Optimization of compound die design with double cutting process parameters and stress analysis using theoretical, numerical and statistical methodology

Abstract

This research overcomes the current knowledge gap in investigating the optimum piercing punch cutting geometry profile, compound die, and double cutting process parameters, and the analysis of cutting tools’ stresses. The main aim of the research is to study the contribution of different parameters to obtain optimum design of the compound die with its cutting tools, and to improve the cutting quality of ferrous and nonferrous products. Different piercing punches such as flat, chamfer, convex and concave hemispheres have been investigated. Dependent and independent parameters which have a high influence on the die performance and product quality have also been examined. These parameters involve punch-die clearance, blank holder force, cutting velocity, cutting tools’ wear radius, and type of sheet metal and thickness. Several models of the compound die are designed using standard mathematical equations to study the effect of design changes on product quality in terms of burr heights produced. These models are used to produce exhaust gas recirculation plate and circular washer. Finite element technique (ANSYS software) and statistical methods with Minitab program have been used to achieve the research objectives. ANSYS is used to simulate the cutting operation and to analyse the sheet material deformation. The statistical methods are used to obtain the optimum values of selected parameters. This study provides better outcomes compared to experimental data published in the literature. The final results indicate that the optimum design of the compound die can be achieved based on three criteria. These are clean cutting surface of the product under minimum burr height, lowest stress at the tool cutting edge, and implementing the double cutting operation using developed compound die without failure. The current research provides a better prediction of burr heights and efficient use of compound dies. The outcome indicates that the burr heights of the final product are at a smaller size for thicker sheet materials and at a larger size for thinner sheets. The findings provide optimum design and developed models of the compound die, improved product quality, lowest burr heights compared with published data, and minimum stress levels for the compound die cutting tools.