Papers by Keyword: Die

Abstract: The technology repair and restoration dies for hot punching is considered. During the overhaul the hammer die, a layer of metal is removed from the side the mirror to the entire depth the cavity of the stream, then the figure the new stream is marked, and then the stream is milled as in a new punch. Sometimes such methods restoring punches as electric arc surfacing welding or deformation with a special punch in the form of a stream are used. When installing inserts in a punch, it is necessary to compensate for the removed metal layer with special linings. Welding electrodes must be selected depending on the requirements for the base metal and service properties the deposited layer – hardness, heat resistance, allowable specific pressures, machinability, heat treatment acceptance, etc.

Abstract: LVD Company NV and Kawasaki Heavy Industries, ltd. developed the cutting-edge, high performance CNC press brake [1] for high accuracy/precision bending of approx.10m (L) by 2.5m (W) size aircraft skins. Those skin sheets have complex shapes which include mainly machine milled thickness reduction area called pockets, thickness tapers, cutouts for the windows and doors. Due to those characters, the materials have large thickness variation between less than 2 mm and more than 11 mm in a single skin sheet. Here in this paper, the overview of this intelligence press brake equipment and its forming process are described. The materials with complex shapes described above can be bent accurately including material edges with the features of the press brake which are the synchronized material handling system, 210 numbers of variable punches, the special die suitable for the variable punches, the curvature measurement devices, and an automated bending mechanism with curvature feedback /feedforward. In addition, cardboard-like-filler jigs which are used to make thickness variations flat in a traditional bending process and shims to adjust regional press strokes can be eliminated, which reduce significant process time and product quality without worker’s superior skills. As a result, full automation of accurate bending process of aircraft skins have been achieved.

Abstract: This research aimed to reduce die and punch wear and improved the quality of the production process with the application of the Lean Six Sigma methodology. Die and punch had limited capability in cutting material edges in the case study company. The root-cause analysis showed a correlation between the hard coating and the lubricant effect on wear reduction using the design of experiments and DMAIC based on the Six Sigma approach. The results indicated that a combination of AICrN-PVD coating and aloe vera oil provided the most outstanding results in terms of wear reduction. Moreover, it had the potential to minimize the cost of product defects or repairs significantly. These findings showed the effect of the Lean Six-Sigma approach at the die production process, which increased operational efficiency and consistency to enhance business performance and meet customer requirements.

Abstract: Plastic forming, in many cases, includes the drawing of hollow cylindrical products as the main operation. For the manufacture of such products, round blanks are used as semi-finished products. However, during the blank production from strips or tapes, their geometry causes a very significant metal loss. A very effective way to reduce metal loss is to replace round billets with square ones. The use of square blanks gives an additional increase in the height of the products. In this regard, the article investigates the drawing of a square blank into a cylindrical die. The research was carried out on the basis of the analysis of experimental work and computer modeling. According to the results of the research the rational ratios of the geometric dimensions of the tool and workpieces are found.

Abstract: Technological processes have a significant influence on the properties of the metallic formed pieces during production. Due to the plastic deformation, the shape of the component is changed and the degree of the structural anisotropy is increased - the orientation of the grain boundaries in the different parts of the component. It is important to identify these changes, to analyse them and optimize the technological processes. We get an important knowledge of relationship “technological parameters – microstructure – properties”. The article presents the results of the solution of a partial task from this area. It deals with changing of the geometric shape of the component when it is deformed. Specifically, the tubes (material EN SPT 360, STN 411 353) were drawn through the dies with different reduction angles. The dimensions (length and angle), roundness, cylindricity, coaxiality and surface roughness were evaluated.

Abstract: Drawing is characterized by non-uniform character of plastic deformation, which is transferred from the die to the processed wire. Such impact causes specific change of wire microstructure. In the surface area the thin layer with highly deformed grains is observed. It is important to measure the thickness of this thin layer. For this purpose it is proposed in this paper to use the value of coefficient of anisotropy, which is calculated as the ratio of mean quantity of phase particles, crossed by secant line perpendicular to deformation axis on the unit of secant line length to the mean quantity of phase particles, crossed by secant line parallel to deformation axis on the unit of secant line length. Distribution of coefficient of anisotropy, both for low and high carbon steel wire after drawing, was obtained by Thixomet PRO software. It made it possible to calculate the thickness of highly deformed area automatically taking into consideration the difference of steels microstructure.

Abstract: Approbation results of the method for obtaining of the metallic composite material via dynamic impregnation of the fiber with Al alloy using pulse-magnetic field are presented. Process schemes and factors improving adhesive properties and wetting quality of the fiber with the alloy are shown. Results of experimental investigation of the process and external view of the metallic composite samples are given.

Abstract: The dimensions calculation methods of one-channel dies operating corbels for solid profiles pressing are described, these methods are based on similarity theory and dimensional analysis. According to these methods, setting dimensions of the operating corbel on the K profile section, it is possible to calculate operating corbels dimensions on each other section of the i profile, depending on their position relative to the die center, ensuring the outflow evenness. Calculation example of the die operating corbels for the pressing of the ribbed profile made of AV alloy is given.

Abstract: The article discusses theoretic foundations and parameters of a latch die cutting process modelled in the software system Deform - 2D. The analysis concerns standard methods of latch cutting which causes the excessive edge deformation (over 10% of a sheet thickness) that does not meet the customers' requirements.

Abstract: This research aimed to apply the transfer die technology together with the forming simulation by using finite element method to assist the analysis and the design of a high-precision continuous forming die for the panel auto part forming, which was made from 1.4 mm thick steel JFS A3001. The outcome of the finite element simulation of a specimen could be applied in forming a specimen without any specimen damage. Therefore, the high-precision continuous forming die was designed based on the results and factors from the forming simulation. After the design, the high-precision continuous forming die was manufactured and the specimen stamping test was conducted to satisfy the customer’s specifications. The results from the testing shown that the specimens obtained from the forming process are similar to the sample provided from the customer. Only minor forming die modification was required. In addition, the results of specimens inspection according to the inspection location using measuring tools shown that the size and the circumference of the specimens were in an acceptable range with more than 0.05 significance level of P-value (P-Value >α) and 95% statistical confidence level. As a result, die manufacturers can effectively save time, reduce cost and minimize risk occurred from errors in the die manufacturing.