Technical Briefs

Progressive Die Strip Layout Optimization for Minimum Unbalanced Moments

[+] Author and Article Information
Serdar Tumkor

Design and Manufacturing Institute, Stevens Institute of Technology, Castle Point on Hudson, Hoboken, NJ 07030stumkor@stevens.edu

Kishore Pochiraju

Design and Manufacturing Institute, Stevens Institute of Technology, Castle Point on Hudson, Hoboken, NJ 07030

J. Manuf. Sci. Eng 132(2), 024502 (Apr 21, 2010) (7 pages) doi:10.1115/1.4001518 History: Received May 13, 2009; Revised March 18, 2010; Published April 21, 2010; Online April 21, 2010

Progressive die stamping is a forming process that uses a series of stamping stations to perform simultaneous operations as the sheet is transported incrementally through the die. Designing of progressive die sets and evaluation of the operation for highly complex workpieces are time consuming and iterative at the early stages in the product design. The progressive die design starts with 3D modeling of the part and continues with process sequence planning and strip layout. The strip layout is usually performed manually by experienced progressive die designers. This process begins with unfolding the part and constructing the required part geometry with a series of forming operations. In this study, the same process steps have been used to automate the progressive die design for a given part and stamping press capacity. Therefore, the strip layout already considers the scrap and press tonnage minimizations. A genetic algorithm is used to optimize the strip working sequence with the objective of minimizing the moment difference between two sides of the die. A moment-optimum strip layout will extend the life expectancy of the die, and the maintenance cost will be lowered, particularly for high production rate components.

Copyright © 2010 by American Society of Mechanical Engineers
Topics: Strips , Design , Optimization
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Figure 1

Part chosen for illustrating the torque optimization methodology

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Figure 2

Strip layout design

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Figure 3

Cutting and bending processes

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Figure 4

Two-up strip layout

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Figure 5

Flow chart of genetic algorithm

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Figure 6

Manufacturing restrictions leading to grouping of operations

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Figure 7

Operations requiring sequencing for balanced strip layout

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Figure 8

Crossover of genomes for one-up strip after 360 evaluations

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Figure 9

Optimal sequence of one-up strip layout

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Figure 10

Initial two-up strip layout

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Figure 11

Crossover and the list of genomes for the two-up strip after 1150 evaluations

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Figure 12

Optimum sequence of two-up strip layout




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