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Journal of Materials Processing Technology 182 (2007) 456461 A short note on an intelligent system for selection of materials for progressi S. Kumar a, , R Colle form Abstract during an modules, of of Kno v the user is demonstrated component. upon K 1. Introduction Progressive die is widely used for mass production of sheet metal components due to its high productivity, high precision and relatively economic cost in terms of per piece of prod- uct. tion The ponents the ods the e die books, computer with gressi for however, these systems do not take in account the availabil- ity of other suitable materials for the choice of user for better performance of die components and hence the long life of pro- gressive die. Further, these systems do not have even knowledge base consisting of experienced knowledge of domain experts 0924-0136/$ doi: The design of die components and their material selec- are major activities during progressive die design 1. selection of proper materials for progressive die com- essentially increases the die life and hence reduces cost of production of sheet metal parts. Traditional meth- for carrying out this important activity are dependent on vast experience and depth of knowledge of die design xperts. Most of the times, material selection for progressive components is carried out manually using die design hand- material handbooks, thumb-rules and heuristics. Existing -aided die design systems have still not fully dealt the core die design issue of material selection for pro- ve die components. Some existing CAD/CAM systems progressive dies 24 are able to generate bill of materials, Corresponding author. Tel.: +91 130 2210756; fax: +91 130 2210755. E-mail address: skbudhwar2003yahoo.co.in (S. Kumar). in material selection for progressive die components. World- wide researchers 5,6 have stressed to apply research efforts for capturing and documenting the invaluable practical knowl- edge of experienced die designers and toolmakers through the applications of artificial intelligence (AI) techniques. The highly experience based progressive die design activities such as mate- rial selection of die components can be simplified by using knowledge-based system (KBS) or intelligent system approach Development of such system can prove a landmark to ease the complexities involved in the process of material selection for die components. Although long life of all the components of progressive die is desirable, however special due attention is required to improve the life of active components (i.e. punch and die/inserts). For selecting the suitable material for a progressive die component, the die designer properly investigates the functional require- ments of that component and then a critical study is carried out to identify the required mechanical properties and possible causes, see front matter 2006 Elsevier B.V. All rights reserved. 10.1016/j.jmatprotec.2006.09.004 a Department of Mechanical Engineering, Hindu b Department of Mechanical Engineering Received 10 January 2006; received in revised Selection of materials for die components is an important activity intelligent system for selection of materials for progressive die components. namely DIEMAT and SELHRD. The module DIEMAT is designed progressive die. The module SELHRD is developed for determination wledge for both the modules of the proposed system is acquired, analyzed, ariety. The system is coded in the AutoLISP language and loaded into through the user interface. The usefulness of the proposed system The knowledge base of the system can be modified depending 2006 Elsevier B.V. All rights reserved. eywords: Progressive die; Material selection; Knowledge base; Intelligent system ve die components . Singh b ge of Engineering, Sonepat, Haryana, India , CRSCE, Murthal, Haryana, India 15 August 2006; accepted 11 September 2006 progressive die design in stamping industries. This paper presents The proposed system SMPDC comprises of two knowledge base for selection of materials for both active and inactive components hardness range of materials for active components of progressive die. tabulated and incorporated into a set of production rules of IF-THEN prompt area of AutoCAD. The system is designed to interact with the through a sample run using an example of an industrial the availability of new materials and advancement in technology. S. Kumar, R. Singh / Journal of Materials Processing Technology 182 (2007) 456461 457 which may result the failure of the component. The selection of material for a given application depends on which failure mech- anisms dominate. The basic idea of a die designer is to select a suitable material such that all other failure mechanisms except wear are eliminated. The wear can then be optimized to match the required production quantity of sheet metal parts. To obtain longer die life and hence higher productivity, tool steels are being widely used as materials for die components. One of the most important advantages of using steels as cutting tool materials is that, they are originally soft and machinable, by applying suitable heat treatment, they become extremely hard and wear resistant. Selection of suitable hardness range of selected mate- rials of die components depends on the geometry of the part to be manufactured on progressive die. The specific objective of the present work is the development of an intelligent system for selection of materials for progressive die components to assist the die designers and toolmakers working in small and medium size sheet metal industries. A brief description of the procedure Table 1 A sample of production rules incorporated in module DIEMAT S. no. IF THEN 1 Sheet material = Al or Cu or brass or Pb or beryllium copper Select an easily available material for punch and die/inserts from the following: EN-31 (5660 HRC) (AISI 52100) OR UHB-ARNE (5462 HRC) (AISI O1, W.-Nr. 1.2510) 5 Shear strength of sheet material (kgf/mm 2 ) 20 Type of operations = shearing Production quantity 100,000 2 Sheet material = mild steel or stainless steel or austenitic stainless steel or hardened steel or CRCA or spring steel Select an easily available material for punch and die/inserts from the following: SEVERKER 3 (6064 HRC) (AISI D6 (D3), W.-Nr. 1.2436, JIS-SKD2) OR UHB-VANADIS 6 (6264 HRC) OR UHB-VANADIS 10 (6064 HRC)30 1,000,000 3 Sheet material = Al or Cu or brass or Pb or beryllium copper Select an easily available material for punch and die/inserts from the following: EN-31 (5660 HRC) (AISI 52100) OR UHB-ARNE (5462 HRC) (AISI O1, W.-Nr. 1.2510) OR UHB-CALMAX (5659 HRC) 5 Shear strength of sheet material (kgf/mm 2 ) 20 Type of operations = forming or forming and shearing both Production quantity 100,000 4 Sheet material = mild steel or stainless steel or austenitic stainless steel or hardened steel or CRCA or spring steel Select an easily available material for punch and die/inserts from the following: SEVERKER 21 (5862 HRC) (AISI D2, W.-Nr. 1.2379, JIS-SKD11) OR AISI A2 (5862 HRC) (UHB-RIGOR, W.-Nr. 1.2363) 30 Shear strength of sheet material (kgf/mm 2 ) 70 Type of operations = forming or forming and shearing both 100,000 2mm Sheet thickness 5 mm Geometry of blanked part = normal Hardness range of selected material in HRC 4 Sheet thickness2mm Sheet thickness 5mm Geometry of blanked part = complicated Hardness range of selected material in HRC 6 Sheet thickness2mm Sheet thickness 5 mm Geometry of blanked part = complicated Hardness range of selected material in HRC 6 Sheet thickness5mm Sheet thickness 8 mm Geometry of blanked part = complicated Hardness range of selected material in HRC 8 Sheet thickness8mm Geometry of blanked part = simple or normal or complicated Use same range of hardness as mentioned with the selected material Uselowerlimit of hardness = upper limit of hardness of selected material-4.0 Use upper limit of hardness = upper limit of hardness of selected material Usesame range of hardness as mentioned with the selected material Uselowerlimit of hardness = upper limit of hardness of selected material-6.0 Use upper limit of hardness = upper limit of hardness of selected material Uselowerlimit of hardness = upper limit of hardness of selected material-8.0 Use upper limit of hardness = upper limit of hardness of selected material Usesame range of hardness as mentioned with the selected material S. Kumar, R. Singh / Journal of Materials Processing Technology 182 (2007) 456461 459 intelligent system Ho can in better Both interacti sheet sion by during advices rele entering area through gram for ments close of 3. 2.4 system Fig. 1. Execution of proposed SMPDC comprises of more than 60 production rules. wever, the system is flexible enough as its knowledge base be updated and modified, if necessary, on the advancement technology and availability of new materials in future having performance than recommended by the proposed system. the modules of the proposed system are designed to be ve in nature to enable the user to input the essential metal component data; and to displays the optimal deci- choices for the users benefit. The former is accomplished flashing AutoCAD prompts to the user at appropriate stages a consultation to feed data items. Messages or items of are likewise flashed into the computer screen whenever vant production rules are fired. The system can be loaded by the command (load “A: SMPDC.LSP”) in the prompt of AutoCAD. The execution of the system is demonstrated a flow chart as shown in Fig. 1. The output of the pro- includes the intelligent advices for selection of materials active elements (i.e. punch and die/inserts) and inactive ele- (i.e. plate elements, guiding and locating elements) and hardness range of the material selected for active elements progressive die. Sample run of the proposed system The proposed system is implemented on PC (Pentium 4 CPU, GHz, 256 MB of RAM) with Autodesk AutoCAD 2004. The for nents. obtained ligent gi found try India) Fig. ness system SMPDC. has been tested for different types of sheet metal parts the problem of material selection for progressive die compo- Typical prompts, user responses and the recommendations by the user during the execution of the proposed intel- system SMPDC for an example component (Fig. 2) are ven in Table 3. The recommended materials by the system were to be reasonably close to those actually used in indus- (Indo-Asian Fuse Gear Private Limited, Murthal, Haryana, for the example component. 2. Example component (all dimensions in mm): Brass, sheet thick- = 0.6 mm. 460 S. Kumar, R. Singh / Journal of Materials Processing Technology 182 (2007) 456461 Table 3 Typical prompts, user responses and expert advice generated during execution of the proposed intelligent system SMPDC for example component Prompt Example data entry Advice to the user (Load “A: SMPDC.LSP”) Please enter command SMPDC SMPDC Welcome to the module SMPDC. Please enter command DIEMAT DIEMAT Please Please Please Please select (5660 Please select plate OR plate: Please SELHRD 4. selection tion stage to by prepared sheet to ti e enter sheet material Brass enter the type of operations Shearing enter shear strength of sheet material 15 kgf/mm 2 enter required production quantity of sheet metal parts 90,000 Please EN-31 1.2510) enter the category of inactive elements (i.e. plate elements, locating and guiding elements) Plate elements Please Top 52100) Punch 1.2510) Punch back Stripper plate: Die support enter the category of inactive elements Guiding and locating elements Please select following: Die gages 1148) Die stops 6150) Lifter (R a Nr.1.2379, JIS-SKD11) Guide pin Ball cage Sleeve (R Shank (R a Dowel pins (AISI 1055) Please enter Please enter the selected material of punch and die/inserts EN-31 (5660 HRC) Typical analysis and P each = Please enter sheet thickness (mm) 0.6 Please enter the geometry of blanked part (i.e. simple/normal/complicated) Normal Please enter the difference of upper limit and lower limit of hardness (HRC) of selected material 4.0 Use lower limit Use upper limit Conclusion The proposed system is capable of giving expert advice on of materials for progressive die components and selec- of close hardness range of materials during the design of progressive dies. The user has been provided an option select easily available materials from the advice received the proposed system and then a bill of materials can be suitably. The system has been tested for variety of metal components and proved to be powerful and easy handle because of its rich knowledge base and highly interac- ve nature. The sample run of the system using an industrial xample component has demonstrated the usefulness of the system. kno the ogy can within industries. Refer 1 an easily available material for punch and die/inserts from the following: HRC) (AISI 52100) OR UHB-ARNE (5462 HRC) (AISI O1, W.-Nr. an easily available material for plate elements from the following: and bottom plate: Mild steel OR UHB-11 (AISI 1148) OR EN-31 (AISI UHB-FORMAX (W. Nr.-10050, SS-2172) OR EN-8 (AISI 1040) Mild steel OR EN-8 (AISI 1040) OR UHB-ARNE (AISI O1, W.-Nr. plate: EN-31 (AISI 52100) OR UHB-ARNE (AISI O1, W.-Nr. 1.2510) EN-31 (AISI 52100) OR UHB-11 (AISI 1148) plate: EN-31 (AISI 52100) an easily available material for guiding and locating elements from the (R a = 0.10.4H9262m) (4850 HRC): EN-31 (AISI 52100) OR UHB-11 (AISI (R a = 0.10.4H9262m) (4246 HRC): EN-31 (AISI 52100) OR EN-47 (AISI = 0.10.4H9262m) (5255 HRC): HCHCr OR SEVERKER-21 (AISI D2, W.- OR H.S.S. and guide piller pin (R a = 0.10.4H9262m) (5052 HRC): EN-353 (R a = 0.0250.05H9262m): Aluminium OR Brass OR plastics a = 0.10.4H9262m): EN-31 (AISI 52100) = 0.83.2H9262m): Mild steel (R a = 0.83.2H9262m) (5052 HRC): C-40 OR EN-8 (AISI 1040) OR EN-9 OR Silver steel command SELHRD of EN-31: C = 0.90/1.2, Si = 0.10/0.35, Mn = 0.30/0.75, Cr = 1.0/1.6, S 0.025 (maximum) of hardness = upper limit of hardness of selected material-2.0, and of hardness same as the upper limit of hardness of selected material The system supports mainly tool steels, however, its wledge base can be modified and updated depending upon availability of new materials and advancement in technol- . 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