Design, Development and Analysis of forming tool
for side panel of an Automobile.
Ulhas K Annigeri, Y P Deepthi, Raghavendra Ravi Kiran K
Asst. Professor ([Link]), Asst. Professor, Asst. Professor ([Link])
uk_annegeri@[Link], p_deepthi@[Link], kr_ravikiran@[Link].
Amrita Vishwa Vidyapeetham, Bengaluru.
1 Abstract tool combines maximum production and
The design, development and structural least maintenance with lowest feasible life
analysis of forming tool for a side panel cost[1]. It helps to serve maximum
of an automobile is carried out in this utilization of least expensive stamping
endeavor. material available. The profile of the
The design protocol is on conventional lines, component that has to be formed, is
based on tried and tested norms developed machined on the die and punch with the help
through expertise and experience reported in of CAD data and Computer Numerical
literature and design chapters. Solid works Controlled machines through programming,
2003, Auto CAD R2004 software has been based on a suitable reference datum or
used for modeling and detailing. Finite tooling holes. With the advent of such high
Element Analysis package Ansys5.4 has technologies in the field of Computer-Aided
been used to determine the stresses that are Manufacturing, production of complex
induced in the Forming tool. This paper profiled three dimensional sheet metal
gives a brief overview of fabrication of tool, components for automobile industry has
tool cost estimation and finally an insight become easier than it was a decade ago[2].
into the stresses induced in the forming tool. Press components are widely used in
Keywords: Forming tool, Finite element automobile, aerospace, electrical,
analysis, telecommunication & domestic appliance
industries[3].
2 Introduction
3 Forming tool
For large-scale production from sheet metal,
press working is fast and relatively easiest Press forming is a process in which sheet
method to generate the components. A press metal is confined to the contours of die and
punch. The operation of forming is similar 4.2 Component details
to bending except that the line of bend is Material : Cold rolled steel 7C4 to IS: 1570
curved instead of straight and plastic
Thickness: 0.7mm.
deformation in the material is more severe.
Length: 400mm.
The sheet metal to be formed is kept on the
Width: 323mm.
die which has the negative profile of the
component machined on it within the Maximum forming depth: 15.7mm.
nesting provided. The punch with positive Grade of sheet: Drawable quality in soft
Condition.
profile then descends and hits the sheet
Table 1 Chemical Properties of Work Piece
metal to form it to the required profile [3]
Chemical composition wt %—
4 Component Study min max
Data for developing the component are Carbon 0.08 0.12
obtained from customer. The component is a
Manganese 0.3 0.5
rear side L.H (left hand side) exterior side
panel of an automobile. Sulphur - 0.05
4.1 Design Requirements Phosphorus - 0.04
Table 2 Mechanical properties
Maximum forming depth: 15.7 mm.
Ultimate tensile strength: 410 N/mm2
Eight embossing features of height: 1.5mm.
Yield strength: 250 N/mm2
Pierced holes of Diameter: 10.2mm,
Shear strength: 350 N/mm2
15.2mm, 7mm, 8.7mm.
Density: 7.82x10-3 g/mm3
oblong hole : 8.2mm x 11.2mm.
Young’s modulus: 2.05 x 105 N/ mm2
Up flange : 27 degrees with a bend radii of
3mm to a depth of 16mm.
Down flange : 95 degrees of bend radius
25mm with 16mm depth.
4.3 Press data
Capacity of the press : 2486400N
Type of press: Mechanical ,Single crank
Model: SN1-250(S),C- frame
Shut height of the press : 370 mm
Stroke: 250 mm
Slide adjustment : 120 mm
Ejection system: Die cushion arrangement
Bed size: 900mm x 1500 mm
Figure 1: Orthographic views of LH side panel
Bolster plate thickness: 180 mm
In the first stage tool, formed part and
5 Methodology
embossing features are developed.
5.1 Blank Development
In the second stage tool trimmed profile
Component CAD data given by the
with two pierced holes of diameter 10.2mm
customer is utilized to develop the blank
are developed.
size and the size so developed based on the
Program zero value is 0.7x366x445. (Refer In the third stage tool the up flanging of
Fig 1) 27degrees and down flanging of 95 degrees
are developed.
In the fourth stage tool the holes of diameter
7.2mm, 8.7mm,15.2mm, oblong hole of
8.2mmx11.2mm are developed.
In this paper only the first stage, forming
tool development has been discussed.
5.2 Design of Forming Tool Therefore, 1.3 x 470000 = 620000 N
Forming force =P*T*UTS [4]
This is well within the permissible limit of
= (445mm *2+366mm *2) * 0.7mm*410 the 2486400N press, which is to be used.
= 465514 N
Embossing force = H*T*UTS [4]
= 1.5mm*0.7mm*410
= 430.5 N
Where P=Perimeter in mm
H= Emboss height in mm
T= Thickness in mm
Figure 3 Final formed component details
2
UTS =Ultimate tensile strength in N/mm
6 Structural Analysis
Total force required = 465944.5 ~ 470000N
In this dissertation work, structural static
analysis of forming die and punch is carried
out to find maximum deflection and stresses
so as to ascertain that they are within the
permissible value of 0.05mm[1]. The
forming force is applied on forming die and
punch as surface load in on the forming
area. The applied load is in the Y-direction
of the Cartesian coordinate system with
Figure 2 3D model of forming tool developed in stepped input with no intermediate sub
solid Works 2003
steps. The time of application of stepped
5.3 Selection of Press load is one second. In the present analysis
Based on practical experience, the press the effect of steady loading conditions are
should be capable of delivering calculated ignoring the steady inertia loads
approximately 30-40% greater force than such as gravity and also inertia, damping
total forming force required by tool [3] effects caused by the time varying loads.
The solution to the problem is solved using The size of the element is chosen based on
frontal solver available with Ansys version the RAM capacity of the computer being
5.4. The program calculates nodal degree of used to solve the problem. In the present
freedom solution by back substitution and analysis smart size “6” is used to define the
uses the individual element matrices to mesh density. After meshing the die nearly
calculate element solution[5]. In the present 6000 elements were generated and the time
work nodal solutions are displayed in the duration to solve the problem was 15
power graphics display mode since display minutes. The mesh density was chosen
is at a much faster rate than the alternate full purely on iterative basis after finding the
display method. results with a much finer and coarser mesh.
The element is defined by ten nodes having
6.1 Modeling and Meshing
three structural degrees of freedom at each
Solid modeling of the punch and die is
node. The mesh is refined using h-
carried out using Solid Works 2003 by
convergence method to get converged
importing Auto CAD drawings in the DXF
solution.
format. Solid model is imported from
6.2 Boundary conditions
Solid Works software in IGES format into
The boundary conditions specify the
Ansys5.4 package. The discontinuity and
constraints that are imposed on the
extra lines in the imported model are
component at various regions. All the nodes
repaired to eliminate these errors. The model
of the bottom faces of forming die and
is free meshed using isoparametric
punch are fixed in all three directions.
SOLID92 3-D 10node tetrahedral structural
solid. Due to curved areas at the area of i.e Ux =Uy=Uz = 0[1]
application of load the mesh has become
6.3 Loads
much finer at these regions as can be seen
For static structural analysis loading is
from the figure m1 and m5.SOLID92 has a
considered during closed condition of the
quadratic displacement behavior and is well
press tool. During this condition the punch
suited to model irregular meshes as in this
exerts a pressure equal to applied load of
particular case. The element also has
twice the forming force over the top surface
plasticity, creep, swelling, stress stiffening,
area of the punch and die.
large deflection and large strain capabilities.
The applied load is taken as twice the The material FG300 has an ultimate
forming load considering the dynamic compressive strength of 960N/mm2. From
factor. this we conclude that stresses are well
within the permissible value and also the
Pa = L/A where, L= 2x470000=940000N.
deflection is well within the permissible
Area = 162870 mm2 value of 0.05mm.
Therefore, Pa = 940000/162870
= 5.78 = 6 N/mm2
6.4 Material properties
Gray Cast Iron: FG 300
E = 1.17 x 105 N/mm2
µ = 0.26
6.5 Results Figure 4 Meshed Die
The figure numbers 4 to 11 show the
meshed model, boundary conditions applied,
deflection and von Mises stresses induced.
6.6 Analysis Results
Table 3 FEM Results
Parameters Punch Die
Max
0.016mm 0.012mm
deflection
von Mises Figure 5 Die with boundary conditions applied
2 2
57.4N/mm 51.11N/mm
stresses
Figure 9 Punch with boundary conditions applied
Figure 6 Deflections in die in mm
Figure 10 Deflections in punch in mm
Figure 7 Vonmises stresses in die in MPa
Figure 11 Vonmisses stresses in punch in MPa
Figure 8 Meshed Punch
7 Conclusion 5 [Link] & [Link] , “Die
design fundamentals” Second
It is observed that the design of forming tool is
edition, 1962, industrial press Inc.
safe as the von mises stress is well within the
compressive strength of the material for both 6 [Link],[Link],
punch and die. Finite elements in engineering, third
edition, 2003.
The deflection of both punch and die are well
7 Bruce M. Irons,”A frontal solution
within the allowable deflection of 0.05 mm
program for finite element
and hence we conclude that the design of both
analysis,”Int.J for numerical methods
forming punch and die is safe.
in Eng., Vol. 2, 5-32
The reduction in web thickness of punch and
8 [Link],”It’s easy to calculate die
die by 30% didn’t interfere with the allowable
clearances,” American machinist
stress and deflection values of punch and die.
reference sheet.
This has made us conclude that weight
reduction of 4.2 kg is possible.
8 References
1 Smith D. A, Die Design Handbook, Soc.
of mfg Engrs Publ., 1990
2 [Link] etal.,”Design and
Analysis of Progressive Tool”
International Journal of Engineering
Research & Technology (IJERT) Vol. 1
Issue 6, August - 2012 ISSN: 2278-0181
3 D.F. Wilhem, Understanding presses and
press operation
4 Donaldson, Goold, Lecain, Tool Design,
Tata Mcgraw-Hill publishing company,
New Delhi, 1988.
