AI Applications to Metal Stamping Die Design– A Review

Metal stamping die design is a complex, experiencebased and time-consuming task. Various artificial intelligence (AI) techniques are being used by worldwide researchers for stamping die design to reduce complexity, dependence on human expertise and time taken in design process as well as to improve design efficiency. In this paper a comprehensive review of applications of AI techniques in manufacturability evaluation of sheet metal parts, die design and process planning of metal stamping die is presented. Further the salient features of major research work published in the area of metal stamping are presented in tabular form and scope of future research work is identified.




References:
[1] H.S. Ismail, K.K.B. Hon and K. Huang, "An intelligent object-oriented
approach to the design and assembly of press tools," Ann. CIRP, vol.44,
pp. 91-96, 1995.
[2] R. Pilani, K. Narasimhan, S.K. Maiti, U.P. Singh and P.P. Date, "A
hybrid intelligent systems approach for die design in sheet metal
forming," Int. J. of Adv. Manuf. Technol., vol. 16, pp. 370-375, 2000.
[3] S.B. Tor, G.A. Britton and W.Y. Zhang, "Indexing & retrieval in metal
stamping die design using case based reasoning," J. Computing &
Information Sci. in Eng., ASME, vol.3, pp. 355-362, 2003.
[4] M.C. Cakir, O. Irfan and K. Cavdar, "An expert system approach for die
and mold making operations," Robo. & Comp. Integrated Manuf.,
vol.21, pp. 175-183, 2005.
[5] A. Soman and M. Campbell, "A grammar-based approach to sheet metal
design," Proc. of DETC02 ASME Design Engi. Tech. Conf., Montreal,
Canada, 2002, pp.485-493
[6] R. Hambli and H. Miller, "BLANKSOFT: A code for sheet metal
blanking processes optimization," J. Mater. Process. Technol., vol.141,
pp. 234-242, 2003.
[7] A.Y.C. Nee, "Developing CAD/CAM software for the tool and die
industry: A role to be played by tertiary institutions," Int. J. Mech. Eng.
Edu., vol.14, pp. 263-271, 1986.
[8] K. Shirai and H. Murakami, "A compact and practical CAD: CAM
system for progressive die," Bull. Jpn. Soc. Prec. Eng., vol. 23, pp. 25-
30, 1989.
[9] M.R. Duffey and Q. Sun, "Knowledge-based design of progressive
stamping dies," J. Mater. Process. Technol., vol. 28, pp. 221-227, 1991.
[10] Y.K.D.V. Prasad and S. Somasundaram, "CADDS: an automated die
design system for sheet metal blanking," Comput. Control Eng. J., vol.
3, pp. 185-191, 1992.
[11] S.B. Park, "An expert system of progressive die design for electron gun
grid parts," J. Mater. Process. Technol., vol.88, pp. 216-221, 1999.
[12] J.C. Choi and C. Kim, "A compact and practical CAD/CAM system for
the blanking or piercing of irregular shaped-sheet metal products for
progressive working", J. Mater. Process. Technol., vol.110, pp. 36-46,
2001.
[13] S.Kumar and R. Singh, "Trends and developments in intelligent
computer aided design of progressive dies," Adv. Mater. Res., vol. 6, pp.
241-248, 2005.
[14] A. Jahan, M.Y. Ismail, S.M. Sapuan and F. Mustapha, "Material
screening and choosing methods- a review," Mater. & Design, vol.31,
pp. 696-705, 2009.
[15] A. Makinouchi, "Sheet metal forming in simulation in industry," J.
Mater. Process. Technol., vol.60, pp.19-22, 1996.
[16] S. Nakahara, K. Toshio, K. Tamura, F. Asuke, C. Soda and T.
Nakamura, "Computer aided progressive die design," Proc. of the 19th
Machine Tool Design Res. Conf., McMillan, London, 1978, pp. 171-
176.
[17] A. De Sam Lazaro, D. T. Engquist and D. B. Edwards, "An intelligent
design for manufacturability system for sheet-metal parts," Concur. Eng.
: Rese. & Appli., vol. 1, pp. 117-123, 1993.
[18] M. Shpitalni and D. Saddan, "Automatic determination of bending
sequence in sheet metal products," Ann. CIRP, vol. 43, pp.23-26, 1994.
[19] H. Meerkamm, "Product modeling: a prerequisite for effective product
development," Proc. of Product Modeler, Erlangen, University of
Erlangen, 1995, pp. 25-47.
[20] M. Tisza, "Expert systems for metal forming," J. Mater. Process.
Technol., vol.53, pp. 423-432, 1995.
[21] R.S. Lee, L.C. Chuang, T.T. Yu and M.T Wu, "Development of an
assessment system for sheet metal forming," Proc. of the Inter. Conf. On
precision Eng. (2nd ICMT), Trends and innovations in precision manuf.
Technol., Singapur, 1995, pp. 515-518.
[22] R. Mantripragada, G. KinFzel and T. Altan, "A computer-aided
engineering system for feature-based design of box-type sheet metal
parts," J. Mater. Process. Technol., vol.59, pp.241-248, 1996.
[23] S. Yeh, M. Kamran, J.M.E. Terry and B.O. Nnaji, "A design advisor for
sheet metal fabrication," IIE Trans., vol. 28, pp.1-10. 1996.
[24] R.Radhakrishnan, A. Araya, M. Kamran and B.O. Nnaji, "Design
Rule Checker for Sheet Metal Components Using Medial Axis
Transformation and Geometric Reasoning," J. of Manuf. Sys., vol.15, pp.
179-189, 1996.
[25] S.K. Gupta, D.A. Bourne, K.H. Kim and S.S.Krishnan, "Automated
process planning for sheet metal bending operations," J. Manuf. Sys.,
vol.17, pp. 338-360, 1998.
[26] S.Q. Xie, Y.L. Tu, J.Q. Liu and Z.D. Zhou, "Integrated concurrent
approach for compound sheet metal cutting and punching," Int. J. Prod.
Res., vol.39, pp.1095-1112, 2001.
[27] D.B. Tang, L. Zheng, L. Zhizhong and K. Chin, "An intelligent featurebased
design for stamping system," Int. J. Manuf. Technol., vol.18,
pp.193-200, 2001.
[28] K.V. Ramana and P.V.M. Rao, "Automated manufacturability
evaluation system for sheet metal components in mass production," Int.
J. Prod. Res., vol. 43, pp. 3889-3913, 2005.
[29] S. Kumar, R. Singh and G. S. Sekhon, " CCKBS: A component check
knowledge base system for accessing manufacturability of sheet metal
parts," J. Mater. Process. Technol, vol. 172, pp. 64-69, 2006.
[30] T. Giannakakis and G.C. Vosniakos, "Sheet metal cutting and piercing
operations planning and tools configuration by an expert system," Int. J.
Adv. Manuf. Technol., pp. 658-670, 2008.
[31] S.A. Shukor and D. A. Axinte, "Manufacturability analysis system:
issues and future trends," Int. J. Prod. Res., vol.47, pp.1369- 1390, 2009.
[32] Z.C. Lin, C.Y. Hsu and K.H. Yao, "Planning and building an integrated
design software of blanking and piercing dies (ESSCP) with a micro
expert system as a main structure," J. Chin. Soc. Mech. Engrs., vol.10,
pp .101-120, 1989.
[33] S.K. Sitaram, G.L. Kinzel and T. Altan , "A knowledge based system for
process-sequence design in axi symmentric sheet metal," J. Mater.
Process. Technol., vol.25, pp. 247-271, 1991.
[34] Z. Li, J. Li, Z. Li, G. Wang and J. Xiao, "CAD/CAM of progressive dies
for household electronic appliances," Proc. of Int. Conf on Adv. Technol.
& Machinery in Metal Forming, Wuhan China, 1992, pp.71-77.
[35] A.Y.C. Nee and K.Y. Foong, "Some considerations in the design and
automatic staging of progressive dies," J. Mater. Process. Technol., vol.
29, pp. 147-158, 1992.
[36] B.T. Cheok and K.Y.Foong, "An intelligent planning aid for the design
of progressive dies," Proc. Institu. of Mech Engg.,Part B : J. Engg.
Manuf., vol.210, pp. 25-35, 1996.
[37] B. T. Cheok and A. Y. C. Nee, "Configuration of progressive dies,"
Artificial Intelligence for Engineering Design, Analysis and
Manufacturing, vol.12, pp. 405-418, 1998.
[38] S.K. Esche, S. Khamitkar, G. Kinzel and T. Altan, "Process and die
design for multi-step forming of round parts from sheet metal," J. Mater.
Process. Technol., vol. 59, pp. 24-33, 1996.
[39] K. Huang, H. S. Ismail and K. K. B Hon, "Automated Design of
Progressive Dies," Proc. Institu. of Mech Eng., Part B : J. Engg. Manuf.,
vol.210 (B4), pp. 367-376,1996.
[40] S.K. Ong, L.J. De Vin, A.Y.C. Nee and H.J.J. Kals, "Fuzzy set theory
applied to bend sequencing for sheet metal bending," J. Mater. Process.
Technol., vol. 69, pp.29-36, 1997.
[41] S. Choudhary and V. Allada, "Integrated manufacturing system for
precision press tooling," Int. J. Adv. Manuf. Technol., vol.15, pp. 356-
365. 1999.
[42] R. Singh and G.S. Sekhon, "An expert system for optimal selection of a
press for a sheet metal operation," J. Mater. Process. Technol., vol. 86,
pp.131-138, 1999.
[43] L. Caiyuan, L. Jianjun, W. Jianyong and X. Xiangzhi, "HPRODIE: using
feature modeling and feature mapping to speed up progressive die
design," Int. J. Prod. Res., vol. 39/18, pp. 4133 -4155, 2001.
[44] J.H. Kim, C. Kim and J.C. Choi, "A Study on the development of
computer aided die design system for lead frame of semiconductor
chip," Int. J. of Koren Soc. of Precision. Eng., vol. 2, pp.38-47, 2001.
[45] X. Shi, J. Chen, Y. Peng and X. Ruan, "Development of a Knowledge-
Based Process Planning System for an Auto Panel," Int. J. Adv. Manuf.
Technol., vol. 19, pp. 898-904, 2002.
[46] G.C. Vosniakos, I. Segredou and T. Giannakakis, " Logic programming
for process planning in the domain of sheet metal forming with
progressive dies," J. Intell. Manuf., vol.16, pp.479-497, 2005.
[47] S. Kumar and R. Singh, "A knowledge-based system to automate the
selection of progressive die components," Int. J. of Mater. Sci. &
Surface Eng., vol.1, pp. 85-96, 2007.
[48] Y. Dequan, Z. Rui, C. Jun and Z. Zhen, "Research of knowledge based
system for stamping process planning," Int. J. Manuf. Technol., 29, pp.
663-669, 2006.
[49] W.L. Chan, M.W. Fu and J. Lu, "An integrated FEM and ANN
methodology for metal-formed product design," Eng. Appli. Artificial
Intell. , vol.21, pp. 1170- 1181, 2008.
[50] Chi Z, "Mining rules from stamping die designs," 3rd Int. Conf.
Innovative Compu. Information & Control, Dalian, 2008, pp.74 - 74.
[51] Z. Zhibing, L.Yuqi, D.Ting and L Zhigang, "Blank design and
formability prediction of complicated progressive die stamping part
using a multi-step unfolding method," J. Mater. Process. Technol.,
vol.205, pp. 425-431, 2008.
[52] C.Y. Chu, S. B. Tor and G. A. Britton, "Theoretic algorithm for
automatic operation sequencing for progressive die design," Int. J. Prod.
Res., vol.46, pp. 2965-2988, 2008.
[53] M. Ghatrehnaby and B. Arezoo, "A fully automated nesting and piloting
system for progressive dies," J. Mater. Process. Technol., vol.209, pp.
525-535, 2009.