Design analysis of tools and process

simulation for a component with

multiple bends
REPORT
Submitted by
SUDHAKAR.K (2013214035)

Under the Guidance of

Dr. Latha Nagendran

Professor
College of Engineering Guindy
Anna University, Chennai

ANNA UNIVERSITY CHENNAI 600 025

(CEG Campus)
October 2014

Introduction:
I offered a project of designing a multiple bend components in SVL ENTERPRISES- A vendor
of TI cycles. SVL is a medium scale Industry located in Thiruvallur.

Major works they are done

Bicycle stands for TI cycles
Bicycle carriers for TI cycles
Channels for TI metal forming
Crank case plating for Caterpillar.

Bicycle side stand component:

I take the process reduction of the bicycle side stand. The various component of the bicycle
side stand are

Bracket
Leg rod
Cup
Holder
bush
Springs
Washers
Rivets

Bracket:
Bracket is a component that connects the leg rod and bicycle wheel holder. The various
process of manufacturing of bracket are
1.
2.
3.
4.
5.
6.
7.
8.

Sheet strip cutting

Piercing, Notching and blanking
Company identity Marking tool
First forming
Second forming
Folding
Acid cleaning
Powder coating

PROCESS ILLUSTRATION

Bracket material:
According to IS 1079: 2069 Sheet material is selected

HR3 DD grade
Density =7850 kg / mm3
Tensile strength = 300 N / mm2
Percentage of elongation = 23%
Delivery condition is hot rolled Annealed Normalized and Descaled.
Min internal bend radius is of thickness

Composition:
C
0.08

Mn
0.40

P
0.035

S
0.030

Cr
0.05

Si
0.030

Marking tool
Marking of company identity is done by the coining operation. Coining is a form of
precision stamping in which a work piece is subjected to a sufficiently high stress to induce plastic
flow on the surface of the material.
Force required to Identity marking
Coining force = Perimeter x Depth of impression x Tensile strength
Avg. perimeter = 120 mm (calculating by measuring the outside length of the letters)
Force = 120 x 0.5 x 300
= 18,000 N
Embossing:
Embossing is a process for producing raised or sunken designs or relief in sheet metal. This
process can be made by means of matched male and female roller dies, or by passing sheet or a
strip of metal between rolls of the desired pattern.
Force required to embossing
Embossing Force = Perimeter (P) x Average embossing depth (D) x Tensile strength (S)
During first forming:
For small embossing, Force = P x D x S
= 42 x 3 x 300
= 37,900 N

For long embossing, Force = P x D x S

= 58 x 6 x 300
=104400 N
During second forming:
For small embossing, Force = P x D x S
=38 x 2 x 300
= 22,800 N
For long embossing,

Force = P x D x S
= 56 x 3 x 300
= 50400 N

Bending:
Sheet metal bending is the plastic deformation of the work over an axis, creating a change
in the part's geometry.
Force required to bending:
Force =

k = Bending factor = 1.33

s = ultimate tensile strength
l = length of bend part
t = thickness
w = die opening = 8t
Force =

1.33 X 42 X 300 X 2.52

8 X 2.5

= 5236.8 N
= 5237 N
Here three places the V- bending is happened. So, three times of the bending force was required.
Total force = 18000 + 37900 + 104400 + 22800 + 50400 +5237 x 3
= 249211 N
= 25 tons (approximately)

Press selection
25 ton force is required to for the component. Considering the safety and availability the press 30
tonnage press is selected.
Press specification
Capacity

Table size

Shut height

Stroke length

Ram
Adjustment

Stokes per
minute

Power
required

30 tons

450 x 500

275 mm

75 mm

30 mm

65 mm

3 H.P

Tool height:
Max. Tool height = Shut height adjustment
= 275 10
= 265 mm
Min. Tool height = Max. Tool height - Ram Adjustment
= 265 -30
= 235 mm
Optimum tool height = Min. Tool height + regrind allowance
= 235 + 15
=250 mm
Spring back

Due to the plastic-elastic forming of a work piece, there is a spring back at the end of a
bending process. When bending is done, the residual stresses cause the material to spring back
towards its original position, so the sheet must be over-bent to achieve the proper bend angle.

The amount of spring back is dependent on the material, and the type of forming. The spring
back has to be compensated to achieve an accurate result.
The spring back angle also depends upon the bend angle and the material properties. A
spring back is compensated by two ways
1. Over bending the sheet to get the proper bent angle.
2. Bottoming or squeezing the material at the bend line.
In our project embossing gives the additional stiffness to the bend angle and it reduce the spring
back of the material. Based on the internal bending radius and tensile strength of the spring back
angle is selected from the table shown in P.H Joshi book (see reference)
For tensile strength 300 N / mm2 and Bending radius below the thickness of the sheet
Bend angle

90

60

30

Spring back angle

4.7

3.1

1.6

Die material:
According to ISO 4957: 1999, High carbon high chromium steels.
D2 is the popular choice of the tool makers material. It has good wear resistance, high toughness
and high dimensional stability.

Carbon

Chromium

Manganese

Vanadium

Molybdenum

1.55%

12.00%

0.45%

0.80%

0.85%

Density= 7700 Kg / mm3

Rockwell hardness =65
Poisons ratio =0.27-0.3
Elastic modulus = 190 210 GPa.
Ultimate tensile strength = 260 390 GPa

Hexagonal socket headed screw:

It is used to connect the bottom shoe and top shoe with the die sets.
Material Specification: ASTM A574M / DIN ENISO4762-alloy steel
Hardness: RC 38 43
Max. Permissible stress on the threads: 120 N / mm2
No of Screws: 12

Load on the single Screw

Permissible stress =
area of bolt on the crest

Load on one Screw

Total load

No of Screw

250 103
12

= 20.83 x 103 N
=

dc 2 =

P
dc 2
4
20.83 X 103 X 4
120 X

= 14.86 mm
Major diameter of thread D = dc / 0.8

= 18 mm (approximately)
M18 Screw is selected
According to IS 2269 1967 and from the PSG data book Page No. 5.61 the various dimension
of the screw are selected.

Die sets:
Selecting the standard die sets from standard catalogue based on the size of the table and
availability. The standard provides that (all dimensions in mm)

A1

C1

C2

315

200

171

50

50

225

45

Pillar set:
Corresponding to the die set, the pillar set of 30 mm diameter should be recommended.
Pillar length = Tool height Regrind allowance (two sides)
= 250 40
= 210 mm
Bush set:
Corresponding to the die set, the bush set of 55 mm outer diameter and 30 mm inside diameter
has to be recommended.
Pillar length = (stroke length + Regrind allowance) + (Bolt thickness Base allowance)
= (75 + 15) + (50 -20) = 90 + 30
= 120 mm

MODEL:
Process:

Hexagonal socket headed screw:

Die set assembly:

Top view:

Front view:

Isometric View:

REFERENCES

Ivana Suchy Handbook of Die Design second edition McGrew-Hill publication, 2006,
ISBN 0-07-146271-6

Donaldson Tool design second edition.

P.H. Joshi Press Tools Revised edition,S.Chand Publication,2008, ISBN81-219-2938-5

R.E Cowley die design fundamentals Second publication, 2000, ISBN 0-8311-1172-0

www.Wikipedia.com

www.google.com

http://www.westyorkssteel.com/tool-steel/d2

https://law.resource.org/pub/in/bis/S10/is.1079.2009.pdf