Design and Analysis of Progressive Die for Chain Link Plate

Abstract

Progressive die follows a sequence of processes in a single die at two or more stations. Design of progressive die is an essential phase in sheet metal manufacturing. Small error at any workplace causes huge manufacturing downtime due to die failure. In this analysis, current die design has low production rate when using multiple stations for sheet metalworking. Each process produced by multiple stations, which increases the loss of time. However, the choice of proper materials for sheet metal plate has become one of the vital features of progressive die design. Due to its long die life has become a requirement for lowering the cost of sheet metal mechanisms. The punch has very short life cycles. The purpose of this paper is to design a new 3D modelling of sheet metal forming die, to optimise a new chain link plate material to improve the performance of the punch component and to analyse the sheet metal punch to increase the punch lifetime cycle. The analysis was conducted by using ABAQUS/CAE to analyse the maximum and minimum stress of punch. The materials used are stainless steel, nickel plate and mild steel. The result of maximum stress obtained from ABAQUS/CAE is used in stress-lifetime prediction calculation. Based on the theory of stress-lifetime prediction, the lower the stress required to deform a material, the longer the life cycle of the punch. From this calculation, we can identify which material is the most suitable for chain link plate production.