Design of Progressive Die Sequence by Considering the Effect of Friction, Temperature and Contact Pressure

Progressive and transfer dies are used for forming of sheet metal parts in large quantities. For a given part, the design of progressive die sequence involves the selection of the number of forming stages as well as the determination of the punch and die dimensions at each stage. This design activity is largely experience-based and requires prototyping involving several trial and error operations. In some cases, empirical data and the experience based design procedure can be combined with Finite Element Method (FEM) based analysis to reduce time and cost. Often, when using FEM in progressive die design, friction and its effect upon temperatures is not adequately considered. However, at each forming station the plastic deformation and the tribological conditions influence the material flow as well as the temperatures and pressures at the tool/workpiece interface. The performance of the lubricant and coolant, used in progressive die forming, is affected significantly by interface pressure and temperatures. Therefore, a progressive process and die design methodology should include the consideration of metal flow as well as temperatures and pressures. Heat transfer coefficient, friction, plastic deformation, forming speed at each forming stage, time for part transfer from one stage to the next, and the ability of the used lubricant to cool the dies, have considerable effect upon a successful stamping. This paper describes a method for designing a progressive die sequence for forming axisymmetric sheet metal parts. The methodology for process sequence design combines experience based empirical data obtained through previous designs, design rules and numerical simulations including plastic deformation and friction. The initial experience-based design was refined using FEM and the thinning of the material in each successive drawing stage was calculated. The thermo-mechanical model was obtained using a constant friction coefficient along the tool/workpiece contact zone. Finally, the tool/workpiece interface temperature and the normal pressures were estimated in order that the lubricant can be selected based on these process conditions. The design predictions, made by using empirical data and FEM, were compared with experimental data.