Die Design Software And Simulation Technology Experience

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Die Design Software andSimulation TechnologyExperienceA Proposed Method forRanking Progressive Die StripsPeter UlintzTechnical DirectorPrecision Metalforming Association

Processing the PartCreating the Strip LayoutCREATING THE STRIP LAYOUT2

A Strip Evaluation Ranking MethodFrom MetalForming Magazine, Tooling By Design, Sept 2012 to Nov. 2012Adapted from Alan C. Lin and Dean K. Sheu, Knowledge-Based Sequence Planning ofShearing Operations in Progressive Dies, International Journal of Production Research, 2010In order to choose the best strip layout from the several possiblestrips, each layout must be compared and ranked on a relevantscoring system. Among many factors that influence the cost andquality of a progressive die, four factors are of prime concern: Station number factor, FnMoment balancing factor, FbStrip stability factor, FsFeed height factor, Fh33

A Strip Evaluation Ranking MethodAn evaluation score (Ev) can then computed based on thesefour factors and their corresponding weighting factors:Ev (wn x Fn) (wb x Fb) (ws x Fs) (wh x Fh)All four evaluation factors are formulated to range from a totalof 10 to 100. A higher score indicates better efficiency in costand production.NOTE: The four weighting factors, wn, wb, ws, wh, are chosen by the designeror process engineer who determines how much importance each factorcontributes to the strip evaluation.44

A Strip Evaluation Ranking MethodStation number factor, Fn, determines how good a striplayout is in terms of the number of stations that it has. Thefactor has values ranging from 10 to 100.An Fn value of 100 (best possible) is for a minimum number ofstations, or two stations total. In contrast that value becomes10 for the maximum number of stations, usually the totalnumber of punches for cutting and bending in the proposedstrip.55

A Strip Evaluation Ranking Method322 stations, Fn 1001211111 stations, Fn 10From MetalForming Magazine, Tooling By Design, P. Ulintz, Sept 2012 to Nov. 201266

A Strip Evaluation Ranking MethodThe station number factor can be formulated by means of thefollowing equation:7-2 511 - 2 9Fn 100 – (90 x 5/9) 50N total number of stations in the strip layoutNmax total number of punches (cutting and bending)Nmin the possible minimum number of stations, Nmin 277

A Strip Evaluation Ranking MethodWhen two or more die stations are performing their task onthe die strip, the forces are simultaneously acting on the stripat different points.If the reaction forces are unbalanced relative to the presscenter line, ram tipping occurs. Since the center of the die isusually placed under the center of the ram, tipping momentseverity must be considered in strip layouts.Thus, a moment balancing factor, Fb, is required88

Slide Tipping:Moment Arm CalculationsCourtesy Dennis Boerger, Aida America99

Slide Tipping:Moment Arm Calculations10

Slide Tipping:Moment Arm CalculationsTipping Moments as Currently ProcessedStation NoTonnageInches from -1.5-1866-4.5-2776-7.5-45810-10.5-105TOTAL MOMENT121.5A positive results indicates center-of-load is left of slide centerShift load to RIGHT to re-center the load11

A Strip Evaluation Ranking MethodFrom MetalForming Magazine, Tooling By Design, Sept 2012 to Nov. 2012Stamping presses have maximum tipping moments establishedby the press machine builder. This rating can used to establish amaximum off-center loading parameter: DmaxThe moment balancing factor can then be calculated by:122200Fb 100 – (90 x 122/200) 45.1When d 0, the center of the ram and the center of the stamping loads arecompletely matched, so the factor Fb 100 (best condition). When d Dmax,the deviation is so serious that it makes Fb 10 (worst condition).1212

Slide Tipping:Moment Arm Calculations7030Courtesy Dennis Boerger, Aida America1313

Slide Tipping:Moment Arm CalculationsShift Load 1.5” to RightStation NoTonnageInches from -3666-6.0-3676-9.0-54810-12.0-120TOTAL MOMENT-914

A Strip Evaluation Ranking MethodFrom MetalForming Magazine, Tooling By Design, Sept 2012 to Nov. 2012Stamping presses have maximum tipping moments establishedby the press machine builder. This rating can used to establish amaximum off-center loading parameter: DmaxThe moment balancing factor can then be calculated by:9200Fb 100 – (90 x 9/200) 95.95When d 0, the center of the ram and the center of the stamping loads arecompletely matched, so the factor Fb 100 (best condition). When d Dmax,the deviation is so serious that it makes Fb 10 (worst condition).1515

The Maximum positive Tipping momentoccours at end stroke (Die fully closed)RAM/BOLSTER TIPPINGM OP50OP60Upper crank positionOP40The Maximum negative Tipping momentoccours about 10 deg before the end stroke141.6 Courtesy of Altair Engineering and FIAT Auto - Italy16

A Strip Evaluation Ranking MethodFrom MetalForming Magazine, Tooling By Design, Sept 2012 to Nov. 2012The strip stability factor (Fs ) determines how reliably thestrip feeds in terms of the connecting material that is left tocarry the parts as the strip progresses through the die.L1L2L3L4 0at cut-offFrom MetalForming Magazine, Tooling By Design, P. Ulintz, Sept 2012 to Nov. 20121717

A Strip Evaluation Ranking MethodFrom MetalForming Magazine, Tooling By Design, Sept 2012 to Nov. 2012For ranking purposes, we identify three connection lengthreductions: optimal, negative, and positive length reductionsOptimal length Lopt reduction would provide a stability rankingof 100. This condition seldom exists, but in terms of stripstability it is the best way to process a progressive-die strip.This occurs when the connecting length is reduced linearlywith the number of die stations. A 10-station die, for example,would remove 10% of connecting material at each station untila finished part separates from the strip in the final station18

A Strip Evaluation Ranking MethodFrom MetalForming Magazine, Tooling By Design, Sept 2012 to Nov. 2012Lneg represents the worst condition, where connecting length isreduced quickly and the blank may become unstable anddifficult to feed.Expect a ranking between 10 and 50 for this type of reductionLpos is a desirable length reduction. The decreasing trendoccurs gently, and part stability of the attached part isoptimized. Thus, feeding and blank positioning should havehigher accuracy and precision.A ranking of 50 to 90 would be typical in this case.19

A Strip Evaluation Ranking MethodThe feed height factor (Fh ) determines how reliably the stripfeeds in terms of the distance that it must lift off the workingstations before progressing through the die.10The maximum possible feed height is equal to the height of an imaginary rectanglethat encloses the formed part, as shown above, plus the safety factor, S20

A Strip Evaluation Ranking MethodFor the process illustrated below, the feed height factor is calculated by:Fh 100 - 90 x (8-2) / (10-2) 32.5The resulting feed height factor is relatively low (100 is best)SSFEEDH 8H 5Step 1Step 2From MetalForming Magazine, Tooling By Design, P. Ulintz, Sept 2012 to Nov. 201221

A Strip Evaluation Ranking MethodThe feed height factor could be improved by altering the two bendingsequence. For this revised process:Fh 100 - 90 x (5-2) / (10-2) 66.25S1H 5Step 1S2FEEDH 5Step 2From MetalForming Magazine, Tooling By Design, P. Ulintz, Sept 2012 to Nov. 201222

A Strip Evaluation Ranking MethodAll four evaluation factors are then formulated to range from a total of10 to 100. A higher score indicates better efficiency in cost andproduction.Ev (wn x 50) (wb x 45) (ws x 53) (wh x 66)Ev 214Weighting factors help prioritize each of the four evaluation factorsrelative to each another so we can better evaluate multiple designsNOTE: The four weighting factors, wn, wb, ws, wh, are chosen by the designeror process engineer who determines how much importance each factorcontributes to the strip evaluation.23

A Strip Evaluation Ranking MethodWeighting factors help prioritize each of the four evaluation factorsrelative to each another:Ev (0.25 x 50) (1 x 45) (0.50 x 53) (0.50 x 66)Ev 117Add one station by splitting the gutting stationEv (0.25 x 40) (1 x 37) (0.50 x 58) (0.50 x 66)Ev 109Add an idle station to better center the die loads, gives:Ev (0.25 x 30) (1 x 80) (0.50 x 62) (0.50 x 66)Ev 15224

Ranking Progressive Die Strips. Die Design Software and Simulation Technology Experience. Peter Ulintz. Technical Director. Precision Metalforming Association . CREATING THE STRIP LAYOUT. Processing the Part. Creating the Strip Layout. 2. 3. In order to choose the best strip layout from the several possible strips, each layout must be compared and ranked on a relevant scoring system. Among .

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