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International journal of advanced production and industrial engineering

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International journal of advanced Science & Technology
production and industrial engineering with Management.

IJAPIE-2017-02-215, Vol 2 (2), 65-70 A Journal for all

Products & Processes.

Design and Analysis of Progressive Die Using Finite Element Method

Dinesh Kumar Kushwaha1, S.S Banwait2, Husain Mehdi1
1
Department of Mechanical Engineering, Meerut Institute of Technology, Meerut, U.P, India
2
Department of Mechanical Engineering, NITTTR, Chandigarh, Panjab, India
*Email: husainmehdi4u@gmail.com

Abstarct : Historically, Early man had made use of wooden die to carve bricks. Since then, dies had been used in
industries, especially for sheet métal and other forming operations. Progressive dies are forming tool comprises of two
or more stations performing different operations. The raw material travels from first station to last to get transformed
into the finished product. In this work an industrial problem at Anand Tracks and Field (P) Limited, regarding the shell
manufacturing of discus throw was identified. The problem in shell manufacturing was regarding the concentricity of
shell. The shell after being manufactured was not found exactly concentric; it means that the shell show some degree of
straightness at the ends. Welding operation was then used to join the two ends so as to ensure the concentricity of the
shell which, consequently increased the manufacturing lead time as well as labor cost. The problems encountered in the
company was solved by designing a progressive die and it was suggested to change the raw material, instead of rod,
plate was proposed to produce the shell. In this work, three stages of die design had been done. In the first phase,
conventional designs had been done and the induced stresses were checked out. In second phase, the die and punch
assembly was developed by using CATIA V5 R 20 software. Eventually, the drawing had been imported in ANSYS 14.0
software; a finite element method analysis software to check the stresses induced

Keywords: Stress, Progressive Die, Finite Element Method

1. INTRODUCTION investigates the effect of potential parameters influencing the

blanking process and their interaction. This helped in
The use of an automated progressive design system with choosing the process leading parameters for the two identical
multiple operations such as piercing, bending and deep products manufactured with a two different materials blanked
drawing for manufacturing products is developed. Especially with a reasonable quality on the same mould. Finite Element
a approach to make a progressive and flexible working Method and Design of Experiment (DOE) is used in order to
system which was based on knowledge base rule [1]. In order achieve the intended model objectives. The combination of
to reduce the stress on the tool during punching/blanking both the technique is proposed to result in a reduction of
operation the use of finite element technique is made. necessary experimental cost and effort in addition to getting a
Analysis of punching/ blanking force is done by varying the higher level of verification [5]. The blanking of thin sheet
models of punching and blanking tools by using finite (0.1–1 mm) of mild steel using an elastic–plastic finite
element models. This model enables the analysis of effects of element method based on the incremental theory of plasticity.
variations of tool geometry on punching/blanking force and The blank diameters are considered in the range 1–4 mm.
on the deformation of punch [2]. Industrial application of dies The study has helped to evaluate the influence of tool
involves structural design tool for punches and dies of motor clearance, friction, sheet thickness, punch/die size and
core based on the functional component. The descriptive blanking layout on the sheet deformation. The punch load
model of punch and dies was established which contains variation with tool travel and stress distribution in the sheet
three aspects of information, geometry information, assembly have been obtained [6]. The behavior of the blank material
related constraint attribute and hole related information on during the process through finite element simulations,
plate [3].The optimization of the punch–die clearance values analytical modeling and experimental work. The objective is
for a given sheet material and thickness by using the finite to contribute towards the development of a system for the on-
element technique and Cockroft and Latham fracture line characterization of the blank material properties during
criterion. In the study, the shearing mechanism has been the punching/blanking process [7].The simulation of fine
studied by simulating the blanking operation of an aluminum blanking processes, and a finite element model valid for
alloy 2024 [4]. A model to predict the shape of cut size in the numerically describing of such operations has been
sheet metal components has been established. The model developed. The numerical simulations of the damage

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 Dinesh Kumar Kushwaha et al.,
International Journal of Advanced Production and Industrial Engineering

evolution and crack initiation and propagation have been

described by means of continuum damage approach [8]. The
finite element (elastic-plastic) analysis of sheet metal forming
process using the finite element software. LUSAS simulation
is carried out to gain accurate and critical understanding of
sheet forming process. Axi-symmetry element mesh and
plain strain element mesh were use incorporated with slide-
line features to model and study the sheet metal forming
process. Simulation of elastic-plastic behavior of aluminum
sheet was carried out under non-linear condition to
investigate sheet metal forming process [9]. Further the
application of dies in manufacturing concern incorporates the Fig: 1 Semi finished Shell
methodology for progressive die sequence design for forming
round cups using finite element method (FEM) based 3. RESULTS AND DISCUSSION
simulations. The process sequence design developed has been
applied to forming of an automotive part and is compared The straightness of ends of shell was the major problem in
with the design obtained from past experience. The manufacturing. In order to maintain the concentricity, a
methodology proposed that the integration of design number of miscellaneous operations were carried out which
experience and FEM simulations could enhance the increased the manufacturing lead time as well as the labor
robustness of the procedure for die design sequence and cost. If the operations are combined or eliminated it will
reduces the die development cost considerably [10]. The surely reduce the manufacturing lead time as well as labor
shearing mechanism is studied by simulating the blanking cost. A progressive die and punch is the proposed possible
operation of an AISI 304 sheet and Simulation used the FEM solution for the problem encountered by the workmanship.
program ANSYS. Also a methodology to obtain optimum
punch-die clearance values for a given sheet material and 3.1 DESIGN OF DIEASSEMBLY
thickness to be blanked, using the finite-element technique is
developed [11].Again Finite element analysis to investigate Progressive dies are made with two or more stations arranged
the effect of the die clearance on shear planes in the fine in sequence. Each station performs an operation on work
blanking of a part of an automobile safety belt. For the piece or provides an idler station, so that the work is
analysis, AISI1045 is selected as the material, which was completed when the last operation has been accomplished. In
used in manufacturing part of an automobile safety belt [12]. this work, as a solution to non-concentricity of shell, the raw
More over simulation of sheet-metal cutting processes by material as well as the entire manufacturing processes was
shearing mechanisms, such as blanking and punching have changed. In this new solution, the raw material recommended
developed a finite element model (FEM) valid for the for shell manufacturing is mild steel plate and shell was
numerical description of such processes. To study the effects carved out from a two station progressive die. The plate was
of varying the process parameters on the geometry of the first punched under smaller die and is then transferred to
sheared edges, and the evolution of the force-punch larger one and finally to the cavity dies which are already
penetration, they implemented a calculation algorithm by available in the industry. After having passed from the dies, a
means of the user routine (UMAT) of ABAQUS/standard finite single piece shell was carved out.
element code [13].Another industrial problem involves In conventional design, taking into account the above
cutting of sheet-metal cutting processes by shearing dimensions of the shell of progressive die, punch was
mechanisms, such as blanking and punching, and developed a designed and the force on the punch was calculated. The
finite element model (FEM) valid for the numerical material recommended for making the dies for the industrial
description of such processes. To study the effects of varying application is H13 steel. Die steel H 13 was selected for
the process parameters on the geometry of the sheared edges, manufacturing of the die and punch assembly. The die
and the evolution of the force-punch penetration, they assembly for shell manufacturing is shown in fig 2.
implemented a calculation algorithm by means of the user
routine (UMAT) of ABAQUS/standard finite element code
[14].

2. PROBLEM FORMULATION
M/s Anand Track and Field Equipment Private Limited is a
manufacturer of various types of sports goods and Athletics
& Gymnastic Gym Equipments. In one of its vendor unit,
M/s Kaushik Engineering Works which is manufacturing the
shell of discus throw; a problem has been identified by the
management of the company regarding the manufacturing of
shell. The shell after being manufactured is not found exactly Fig: 2 Punch and Die Assembly.
concentric; it means that the shell show some degree of
straightness at the ends as shown in fig.1.

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 Dinesh Kumar Kushwaha et al.,
International Journal of Advanced Production and Industrial Engineering

The dimension of the punch holder which is comprises of

three punches and dimensions are shown in fig 3. . The magnitude of P is taken as 4.5 MN in one case and 12.5
MN in the another case to design the punch holder. Taking
both the cases for calculating the force on punches and the
induced corresponding stresses.
Case I: In this case, P = 4.5 MN and the sheet was first
clamped on the smaller station and then is made to travel to
larger station after the operation on first station was
completed and then, it is finally clamped to the last station
where only the final shape is given to the shell. In this case,
the power requirement was less as compared to the second
case. The sheet was first subjected to compressive strength
and then shearing of sheet commences. Hence, the sheet was
designed in compression. The dimensions of the punches are
as follows:
Ds= 154 mm, Dl= 202 mm.
Fig : 3 2D View of Punch Holder
Checking for induced stress
3.2 CALCULATION OF PUNCHING FORCE

For the calculation of force of punching, a standard formula The induced compressive stress in sheet in the smaller punch
is used and the maximum shearing force required to cut the and in bigger punch is different as the area which is resisting
the load is different and is calculated as under. The induced
sheet is
compressive stress is
Fmax= 0.7x UTS x T x L
Where σcs= = 4.5 x 106/ 0.785 x 1542 (1)
T= thickness of the sheet. Where,
L= π x D= total length of sheared area. σcs= Stressesinduced in smaller punch.
{Taking UTS = 432-510 MPa.( C 20 carbon steel)} σcs = 241.59 MPa
Fmax= 0.7x UTS x π x Db x T
σcl= 4.5 x 106/ 0.785 x (2022 – 1542)
Fmax= 0.7x UTS x π x T x Dl
Fmax = 0.7x 510x π x 19 x 202. σcl = 4.5 x 106/13.41 x103 = 335.57 MPa
Fmax = 4.5 MN. Where
σcl= Stresses induced in larger punch.
3.2.1 Design of Punch Holder In both the cases, the induced compressive strength is less
than the allowable yield stress of the punch material H 13 die
The punch holder holds all the punches and the required load steel i.e. (1000 MPa). So design of punch is safe under these
for punching is applied on the punch holder only. The conditions of loading.
material used for punch holder is H 13 steel. The punch σy>σcl or σcs
holder has three punches one is smaller, second one is larger Hence, the punch design is successful and was safe under
and third one is cavity punch as shown in fig 4. The cavity every condition of shearing steel and the punch will perform
punch is used to give desired shape to the shell. As low its intended function.
magnitude of force act on cavity punch so in design it was
neglected. Calculation of Factor of safety: Denoting by σw, σy,σu and n
are the working stress, yield point stress and ultimate tensile
stress of the material and factor of safety respectively, the
magnitude of factor of safety was determined by equation.
The yield point or ultimate strength of material was taken for
calculating the factor of safety. The working stress of the
material was taken as 337.5 MPa. [6]
n= σy/σw (2)
n= = 2.9

Clearance allowance for Die

The clearance between the die and punch [7] can be
determined as c = 0.003 Txτ.
Where
T is the sheet thickness and τ is the shear strength of sheet
Fig: 4 Front View of Punch Holder material.

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 Dinesh Kumar Kushwaha et al.,
International Journal of Advanced Production and Industrial Engineering

According to distortion- energy theory, the shear stress is punch holder and it is supposed that the punches are stopped
calculated by [8] by the sheet for a while, the stress induced is compressive
τ =0.577 xσy/n stress. The compressive stress induced in the punches are
τ = 42.24 MPa The stress induced on the smaller punch will be almost same
c =0.003x19x42.24= 2.4 mm. as the load on punch
σcs = = 4.76 x 106/0.0186 = 255.91 MPa
Case II: Calculation of load when no punch is idle
σcl= 7.734 x 106 / 13.42 x103 = 576 MPa
In this case, the punching starts first from smaller die as usual
but the difference lies in the fact, that when the work piece is
clamped to the larger die, simultaneously new work piece is 3.3 Finite Element Analysis
clamped to the first station. That is why continuous operation
was carried out. In this case, none of the station is kept idle. As main parts in the assembly were dies and punches, so
The rate of production of the shell of discus is high as FEM analysis was made for that part. Also simulation was
compared to the case I. Also the power consumption is more. carried out of these parts. The dies and punches were
The load on each punch and the corresponding induced conventionally designed and later stress analysis was done by
stresses are calculated as under. using ANSYS 14.0 software.
P = Ps +Pl + Pc (3) Mild steel C – 20 was taken for die holder. But the die holder
P = P l + Ps (4) was manufactured by H 13 steel in actual practice. Material
was changed for convenience in calculating the induced
Pc is neglected, as this punch will not take part in cutting
stress as the shearing of mild steel offer maximum stress
operation induced in die holder (H 13 steel).The maximum stress on H
P= [9] (5) 13 steel was by shearing of mild steel C-20 steel.
Solving Equation (4.4) and (4.6), the load on smaller punch; 3.3.1 FEM Analysis for Smaller Punch
= (6)
FEM analysis of the punch holder was done in static
and the load on larger punch;
structural module of ANSYS 14.0 in workbench. The load
(7) was applied on the plate of magnitude 4.5 MN and the
smaller punch was fixed while the other two punches are kept
Taking the material of the punch holder as H13 tool steel, the
free, according to the case I. The normal stress was found out
modulus of elasticity is in this analysis. Fig 5 shows the stress distribution figure of
El= Es= 215 GPa = 215 x 106 MPa the punch holder. The various colors combination shows the
As= Cross sectional area of smaller punch and Al= Cross stress distribution. The red color shows the area of the
sectional area of larger punch highest value of the stress and the blue shows the value of the
As= π/4x 0.1542 = 0.0186 m2 lowest stress. The maximum stress found from this analysis
Al π/4 (Db2 – Ds2) = 13.42 x 103 m2 was 278.5 MPa which was less than the permissible stress.
Therefore, the design is on the safer side.
Taking P= 12.5 MN and after putting all the values in
equation (6), load on smaller punch is
Ps (215 x 106 x 0.0186/ 215 x 106 x 0.0186 + 215 x 106 x
0.0320) x 12.5 x106
= (4 x106/10.5 x 106) x 12.5 x106 = 4.76 MN
Similarly, the load on the larger punch is.
(8)
Pl = (215 x 10 x 0.0302/ 215 x 10 x 0.0302 + 215 x 106 x
6 6

0.0186) x 12.5 x106

Pl= 6. 93/10.493) x 12.5 x 106 = 7.734 MN
P = P l + Ps
P= 4.76 + 7.734
P = 12.5 MN
Fig 5: Stress Distribution (Smaller Punch Fixed)
Stresses Induced in smaller and bigger punch 3.3.2 FEM Analysis for Bigger Punch
It was crucial here to take into account what types of stresses The load applied in this analysis was 4.5 MN and the fixed
are induced in the punches. As the punches moves in the support was given to bigger punch. Fig 6 shows the stress
downward direction, it touches the sheet which is to be cut distributed view of the punch holder. The various color
for producing the shell. If the load applied is on the top of combination shows the stress distributions. The red colour on

| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 2 | Issue. 2 | 2017 | 68 |

 Dinesh Kumar Kushwaha et al.,
International Journal of Advanced Production and Industrial Engineering

the extreme left shows the region of highest stress. The 4. CONCLUSION
maximum stress found on this area was 278.5 MPa
 After studying the entire manufacturing processes, and it
was found that shell was not concentric. Also there was a
gap remains in between both the ends. In order to join
both these ends and to ensure the concentricity of the
shell, welding operation and hand forging were carried
out. Around 2 – 3% of the total shells produced were
rejected
 Conventional Design of die assembly was done. It was
found that the stresses induced in the smaller and bigger
punch are 241.59 MPa and 335.57 MPa respectively.
When no punch is idle, stress induced was 576 MPa.
Also the induced stress is less than the permissible limit
of stress of H13 steel (i.e. 1000 MPa.
 Progressive die of three stations has been developed
Fig 6: Stress Distribution (Bigger Punch Fixed)
using CATIA V5 software and parts were assembled.
The punching and blanking operations are performed on
3.3.3 FEM Analysis for Cavity Punch
first two stations and third punch was employed to give
Fig. 7 shows the stress distribution of punch holder when the final shape to the shell
cavity punch was fixed and load of 4.5 MN was applied. The  Stress verification was done by finite element method
areas on punch holder of smaller punch show region of using ANSYS 14.0 release software. The punch holder
highest stress. was imported from CATIA V5 software and the normal
stresses were calculated. The highest stress obtained was
278 MPa which was under safe limit of allowable stress.
 Several major and minor manufacturing processes
involved in shell manufacturing were combined in two
operations i.e. punching and blanking.

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| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 2 | Issue. 2 | 2017 | 69 |

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