Abstract: Flanges are widely used for connecting valves, pipes and other industrial devices such as gearboxes. Method of producing a flange has a considerable impact on the manner of their involvement with the industrial engines and gearboxes. By Using die casting instead of sand casting and machining for manufacturing flanges, production speed and dimensional accuracy of the parts increases. Also, in die casting, obtained dimensions are close to final dimensions and hence the need for machining flanges after die casting process decreases which makes a significant savings in raw materials and improves the mechanical properties of flanges. In this paper, a typical die of an industrial helical gearbox flange (size ISO 50) was designed and die casting process for producing this type of flange was simulated using ProCAST software. The results of simulation were used for optimizing die design. Finally, using the results of the analysis, optimized die was built.
Abstract: During the last few years, several sheet hydroforming
processes have been introduced. Despite the advantages of these
methods, they have some limitations. Of the processes, the two main
ones are the standard hydroforming and hydromechanical deep
drawing. A new sheet hydroforming die set was proposed that has the
advantages of both processes and eliminates their limitations. In this
method, a polyurethane plate was used as a part of the die-set to
control the blank holder force. This paper outlines the Taguchi
optimization methodology, which is applied to optimize the effective
parameters in forming cylindrical cups by the new die set of sheet
hydroforming process. The process parameters evaluated in this
research are polyurethane hardness, polyurethane thickness, forming
pressure path and polyurethane hole diameter. The design of
experiments based upon L9 orthogonal arrays by Taguchi was used
and analysis of variance (ANOVA) was employed to analyze the
effect of these parameters on the forming pressure. The analysis of
the results showed that the optimal combination for low forming
pressure is harder polyurethane, bigger diameter of polyurethane hole
and thinner polyurethane. Finally, the confirmation test was derived
based on the optimal combination of parameters and it was shown
that the Taguchi method is suitable to examine the optimization
process.
Abstract: This paper aims to study the methodology of building the knowledge of planning adequate punches in order to complete the task of strip layout for shearing processes, using progressive dies. The proposed methodology uses die design rules and characteristics of different types of punches to classify them into five groups: prior use (the punches must be used first), posterior use (must be used last), compatible use (may be used together), sequential use (certain punches must precede some others) and simultaneous use (must be used together). With these five groups of punches, the searching space of feasible designs will be greatly reduced, and superimposition becomes a more effective method of punch layout. The superimposition scheme will generate many feasible solutions, an evaluation function based on number of stages, moment balancing and strip stability is developed for helping designers to find better solutions.
Abstract: 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.