Title: Machining of dies to reduce the press-die deformation

Authors: Dionisio Del Pozo, Jesus Ma Lopez, Juan Manuel Pedrero, Aitzol Lamikiz

Addresses: Robotiker Technology Center, Automotive Unit, Intelligent Manufacturing Systems, Parque Tecnologico, Edif. 202, Zamudio, E48170, Spain. ' Robotiker Technology Center, Automotive Unit, Intelligent Manufacturing Systems, Parque Tecnologico, Edif. 202, Zamudio, E48170, Spain. ' Robotiker Technology Center, Automotive Unit, Intelligent Manufacturing Systems, Parque Tecnologico, Edif. 202, Zamudio, E48170, Spain. ' Escuela Tecnica Superior de Ingenieros Industriales, Departamento de Ingenieria Mecanica, Universidad del Pais Vasco, c/Alameda de Urquijo, s/n, Bilbao, E48013, Spain

Abstract: In this work, a methodological scheme for a reduction of both the try-out and lead-time of complex stamping/draw dies is presented, since it is commonly known that dies and punches are deformed during stamping process leading to changes in the shape and making very costly their manufacturing. The finite element simulation of the system press/tool behaviour along the stamping process results in criteria for the best design of high-cost dies/punches. Die deflection during the pressing process is, in this work, investigated in order to correct the sculptured surfaces of the die or punch in the manufacturing, specifically the finishing milling pass stage. With the proposed methodology, die manufacturers are able to avoid errors coming from die deformation due to their asymmetrical shape, in a systematic form. At the same time, time of manual adjustment and polishing is reduced in a 30%. Examples are deeply explained as well as experimental evidences. Modifications of the main geometry, components and functional parameters are so recommended.

Keywords: die machining; press die deformation; die try out; drawing dies; stamping dies; finite element method; FEM; press tool behaviour; die deflection; finish milling pass; machinability; lead times; simulation; sculptured surfaces.

DOI: 10.1504/IJMMM.2010.036141

International Journal of Machining and Machinability of Materials, 2010 Vol.8 No.3/4, pp.306 - 325

Published online: 22 Oct 2010 *

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