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International Journal of Trend in Research and Development, Volume 3(4), ISSN: 2394-9333
www.ijtrd.com
IJTRD | Jul-Aug 2016 Available [email protected] 227
Designing of Punch and Die for Blanking, Forming
and Bending Press Tools to Manufacture Fuel Filter
Bracket Component Using Finite Element Method 1Chandranath.M,
2Dr G Mallesh and
3Dr. D. Ramegowda,
2Associate Professor,
3Principal
2Department of Mechanical Engineering, SJCE-Mysuru, India
1,3PG Studies, Govt tool room and training centre, Mysuru, Karnataka, India
Abstract — This paper presents Finite Element analysis
technique to design the Blanking, forming and bending press
tools punch and die for Fuel filter bracket component using
static structural analysis. Press tools are used to manufacture
sheet metal components. These sheet metal components are
widely used in Automobile and Aerospace domain. The sheet
metal components are manufactured by applying the
predetermined force or pressure. The design, manufacturing
and safety requirement needs a design based on Finite element
method. The static structural analysis is carried out to find
possibilities of failure and to design Punch and die of Press
tool. Fuel filter bracket component is a part of fuel filter
assembly unit of automobile. Sequence of operation is planned
initially and then press tool is designed and analyzed. The
analysis helps in avoiding the costly tryouts and optimizing the
design with safety and cost effectiveness. With the assistance
of structural analysis, the problem regions, causes and
solutions can be found using the Computer aided Engineering
techniques.
Index Terms — Finite Element Analysis, Blanking, Bending
and Forming
I. INTRODUCTION
Press tool device is used to produce sheet metal parts by
cutting, non-cutting and hybrid operations. Most of
Automobile and Aerospace mass production products are
manufactured by Sheet metal technology. The Blanking,
Forming and Bending are main sheet metal operations in
making components. Blanking is a cutting operation in which
punched out piece is a component. Forming is shaping the
metal to the desired contour around nonlinear axis. Bending is
shaping the metal around a straight axis. A sheet metal is
subjected to plastic deformations using press tool to confirm to
a planned shape in forming and bending operations. A sheet
metal is subjected to shearing in blanking operation. During
design process, the optimization of parameters of Punch and
Die has to be done correctly to eliminate failure and to ensure
safety. Finite Element analysis software can be used in the
design of Blanking, forming and bending punch and dies. The
structural analysis method has been established as a practical
methodology to access failure. With this methodology die
tryout may be removed and safety can be ensured and
productivity can be increased by reducing tool cost and lead-
times. The static structural analysis can be used in design of
Punch and Die.
II. COMPONENT STUDY
The name of the component is Fuel Filter Bracket. It is an
automobile component used in automobile vehicle fuel filter.
The three stages of operations Blanking, Forming and Bending
are used to produce this component.
Figure 1: Fuel filter bracket
Material: MS CR2
III. STATIC STRUCTURAL ANALYSIS OF PUNCH
AND DIE
The analysis is carried out using Catia software with CAE
application. The solid models created using Catia Software are
analysed using Catia Generative Structural Analysis work
bench. In this context only the critical functional parts which
undergo repeated stresses like Punch and die are considered for
analysis purpose. The analysis of punch and die for blanking,
forming and bending operations are analysed by applying
material properties, boundary conditions, Load and then it is
solved for results Punch and die Material used for Blanking
Press tool: High carbon high chromium Grade D2 steel
Chemical ingredients: Copper =1.55%, Silicon =0.3%,
Molybdenum =1%, Manganese =0.3%, Chromium =12%
Punch and die Material used for Forming & bending Press tool:
Oil Hardened Non Shrinking Steel
Chemical contents: C=0.85 to 1, Mn=1 to 1.4, Si=0.5, Cr=0.4
to 0.6, Ni= 0.3 W= 0.4 to 0.6, V= 0.3, Cu= 0.25, P= 0.03, S=
0.03 percentages.
Element Type: Linear tetrahedron Solid Mesh
The Global mesh size is used for larger surface areas and
smaller fine mesh is used at fillets to get correct results with
less computation time.
International Journal of Trend in Research and Development, Volume 3(4), ISSN: 2394-9333
www.ijtrd.com
IJTRD | Jul-Aug 2016 Available [email protected] 228
Global and Fine Mesh Elements Size
A. Tool Calculations
Shear Force:
Shear Force = Length of Cut x Thickness x Shear Strength
Shear Force= 439.446 x 2 x 280
Shear Force=246089.76N
Forming Tool Force
Forming Force= Component thickness (mm) x Forming length
in X and Y axis (mm) x Ultimate tensile Strength (N/mm2)
=2 x (22.5+135) x 560
=176400N
=17.98 Tons
Pad Force = 25% of forming force
= 0.25 x 17.98
= 4.495 Tons
Total force = Forming force + Pad force
= 17.98 + 4.495
= 22.475 Tons
= 220479.75N
Bending Tool Force
Bending Force = Component thickness (mm) x Forming length
in X and Y axis (mm) x Ultimate tensile Strength (N/mm2)
= 2 x (53+61) x 560
=127680N = 13.015Tons
Pad Force = 25% of forming force
= 0.25 x 13.015
= 3.25 Tons
Total force = Forming force + Pad force
= 13.015 + 3.25
= 16.26 Tons
= 159510.6N
B. Blanking Tool Design
3D Model is created using Catia software. Blanking is a cutting
operation in which punched out piece is a component. The 3D
models of tool, punch, die and component are shown below.
Figure 2: Blanking Press Tool
Figure 3: Blanking tool Punch and Die
Figure 4: Blanking component
C. Analysis of Punch for blanking operation
Applied Load: 246089.76N
Figure 5 Punch Boundary condition
Figure 6 Blanking Punch Mesh
International Journal of Trend in Research and Development, Volume 3(4), ISSN: 2394-9333
www.ijtrd.com
IJTRD | Jul-Aug 2016 Available [email protected] 229
Figure 7: Von Mises Stress of Blanking Punch
D. Analysis Results
Table 1: Blank Punch Von-Mises Stress results
Objective Von-Mises Stress (MPa)
Minimum 2.96
Maximum 1180
E. Analysis of Die for blanking operation
Applied Load: 246089.76N
Figure 8: Blanking Die Mesh
Figure 9:Blanking Die Boundary condition
Figure 10: Von Mises Stress of Blanking Die
Analysis Results:
Table 2: Blank Die Von-Mises Stress results
Objective Von-Mises Stress (MPa)
Minimum 2.95
Maximum 171
F. Forming Tool Design
3D model of the Forming tool with Rear pillar press tool is
designed. The 3D Models of tool, die, punch and component
for Forming process are shown below.
Figure 11: Forming Press Tool
Figure 12: Forming tool Punch and Die
Figure 13:Forming component
G. Analysis of Punch for forming operation
Applied Load: 220479.75N
The Pressure = 111.3MPa is applied based on forming Load of
220479.75N and corresponding Contact area on Punch.
Figure 14: Forming Punch Mesh
International Journal of Trend in Research and Development, Volume 3(4), ISSN: 2394-9333
www.ijtrd.com
IJTRD | Jul-Aug 2016 Available [email protected] 230
Figure 15: Forming Punch Boundary condition
Figure 16: Von Mises Stress of Forming Punch
Analysis Results:
Table 3: Forming Punch Von-Mises Stress results
Objective Von-Mises Stress (MPa)
Minimum 0.797
Maximum 249
H. Analysis of Die for Forming operation
Applied Load: 220479.75N
The Pressure of 113.88MPa is applied based upon forming
Load of 220479.75N and corresponding Contact area on Die.
Figure 17: Forming Die Mesh
Figure 18: Forming Die Boundary condition
Figure 19: Von Mises Stress of Forming Die
Analysis Results:
Table 4: Forming Die Von-Mises Stress results
Objective Von-Mises Stress (MPa)
Minimum 0.154
Maximum 193
Figure 20: Forming Press tool
I. Bending Tool Design
3D model of the Bending tool with Rear pillar press tool is
designed. The 3D models of tool, die, punch and component
for bending process is shown in Fig
Figure 21: Bending Tool
Figure 22: Bending Punch and Die
International Journal of Trend in Research and Development, Volume 3(4), ISSN: 2394-9333
www.ijtrd.com
IJTRD | Jul-Aug 2016 Available [email protected] 231
Figure 23: Bending component
J. Analysis of Punch for Bending or flanging operation
Applied Load: 159510.6N
The Pressure of 50.22MPa is applied based on flanging Load
of 159510.6N and corresponding Contact area on Punch.
Figure 24: Bending Punch Mesh
Figure 25: Bending Punch Boundary condition
Figure 26: Von Mises Stress of Bending Punch
Figure 27: Bending Press tool
Analysis Results:
Table 5 Bending Punch Von-Mises Stress results
Objective Von-Mises Stress (MPa)
Minimum 0.0715
Maximum 48.6
K. Analysis of Ejector for bending operation
Applied Load: 159510.6N
The Pressure of 74.58MPa is applied based on Flanging Load
of 159510.6N and corresponding Contact area on Ejector.
Figure 28: Bending Ejector Mesh
Figure 29: Bending Ejector Boundary condition
International Journal of Trend in Research and Development, Volume 3(4), ISSN: 2394-9333
www.ijtrd.com
IJTRD | Jul-Aug 2016 Available [email protected] 232
Figure 30: Von Mises Stress of Bending Ejector
Table 6: Bending Ejector Von-Mises Stress results
Objective Von-Mises Stress (MPa)
Minimum 0
Maximum 129
The resulting stress distribution in Punch and die components
due to Press tool forces and pressure were found using FEM
analysis. The Von-Mises stress is considered to know the
failure of components due to excess of yield stress.
IV. RESULTS AND DISCUSSION
The results in above Tables shows that Von Mises stresses
induced in Punches and dies are less than the yield stress of
material. Hence the design is safe. The components are
manufactured using blanking stage 01, forming stage 02 and
forming stage 03 press tools using the designed punches and
dies based on FEM method. All the dimensions of component
were found acceptable with safe functioning of Press tool.
References
[1] Anudeep S and N. Ramesha, “Design and Analysis of
Blanking and Bending Press Tool to Produce Anchor
Bracket Component”, International Journal of
Engineering Research & Technology (IJERT),
ISSN: 2278-0181, Vol. 4 Issue 04, April-2015.
[2] Dr D. Ramegouda and Nandish Harti, “Conceptual Design
of Blanking tool for Washer special”, National Joint
Conference On Innovation In Engineering & Technology
(NJCIET-2015), Canara Engineering College, Mangalore,
29 April 2015.
[3] Jutz-Scharkus, Westermann Tables, Revised second
edition, new age international(P) limited, publisher Year
2006.
[4] GT&TC Standard Data Hand Book.