawing is also a process of forming sheet
drawing are deep and seamless. Tact with the punch - metal through a forming die with a punch. Metal in
the punch radius - and thinnest in the areas where the area of the die shoulder undergoes a lot of stress,
stresses are greatest. This dissertation work would and will result in wrinkles if a blank holder is not
focus on eliminating the Design problems arising out used to control the flow of material into the die.
of incorrect selection of values for the variables / Material is usually thickest in the area where the
parameters. The parameters affecting the quality of metal loses contact with the punch - the punch radius
the component produced could be listed as Blank - and thinnest in the areas where stresses are greatest.
holding pressure, Radii at Die entry & punch nose, Deep drawing is often used to produce metal objects
Material of the component, Thickness of sheet, Depth that are more than half their diameters in height. The
of Form/ Draw, Use of Mechanical or Hydraulic metal is stretched around a plug, and then moved into
Press, Shape of the blank. the die.
Sheet metal forming is one of the most widely used
manufacturing processes for the fabrication of a wide
range of products in many industries. The reason
behind sheet metal forming gaining a lot of attention
in modern technology is due to the ease with which
metal may be formed into useful shapes by plastic
deformation processes in which the volume and mass
of the metal are conserved and metal is displaced
from one location to another. Deep drawing is one of
the extensively used sheet metal forming processes in
the industries to have mass production of cup shaped
components in a very short time. In deep drawing, a
flat blank of sheet metal is shaped by the action of a
punch forcing the metal into a die cavity Sheet metal
forming is one of the most common manufacturing
processes to plastically deform a material into a Figure 1.1: Schematic Diagram of Forming With Punch
desired shape. Products include hundreds of and Die
automotive components, beverage cans, consumer
Int. J. Adv. Engg. Res. Studies/III/III/April-June,2014/95-98
 Jadhav et al., International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

Items often made by deep drawing include cupped

baking pans, like muffin pans, and aluminium can
cylinders. However, irregular items, like fire
extinguishers and enclosure covers for oil filters in
trucks are also made this way - as is your kitchen
sink! Products made by deep drawing are deep and
seamless. The finished shape produced by a drawing
press depends on the position in which the blanks are
pushed down. Only malleable metals that are very
resistant to damage by tension and to stress can be
used in this process. Industries where deep drawing is
often used include the dairy industry,
pharmaceuticals, plastic manufacture, and the auto
industry, aerospace and lighting. Companies making
parts by deep drawing need expensive presses and
operations put together by trained engineers, as well
as plates, molds, and other accessories. Unlike metal
stamping, deep drawing uses a single piece blank, not
a continuous stream of blanks.
The productivity of the stamping process in the
industry yields better quality product at a economic
price. The dissertation work is relevant in the context
of developing a cost effective die with a lower lead
time through the phase of Design, Development,
Trials and Testing, Pilot lot production & Regular
supply. The Deep draw process being critical to
evaluate offers higher scope for study and research
while addressing the most suitable design for the
Draw Die.
Geometrical defects in sheet metal forming:
The Forming or deep drawing process allows the
production of large quantities of sheet metal parts of
various complexities. During the process a piece of
sheet metal is clamped between the die and the blank
holder. A force is applied to the blank holder to
prevent wrinkling of the sheet and to control the
material flow during the deformation. When the
punch is pushed into the die cavity the sheet deforms
plastically and thereby it takes the specific shape of
the tools The quality of the final product shape is
determined by the tools design, process parameters,
shape and material of the blank. It is important to
carefully consider all these factors prior to
manufacturing; otherwise a defective product could
result. Typical defects which are observed in sheet Figure 2: Extract from the part drawing for the
metal forming practice are wrinkling, necking and component
subsequent fracture, drawing grooves. In addition to III.2. Developed Blank Length (L0) & Blank
these defects, there is also always geometrical Width (B0)
L0=√ (566²+301²)
distortion caused by elastic spring back. Right after
forming, the shape of the deformed product closely =641mm
B0=696+300+150+300+150
conforms to the geometry of tools. However, as soon
=1600+75mm (as draw bead)
as the tools are retracted, an elastically-driven change
=1675
of the product shape takes place. The attempt of this
III.3. Draw Ratio – At this component, the Draw =
work would also be to minimize the defects evident
H/d = 566/1000 = 0.566 which indicates the draw is
during the development phase of the component
simple & may require only one stage for completion
III. Die Design Calculations
because 0.566 is less than 0.75
The component chosen for this dissertation would is
derived from the projects being undertaken by the III.4. Punch & die clearance.
Calculation formula for finding out the clearance
sponsoring company- Advent tool tech Pvt. Ltd.,
between the Die and Punch clearance for the deep
Pune. The case study shall incorporate the design and
drawing process.
development of the component named - `Panel
C= T+ k ( √ 10 T)
windshield’ that is used over the subassembly of auto
Where,
rickshaw for fixing the glass.
C = Clearance
III.1The specs along with the drawing for this
T = Material Thickness
component are given below:
k = Coefficient ( for Steel sheet =0.07 for commercial
Component Name –Panel windshield
CRCA Steel EDD Grade as per IS513-1994 grade; DD=0.06; EDD=0.05;)
Our case:
Thickness – 1.2 +/- 0.03 mm
Int. J. Adv. Engg. Res. Studies/III/III/April-June,2014/95-98
 Jadhav et al., International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

T = 1.2 mm III.14 Guide pillar & Steel Bush

C = 1.2 + 0.07 X √ 10 X 1.2 Guide pillar =DANLY:5-8040-82;ODϕ 80;FL=400
Clearance between Punch and Die, C = 1.44 PG NO:06
In draw / form tool, Punch is the master, which Steel bush= DANLY:DEMOUNTABLE STEEL
means the Punch shape will perfectly match the part BUSHES 6-8010-64 ID= 80;PF LENG=48;FL=100;
surface / profile. The clearance is given to Die NO:07
surface. III.15 surface finish of die
III.5. Draw Force – Draw Force can be calculated Usually a very good surface finish of the Die is
by empirical relation, preferred, because this reduces the scoring marks or
P =[2(Li+Bi)*t+S{(Lo+bo/Li+Bi)-C}] scratch marks on the final part. Usually a Ra value of
Where, P = Draw Force in Tons at least 5 to 3.2 microns is recommended for the die
Li=Final part length in mm=1115mm surface, in practice.
Bi=Final part width in mm=564mm IV. Die Design & HyprForm Analysis
Lo= Blank length in mm=1675mm
Bo=Blank width in mm=641mm
t = Thickness of Metal in mm = 1.2 mm
S = Shear strength of Metal in Kg/mm2 = 40
Kg/mm2
C = Constant (Take 0.6 to 0.7)
We know that
P = [2(Li+Bi)*t+S{(Lo+bo/Li+Bi)-C}]
=[2(1115+564)*1.2+40{(1675+641/1110+564)-0.7}]
=109843.2kg
=109.8Ton
Factor of safety should be taken as 15%
Therefore,
Draw Force (P) = 110*1.15=126.5≈130ton
III.6. Die Block Dimension –
Die block Dimension -1200mm X 800mm
Material for Die block should be use HCHCr &
Fig: 3 Solid model of the component (Panel windshield)
OHNS Hardness using CAD software by Unigraphics NX-6
Die Block should be harden upto 60 to 62 HRC Analysis of component using CAE/Simulation
III.7. Top Plate – Top Plate Dimension = 2000 mm software `HYPERFORM’
x1 250 mm
Thickness for Top Plate should be 48 to 50 mm
(Take 49 mm)
III.8. Bottom Plate – Bottom Plate Dimension =
1800 mm x1 250 mm
Thickness for Bottom Plate should 58 to 60 mm
(Take 60 mm)
III.9. Punch Height – Height for Punch should be
461.9mm
III.10. Draw & Punch radius – The Draw radius
usually ranges from 4 to 10 times the Blank
thickness,
Therefore, Radius of Draw Die=Rd=4.5x1.2=5.4 Figure 4.1: Result of Analysis for Blank holding force at
mm. 30 Ton
The Punch radius usually ranges from 3 to 4 times Observation: Maximum thinning recorded – 25% of
the Blank thickness, the thickness of the component (acceptable part
Therefore, Radius of Punch = Rp =3 x 1.2 = 3.6 mm quality)
III.12. Blank Holding Force – Blank Holding Force
(B.H.F.) is always 25 % of Draw Force, therefore
B.H.F. can be calculated as,
Blank Holding Force (B.H.F.) = 30 % of Draw Force
= 25 % x 110 = 27.4 Ton ≈ 30 Ton Material for
Blank Holder should be use EN-353 or 20MnCr5
Hardness – Blank Holder should be harden upto 30 to
35 HRC
III.13. Press Tonnage or Press capacity –Press
Tonnage can be calculated by using following
formula, Press Tonnage = Draw Force + Blank
Holding Force (B.H.F.) = 130 + 30 = 160 Ton
Therefore,
Press Capacity of 160 Ton shall be suitable. Figure 4.2: Result of Analysis for `Blank holding force’
Bloster FB=760mm & LR=1930mm at 30 Ton
Top sideFB=585mm &1500mm Observation: No wrinkles or any major defects
Cushin pin=50mm travel which is adjustable. observed (acceptable part quality)

Int. J. Adv. Engg. Res. Studies/III/III/April-June,2014/95-98

 Jadhav et al., International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

range of application of the developed method, parts

with more complex geometries can be considered as
future scope of work.
ACKNOWLEDGEMENTS
The author gratefully acknowledges the support
received from Mr. S.S.Kulkarni, Director- Able
Technologies (India) Pvt. Ltd. Pune, for his technical
and administrative support from conceptual stage to
the final stage for execution of this work. The author
also would like to thanks, Asst. Prof Sunil Hiraman
More SKN Sinhgad Institute of Technology and
Science, Lonavala, Asst Prof. S.L.SHINDE P.G.
Figure 4.3: Result of Analysis for `Blank holding force’ Coordinator, Sinhgad Institute of Technology and
at 30 Ton Science, Lonavala for guidance and crucial inputs
Observation: Accurate formability with no failure over the project work
(acceptable part quality) REFERENCES:
1. Michael P. Pereira, Matthias Weiss , Bernard F. Rolfe , Tim
B. Hilditch, The effect of the die radius profile accuracy on
wear in sheet metal stamping, Institute for Frontier Materials,
Deakin University, Locked Bag 20000, Geelong VIC 3220,
Australia.
2. Gyadari Ramesh, Dr. G.Chandra Mohan Reddy ,A Analysis
of Optimization of Blank Holding Force in Deep Drawing By
Using LS DYNA, International Journal Of Engineering
Research and Applications (IJERA) ISSN: 2248-9622
3. V. Naranje S. Kumar, a knowledge based system for
automated design of deep drawing die for axisymmetric
parts, S.V. National Institute of Technology, Surat, India
4. Farhang Pourboghrata, Senthilkumar Venkatesana, John E.
Carsleyb, LDR and hydroforming limit for deep drawing of
AA5754 aluminum Sheet, Department of Mechanical
Figure 5: Solid model of forming die for component Engineering, Michigan State University, 2241, Engineering
panel windshield by Unigraphics NX-6 Building, East Lansing, MI 48824, USA
5. Jeong-Yeon Lee, Jin-Woo Lee, Myoung-Gyu Lee ⇑, Frédéric
Barlat, An application of homogeneous anisotropic hardening
to springback prediction in pre-strained U draw/bending,
Graduate Institute of Ferrous Technology (GIFT),San 31
Hyoja-dong, Nam-gu, Pohang, Gyeongbuk 790-784
6. Yinfang Jiang n, Yu Huang, Hua Jin, Yongyu Gu, Aiguo
Ren, Liwei Huang, Xiaoming Qian, Research on precision
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semi-die, College of Mechanical Engineering, Jiangsu
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Figure 6: Schematic sketch of forming die for

component by using Unigraphics NX-6
V.CONCLUSION
The conclusion of this work are enumerated and
presented as shown. For a given set of punch die and
working conditions there exists an optimum blank
holding force which prevents the wrinkles and at
same from the stresses induced in the part is
minimum. Sufficient research and deliberation using
the proven QC tools backed up with CAE software
support (HYPERFORM) has offered a feasible
solution to the problem at hand. Steel material like
HCHCr (High carbon High Chromium) & OHNS
(Oil Hardening non Shrinkage) grade for both punch
and die block to suit the components having EDD
(Extra Deep Draw) is recommended per the practices
found in the industries. Thinning and Formability are
ascertained in this study. Suitable blank holding
pressure (30Ton) is recommended for a defect-free
component as per figure 4.1 & 4.2. The results
obtained by mathematical treatment and the results
obtained through the use of software (analytical)
agree reasonably well. These results also establish
generic guidelines for forming die design for Extra
Deep Draw (EDD) materials. In order to expand the
Int. J. Adv. Engg. Res. Studies/III/III/April-June,2014/95-98