TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT IN TAMILABSTRACT IN ENGLISHACKNOWLEDGEMENTLIST OF TABLESLIST OF FIGURES

1 INTRODUCTION11.1INTRODUCTION11.2 OBJECTIVE OF THE PROJECT11.2METHODOLOGY21.4 INTRODUCTION TO BICYCLE SIDE STAND31.4.1 Bracket31.4.2 Leg rod31.4.3 Holder41.4.4 Bush41.3.5 Springs and Washers51.3.6 Rivets, Bolts and Nuts52 LITERATURE REVIEW6

3 MATERIAL AND PROCESS93.1 BRACKET MATERIAL93.1.1 Chemical Composition93.1.2 Mechanical properties93.1.3 Minimum Internal diameter of bend103.1.4 Delivery condition103.2 DIE MATERIAL113.2.1 Chemical composition113.2.2 Mechanical properties113.3 MANUFACTURING PROCESS113.3.1 Sheet strip cutting133.3.2 Piercing, Notching and Blanking133.3.3 Company identity marking133.3.4 First forming143.3.5 Second forming143.3.6 Folding153.3.7 Acid cleaning153.3.8 Powder coating153.3.9 Assembly164 DESIGN CONSIDERATION AND CALCULATION174.1 DESIGN CONSIDERATION174.1.1 Marking174.1.2 Embossing174.1.3 Bending184.1.4 V- Bending184.1.5 Air bending184.1.6 Bottoming194.1.7 Wiping204.1.8 Spring back204.1.9 Spring back compensation224.2 DESIGN CALCULATION224.2.1 Force required for Identity marking224.2.2 Force required for embossing224.2.3 Force required for bending234.3.4 Press selection and specification244.3.5 Tool height254.3.6 Hexagonal socket headed screw264.3.8 Pillar set284.3.9 Bush set285 MODELLING OF TOOL295.1 INTRODUCTION295.2 COMPONENT MODEL IN SEQUENCE295.2.1 Blank modelling295.2.2 First forming305.2.3 Second forming305.3 DIE MODEL315.3.1 Bottom die Model315.3.2 Top die model315.3.3 Modelling of supporting elements316 CONCLUSION356.1 Conclusion356.2 Future work35REFERENCES36

LIST OF FIGURES

FIGURE NO TITLE PAGE NO.

1.1 Proposed methodology21.2 Bracket31.3 Leg rod41.4 Holder4 1.5 Bush42.1 3D model of forming tool developed in solid Works 200363.1 Process flow chart12 3.2 Sheet strip13 3.3 Blank13 3.4 Marking14 3.5 First forming14 3.6 Second forming15 3.7 Folding15 3.8 Powder cleaning16 3.9 Assembly16 4.1 Air bending19 4.2 Bottoming19 4.3 Wiping20 4.4 Illustration of spring back21 4.5 Shut height of press25 4.6 Hexagonal socket headed screw27 4.7 Die set parameters27 5.1 3D Model of blank29 5.2 First forming30 5.3 Second forming30 5.4 Bottom die Model32 5.5 Bottom die Model32 5.6 Location of the blank on the bottom die 33 5.6 Assembly of supporting elements in tool set 33 5.7 Assembly of the die set34

LIST FO TABLES

TABLE NO. TITILE PAGE NO.

3.1Chemical composition of bracket 9 3.2 Minimum Internal diameter of bend10 3.3Chemical composition of die material11 4.1Spring back angle compensation22 4.2Press specification24 4.3Die set parameter specification27

CHAPTER 1INTRODUCTIONINTRODUCTION 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 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. METHODOLOGYThe 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.

Fig.1.1 Proposed methodology 1.4 BICYCLE SIDE STANDBicycle 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 BRACKETBracket 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 Bracket1.4.2 LEG RODLeg 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 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 rod1.4.3 HOLDERHolder 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 Holder1.4.4 BUSHThe 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 Bush1.3.5 SPRINGS AND WASHERSSprings 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 NUTSRivet, 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 2LITERATURE 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 2003Madake 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 V-bending 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

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.31

CHAPTER 3MATERIAL AND PROCESS3.1 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 CompositionTable 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 materialS.No Quality Constituent

DesignationOld designationNameCMnPSMicro-alloy

IHR0NewOrdinary0.251.700.050.045-

iiHR1OCommercial0.150.600.050.035-

iiiHR2DDrawing0.100.450.0400.035-

ivHR3DDDeep Drawing0.080.400.0350.030-

vHR4EDDExtra Deep Drawing0.080.350.0300.030-

ViHR5NewMicro-Alloyed dual Phase0.161.60.0200.0200.2

3.1.2 Mechanical propertiesDensity of the material is 7850 kg / mm3 Tensile strength = 300 N / mm2 Percentage of elongation = 23% 3.1.3 Minimum Internal diameter of bendThe 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 bendS.NoGradeInternal Diameter of Bend

iHR12t

iiHR2T

iiiHR3Close

ivHR4Close

Note wheret is the thickness of work piece3.1.4 Delivery condition The material may be supplied in any one (or, in combination) of the following conditions a) Hot rolled,b) Annealed,c) Normalized, andd) DescaledFrom 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.

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 stability3.2.1 Chemical compositionTable 3.3 shows the chemical composition of the die material which as a high percentage of chromium.Table 3.3 Chemical composition of die materialConstituentCarbon Chromium Manganese Vanadium Molybdenum

Percentage1.55% 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 PROCESSSimple work flow from the sheet strip to the bracket assembly is illustrated in the flow chart shown in fig.3.1

Fig3.1 Process flow chart3.3.1 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 BlankingA 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.

Fig. 3.4 Marking 3.3.4 First formingFig 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 forming3.3.5 Second formingAfter 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.

Fig.3.6 Second forming3.3.6 FoldingIt 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 Folding3.3.7 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 coatingAfter 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

Fig. 3.8 Powder cleaning3.3.9 AssemblyIn 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

CHAPTER 4DESIGN CONSIDERATION AND CALCULATION4.1 DESIGN CONSIDERATION4.1.1 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 adie. 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 formductilemetals. 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 strength4.1.3 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 things4.1.4 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 than 10 mm thick. Spring back depends on material properties, influencing the resulting bend angle.

Fig. 4.1 Air bending4.1.6 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.

Fig. 4.2 Bottoming4.1.7 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 Wiping4.1.8 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. InFig.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 backThe 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 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 compensationIn 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 compensationBend angle906030

Spring back angle4.73.11.6

4.2 DESIGN CALCULATION4.2.1 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 N4.2.2 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 N4.2.3 Force required for bending The V- bending force is calculated using the standard formula[9]

k = Bending factor = 1.33 s = ultimate tensile strength l = length of bend t = thickness w = die opening = 8t

= 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 specificationsCapacity30 tons

TypeC Frame

Table size450 x 500

Shut height275 mm

Stroke length75 mm

Ram Adjustment30 mm

Strokes per minute65

Power required3 H.P

Gross weight19000 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 press4.3.5 Tool height Max. Tool height = Shut height adjustment = 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 mm4.3.6 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

= 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 screw4.3.7 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. Fig 4.7 Die set parametersA B A1 C1 C2 E P

315 200 171 50 50 225 45

Table 4.3 Die set parameter dimensions4.3.8 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) = (75 + 15) + (50 -20) = 90 + 30 = 120 mm

CHAPTER 5MODELLING OF TOOL5.1 INTRODUCTIONComputer 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 blank5.2.2 First formingDuring 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 forming5.2.3 Second formingAfter 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 forming5.3 DIE MODEL5.3.1 Bottom die ModelBefore 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 modelThe 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 elementsSupporting 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.5.6Fig. 5.7 shows the complete assembly of the die set.

Provision for identity marking toolLocating pins

Fig. 5.4 Bottom die Model

Recess for locating pins

Fig. 5.6 Top die model

BlankLocating pinsBottom die

Fig.5.5 Location of blank on the bottom die

Bottom plate Hexagonal socket headed screws Pillar Bush Top plate

Fig. 5.7 Assembly of supporting elements in tool set

Fig 5.8 Assembly of the die set

CHAPTER 6CONCLUSION6.1 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.

REFERENCES1. 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-15245. 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, ISBN-13: 97800003069067. Ivana Suchy Handbook of Die Design, second edition, McGrew-Hill publication, 2006, ISBN 0-07-146271-68. AWP die set standard manufacturers catalogue from the www.awprecision.com9. 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.

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