Design and analysis of deep drawing die for brass socket by using finite element analysis.
DESIGN AND ANALYSIS OF DEEP DRAWING DIE FOR
BRASS SOCKET BY USING FINITE ELEMENT ANALYSIS
NORHIDAYAH BT HASHIM
B050910016
UNIVERSITI TEKNIKAL MALAYSIA MELAKA 2012
(2)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGN AND ANALYSIS OF DEEP DRAWING DIE FOR BRASS
SOCKET BY USING FINITE ELEMENT ANALYSIS
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design)
by
NORHIDAYAH BT HASHIM B050910016
FACULTY OF MANUFACTURING ENGINEERING 2012
(3)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDATAJUK: Design and Analysis of Deep Drawing Die for Brass Socket by using Finite Element Analysis
SESI PENGAJIAN: 2011/ 12 Semest er 2 Saya NORHIDAYAH BT HASHIM
mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i Teknikal Mal aysia Mel aka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Laporan PSM adal ah hak mil ik Universit i Teknikal Mal aysia Mel aka dan penul is. 2. Perpust akaan Universit i Teknikal Mal aysia Mel aka dibenarkan membuat sal inan unt uk
t uj uan pengaj ian sahaj a dengan izin penul is.
3. Perpust akaan dibenarkan membuat sal inan l apor an PSM ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sil a t andakan (√)
PENYELIA PSM
Tarikh: _______________________
** Jika Laporan PSM ini SULIT at au TERHAD, sil a lampirkan surat daripada pihak berkuasa/ organisasi berkenaan dengan menyat akan sekal i sebab dan t empoh l aporan PSM ini perl u dikelaskan sebagai
Al amat Tet ap:
NO. 11 M, Kampung Bel akang Pendang,
Mukim Air Put eh, 06700 Pendang, Kedah.
Tarikh: _________________________ TIDAK TERHAD
TERHAD SULIT
Disahkan ol eh:
(Mengandungi makl umat TERHAD yang t el ah dit ent ukan ol eh organisasi/ badan di mana penyel idikan dij al ankan)
(Mengandungi makl umat yang berdarj ah kesel amat an at au kepent ingan Mal aysia yang t ermakt ub di dal am AKTA RAHSIA RASMI 1972)
(4)
DECLARATION
I hereby, declared this report entitled “Design and Analysis of Deep Drawing Die for Brass Socket by using Finite Element Analysis” is the results of my own research
except as cited in references.
Signature : ………. Author’s Name : ……… Date : ………
(5)
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfilment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Design). The member of the supervisory committee is as follow:
……… Principal Supervisor
(6)
ABSTRAK
Disebabkan oleh kesukaran hubungan-hubungan daya yang berkuasa tinggi, perubahan bentuk bahan dan kecacatan benda kerja telah berpunca daripada beberapa kombinasi faktor. Dalam penyelidikan ini, kaedah paling biasa telah digunakan dalam mengkaji perubahan bentuk bahan, kecacatan benda kerja dan daya lekapan dengan menggunakan kaedah unsur terhingga. Menggunakan kuasa penumbuk yang tidak mencukupi melalui proses lukisan mendalam telah menyebabkan bahan kerja berkedut dan atau terkoyak, tetapi sekiranya kuasa penumbuk terlalu tinggi juga menyebabkan kecacatan bahan kerja. Matlamat penyelidikan ini ialah untuk merekabentuk satu set lukisan mendalam serta menganalisa sama ada proses lukisan mendalam dapat mengurangkan kecacatan bahan kerja atau tidak dalam menghasilkan satu soket loyang. Dengan menggunakan Analisis Dinamik yang eksplisit daripada perisian ANSYS, hasil Analisa Unsur Terhingga (FEA) untuk reka bentuk baru bagi set lukisan mendalam akan diperolehi. Hasil daripada analisa tersebut, daya penumbuk maksimum dalam proses lukisan mendalam telah dapat diketahui dan ianya mampu mengurangkan proses lukisan mendalam untuk menghasilkan soket loyang. Dalam erti kata lain, rekabentuk baru set lukisan mendalam dapat mengurangkan proses lukisan mendalam dalam menghasilkan soket loyang dengan produktiviti tertinggi, kitaran masa terkecil, tenaga kerja yang kurang dan kos yang paling rendah berbanding menggunakan rekabentuk lukisan mendalam yang sedia ada dengan nilai daya penumbuk yang sama.
(7)
ABSTRACT
The difficulty of force relations, workpiece deformation can be caused by a combination of factors. The most common method has been used in analyzing workpiece deformation and fixturing forces by using finite element analysis. Using insufficient punch force gave rise to wrinkled and or torn of the workpiece during the deep drawing process and application of too much punch force also would result unnecessary defects and high contact deformation to the workpiece. The aims of this research were to design a deep drawing die and determine whether a deep drawing process is able to reduce or not in producing a brass socket. By using Explicit Dynamic Analysis from ANSYS software, the result of the Finite Element Analysis for new design of deep drawing die will be obtained. From the result, the maximum punch force of deep drawing die was known and able to reduce the deep drawing process to produce the brass socket. As a result, the new design of deep drawing die presents the shortest process of deep drawing in producing the brass socket with highest productivity, smallest cycle time, less manpower and lowest cost compared to existing design with the same value of punch force.
(8)
DEDICATION
For My Father, Hashim Bin Yunus & all my family especially my youngest brother, Mohd Hafizudin Bin Hashim who is always beside me either in a difficult situation or
(9)
ACKNOWLEDGEMENTS
In the name of Allah S.W.T, the most gracious and the most merciful, thanks a lot for giving me this strength and opportunity to complete this report. In pursuing this research, I would like to thank several people who have contributed to this endeavor. The following individuals provided valuable comments on earlier drafts of the work: Engr Tajul Ariffin Bin Abdullah as my official supervisor, Mr Hirmanto Bin Suib as my industrial supervisor, Mr Taufik as my second reader and others lectures who have significantly helped, whether directly or not. Special thanks to all staff of Jati Beringin Sdn. Bhd. especially to the top managements for their permission and support in allowing me to perform my research at the company’s plant. A very hue appreciation also would like to be given to all the office staff from the Faculty of Manufacturing Engineering (FKP) for their courage and support.
(10)
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii Acknowledgement iv Table of Content v
List of Tables viii
List of Figures ix
List of Abbreviations xii
1. INTRODUCTION 1
1.1 Backgrounds 1
1.1.1 Company 1
1.1.2 Deep Drawing Die 2
1.2 Problem Statement 3
1.3 Objectives 4
1.4 Scope 4
1.5 Structure of the Research 4
1.6 Gantt Chart 6
2. LITERATURE REVIEW 7
2.1 Deep Drawing Process 7
2.1.1 Definition 7
2.1.2 History 9
2.2 Parameters of Deep Drawing Die 11 2.2.1 Properties of Sheet Metal 13 2.2.2 Ratio of Blank Diameter to Punch Diameter 13
2.2.3 Sheet Thickness 14 2.2.4 Clearance between Punch and Deep Drawing Die 15 2.2.5 Blank Holder Force 16 2.2.6 Maximum Force of Punch 17
(11)
2.2.7 Drawn Cup Height 18
2.2.8 Drawn Cup Diameter 21
2.3 Previous Research 22 2.4 Finite Element Analysis (FEA) 24 2.4.1 Explicit Dynamic Analysis 27 3. METHODOLOGY 31 3.1 Flow Chart 31 3.1.1 Phase 0: Planning 33 3.1.2 Phase 1: Concept Development 33 3.1.3 Phase 2: Detail Design 33 3.1.4 Phase 3: Analysis & Refinement 34 3.1.5 Phase 4: Report Submission & Presentation 34
3.2 Process to Produce Brass Socket 34 3.3 Concept Generation 37
3.4 Concept Selection 42 3.5 Material Selection 42 3.6 Workpiece 42 3.7 3D-Modeling 43
3.8 Maximum Punch Force 43
3.9 Drawn Cup Height 46
3.10 Drawn Cup Diameter 48
3.11 Simulation Software 49
4. PROCEDURE OF EXPLICIT DYNAMIC ANALYSIS USING ANSYS 50 4.1 Create Analysis System 50
4.2 Engineering Data 55
4.3 Geometry 57 4.4 Stiffness Behaviour 58
4.5 Define Connections 62
4.5.1 Contact Regions 62 4.5.2 Setting Contact Conditions Manually 65
(12)
4.6.1 Physics Based Meshing 66 4.6.2 Using 3D Rigid Body Contact Meshing 68
4.7 Establish Analysis Settings 70
4.8 Fixed Support 71
4.9 Displacement 72
4.10 Solve 74
4.11 Review Results 79 5. RESULT 84
5.1 Results for Each Conceptual Design 84
5.1.1 Conceptual Design A 85
5.1.2 Conceptual Design B 92
5.1.3 Conceptual Design C 99
5.1.4 Conceptual Design D 107
5.1.5 Conceptual Design E 114
6. DISCUSSION 121
6.1 Total Deformation 121
6.2 Shear Stress 122
6.3 Proposed Design 123
6.4 Energy Evaluation 124
7. CONCLUSION AND RECOMMENDATION 126
7.1 Conclusion 126
7.2 Recommendation 127
REFERENCES 128
APPENDICES
A Gantt Chart for PSM I & PSM II B Drawing of Deep Drawing Die C Properties of Sheet Metal D Properties of Alloy Tool Steel
(13)
LIST OF TABLES
3.1 Process to produce brass socket 35
4.1 Result of total deformation as a tabular data 83
5.1 Tabular data on displacement 85
5.2 Result of total deformation as a tabular data 88
5.3 Result of shear stress as a tabular data 91 5.4 Tabular data on displacement 92
5.5 Result of total deformation as a tabular data 95
5.6 Result of shear stress as a tabular data 98 5.7 Tabular data on displacement 99
5.8 Result of total deformation as a tabular data 102
5.9 Result of shear stress as a tabular data 106
5.10 Tabular data on displacement 107
5.11 Result of total deformation as a tabular data 110
5.12 Result of shear stress as a tabular data 113
5.13 Tabular data on displacement 114
5.14 Result of total deformation as a tabular data 117
5.15 Result of shear stress as a tabular data 120
6.1 Differences between specific value and analysis value of height 121
6.2 Differences between maximum and minimum value of shear stress 122
(14)
LIST OF FIGURES
1.1 Deep drawing concept 2
2.1 Schematic illustration of deep drawing die 8 2.2 Shcematic of conventional deep drawing process; (a) Initial blank
(b) Drawing in process 9 2.3 Forming by flexible media; (a) Hydromechanical deep drawing
(b) High-pressure Hydroforming 10 2.4 Combined Hydroforming, joining and trimming of sheet metal parts
(a) In process (b) Typical parts 10 2.5 Variables in deep drawing die for cylindrical cup 12 2.6 Schematic illustration of drawing ratio variables 14 2.7 Brass 3100 C26000 to 0.28mm thickness 15
2.8 c as a clearance variable 16
2.9 (a) Pure drawing (b) Stretching by draw bead 17 2.10 Approximated Punch load 17 2.11 Circular cup to be drawn 19 2.12 Stresses on an element of flange 19
3.1 Flow Chart for PSM I and PSM II 32 3.2 Concept A is reducing one process to produce brass socket 37 3.3 Concept B is reducing three processes to produce brass socket 38 3.4 Concept C is reducing five processes to produce brass socket 39 3.5 Concept D is reducing two processes to produce brass socket 40 3.6 Concept E is reducing four processes to produce brass socket 41 3.7 Plate of Brass coil 3100 C26000 43 3.8 Variables in deep drawing die 44 3.9 Variables of workpiece for deep drawing process 46
(15)
4.1 Windows for attaching geometry from SolidWorks 2010 file to the system 54 4.2 Engineering Data workspace 56 4.3 Length unit option before start DesignModeler workspace 57 4.4 DesignModeler workspace 58 4.5 PUNCH changes the Stiffness behavior 59 4.6 DIE changing the Stiffness behavior 60
4.7 PLATE changing the Stiffness behavior 61 4.8 Frictional contact region for deep drawing die analysis 64 4.9 Manual contact region for deep drawing die analysis 65 4.10 Meshing option in Mechanical application 67 4.11 Meshing result for deep drawing die analysis 69 4.12 Analysis setting for deep drawing die analysis 70 4.13 Fixed support for deep drawing die analysis 71 4.14 Displacement setting for deep drawing die analysis 73 4.15 Solution Information in Worksheet 74 4.16 Graph of time increment 75 4.17 Graph of energy conservation 76 4.18 Graph of momentum summary 77 4.19 Graph of energy summary 78 4.20 Mechanical Application for Total Deformation 79 4.21 Result of total deformation as an analysis structure 81 4.22 Result of total deformation as a graph displacement versus time 82
5.1 Graph displacement versus time 85 5.2 Result of total deformation as an analysis structure 86 5.3 Result of total deformation as a graph displacement versus time 87 5.4 Result of shear stress as an analysis structure 89 5.5 Result of shear stress as a graph stress versus time 90 5.6 Graph displacement versus time 92 5.7 Result of total deformation as an analysis structure 93 5.8 Result of total deformation as a graph displacement versus time 94 5.9 Result of shear stress as an analysis structure 96 5.10 Result of shear stress as a graph stress versus time 97
(16)
5.11 Graph displacement versus time 99
5.12 Result of total deformation as an analysis structure 100
5.13 Result of total deformation as a graph displacement versus time 101
5.14 Solver output of conceptual design C 103
5.15 Result of shear stress as an analysis structure 104
5.16 Result of shear stress as a graph stress versus time 105
5.17 Graph displacement versus time 107
5.18 Result of total deformation as an analysis structure 108
5.19 Result of total deformation as a graph displacement versus time 109
5.20 Result of shear stress as an analysis structure 111
5.21 Result of shear stress as a graph stress versus time 112
5.22 Graph displacement versus time 114
5.23 Result of total deformation as an analysis structure 115
5.24 Result of total deformation as a graph displacement versus time 116
5.25 Result of shear stress as an analysis structure 118
5.26 Result of shear stress as a graph stress versus time 119
(17)
LIST OF ABBREVIATIONS
JBSB - Jati Beringin Sdn.Bhd. TNB - Tenaga Nasional Berhad TMB - Telekom Malaysia Berhad FEA - Finite Element Analysis
DIN - Deutsches Institut fur Normung, German Institute for Standardization
CES - Canbridge Education Selector 3D - Third Dimensional
AISI - American Iron and Steel Institute UTS - Ultimate Tensile Strength
(18)
CHAPTER 1
INTRODUCTION
This first chapter will discuss about the introduction of the deep drawing die for producing the brass socket of TNB’s pole with different height at Jati Beringin Sdn. Bhd. (JBSB). In this part, the briefing of the background, problem statement, objectives, scope, and structure of the research are discussed.
1.1 Backgrounds
1.1.1 Company
Jati Beringin Sdn. Bhd. (JBSB) was incorporated on 2 September 1997 and operated at Pantai Belimbing, Krubong and Teluk Mas, Melaka. Established by Mr. Asmadi Bin Wahid and his brother Mr. Daud Bin Wahid whose highly experiences in the engineering field. Owned a factory on the 0.5 acres of land in Pantai Belimbing, the 2.5 acres of land in Krubong, and 1 lot of SME Bank in Teluk Mas which they are equipped with a lot of modern machinery and equipment to ensure the smooth operation in order to produce the high standard and quality product. Major in metal fabrication, this company has become a vendor for Tenaga Nasional Berhad (TNB) and Telekom Malaysia Berhad (TMB) to supply pole accessories. Other than that JBSB also involved in furniture manufacturing like to supply steel, lab furniture, office, built-in furniture, interior renovation, custom made steel product for private and government sectors (door, grill, drain cover, etc.), and custom made steel work such as turning, milling, grinding and welding. Today, with all the dynamic, progressive, high education and experience JBSB has become a very competitive and
(19)
strong company. Until September 2011, JBSB already has a paid up capital of RM1.5 millions.
1.1.2 Deep Drawing Die
Deep drawing dies in Jati Beringin Sdn. Bhd. (JBSB) is used to produce the brass socket of TNB’s pole with different height that is 7.5meters (m), 9.0m and 10.0m. Actually, deep drawing die has used two different types of concept in producing the brass socket that is drawn from the plate into the cup and drawn from the cup into the cup. The deep drawing concepts used in producing brass socket are shown in figure 1.1.
Drawn from plate into cup
Drawn from the cup into the cup Figure 1.1: Deep drawing concept
(20)
1.2 Problem Statement
Deep drawing is one of the most important processes for forming sheet metal parts. It is widely used for mass production of hollow shapes in the packaging industry, automotive industry, etc. Deep drawing is a tensile-compressive forming of a sheet blank (or, depending on the material, also of foils or plates) to a hollow body open on one side or the forming of a pre-drawn hollow shape into another with a smaller cross-section without an intentional change in the sheet thickness.
Previously, the deep drawing concepts for producing the brass socket have been mentioned in section 1.1.2 that is drawn from the plate into the cup and drawn from the cup into cup such as drawn from the cup with 20mm diameter into the cup with 19mm diameter. Actually, to produce the brass socket need eight steps in detailed. Step one has used the concept one that is drawn from the plate into cup. Step two until six has used the concept to that is drawn from the cup into the cup. Step seven is removed the wrinkling and tearing that occurred. The last step is making the thread on the brass socket before it's ready to pack.
The major problem for this research is related to the processes itself in producing the brass socket. This means that, if the processes take a long time to complete, the productivity is low and the cycle time is increased. Because of that, it requires more than five stamping machines and manpower to run each of the machines. The company wants to reduce the usage of stamping machines in producing the brass socket. That's why, this research is necessitate to overcome the difficulty.
Besides that, the whole processes involve seven sets of deep drawing die per unit production to produce the brass socket. This serious problem has to overcome because the average cost of purchasing one set of deep drawing die is about RM5, 000 and above. Each of seven process need at least two deep drawing die set for every five years. Another one set is used as an encouragement for deep drawing die set if any problem occurred while making the whole processes.
(21)
1.3 Objectives
The objectives of this research are:
(a) Investigate the design parameters of deep drawing dies.
(b) Analyze the deep drawing dies using Finite Element Analysis (FEA). (c) Propose new design of deep drawing dies.
1.4 Scope
Few necessary elements must be considered to guarantee the objectives of this research achieved. Besides that, the deep drawing die is analyzed by using Finite Element Analysis (FEA) and also studied and do research about the process of a brass socket making to identify which process can be reduced. The scopes of this research are as follows:
(a) Investigate the deep drawing process base on literature study from many sources.
(b) Analyze the existing process of making brass socket and identify which process can be reduced for new deep drawing die.
(c) Analyze the new deep drawing die designs by using Finite Element Analysis (FEA) from ANSYS software with actual specification from the industry of a brass socket making.
1.5 Structure of the Research
Chapter 1 covers the introduction of the research with looking at problem statement, objective and scope of the research. The methodology of this research also clarifies momentarily from PSM I in semester 1 until PSM II in semester 2. Besides that, the significance of the research structure and finding also discussed properly in this chapter.
(22)
Chapter 2 consists of literature review which covering the basic principal of Finite Element Analysis (FEA) and also the parameters of designing a deep drawing die. Besides that, the deep drawing process in producing the brass socket also explains in detailed in this chapter. Thus, the deep drawing die is made from a variety of materials and the importance of material influencing the performance of the deep drawing die will be covered in this chapter. Also covered in this chapter is the several related research journals that used to summaries about the overall work related to the deep drawing die.
Chapter 3 contains a methodology of the research which is explained the flow of the whole research had been done. Planning is a part of project management, which relates to the use of schedules such as Gantt charts to plan and subsequently report the progress of the research. In this chapter, all progress has been divided into five basic phases which is consist of Planning, Concept Development, Details design, Analysis and refinement, Report submission and presentation.
Chapter 4 covers the procedure of the analysis by using ANSYS Workbench 12.0. In this chapter, the detail procedure will be reported as the most common method used in analyzing the brass deformation and fixturing forces by using Finite Element Analysis (FEA). Based on this analysis, the deep drawing defect for brass socket also can be found and reduce simultaneously. Besides that, the step to interpreting the result from the software also will be covered in this chapter.
Chapter 5 continues the discussion on the result that obtained from the simulation. By using Explicit Dynamic Analysis by using ANSYS software, the result of the Finite Element Analysis (FEA) for the new design will be compared with the current design. From the result, the reducing process of deep drawing die in producing the brass socket will be discussed directly.
Chapter 6 is the final chapter that consists of conclusions and future work recommendations. The conclusion of the research is made based on the action which has been done throughout two semesters. The conclusion usually made from the discussion chapter which is in the Chapter 5. After making a conclusion, the recommendations of future works related to this area can easily make based on the area that has not been explored in this research.
(23)
1.6 Gantt Chart
(24)
CHAPTER 2
LITERATURE REVIEW
In this second chapter, Literature review is to review the critical points of current knowledge on this particular project. In this chapter, also discusses the study that will be related to the project would be exercised. Besides, the project must be carried out with the theory, observation, recitation, understanding and documentations that related to how to design and analyze a lifting mechanism of deep drawing dies for brass socket or any related details. Therefore, it is necessary to achieve objectives of the project in more effectiveness and perfect.
2.1 Deep Drawing Process
2.1.1 Definition
Deep drawing is one of the most important processes for forming sheet metal parts. It is used widely for mass production of hollow shapes in the packing industry, automotive industry, manufacturing industry, etc. According to the definition in DIN 8584, deep drawing is the tensile compressive forming of a sheet blank (or, depending on the material, also of foils or plates) to a hollow body open on one side or the forming of a pre-drawn hollow shape into another with a smaller cross-section without an intentional change in the sheet thickness (Siegert K. and Wagner S., 1994).
(1)
strong company. Until September 2011, JBSB already has a paid up capital of RM1.5 millions.
1.1.2 Deep Drawing Die
Deep drawing dies in Jati Beringin Sdn. Bhd. (JBSB) is used to produce the brass socket of TNB’s pole with different height that is 7.5meters (m), 9.0m and 10.0m. Actually, deep drawing die has used two different types of concept in producing the brass socket that is drawn from the plate into the cup and drawn from the cup into the cup. The deep drawing concepts used in producing brass socket are shown in figure 1.1.
Drawn from plate into cup
Drawn from the cup into the cup Figure 1.1: Deep drawing concept
(2)
1.2 Problem Statement
Deep drawing is one of the most important processes for forming sheet metal parts. It is widely used for mass production of hollow shapes in the packaging industry, automotive industry, etc. Deep drawing is a tensile-compressive forming of a sheet blank (or, depending on the material, also of foils or plates) to a hollow body open on one side or the forming of a pre-drawn hollow shape into another with a smaller cross-section without an intentional change in the sheet thickness.
Previously, the deep drawing concepts for producing the brass socket have been mentioned in section 1.1.2 that is drawn from the plate into the cup and drawn from the cup into cup such as drawn from the cup with 20mm diameter into the cup with 19mm diameter. Actually, to produce the brass socket need eight steps in detailed. Step one has used the concept one that is drawn from the plate into cup. Step two until six has used the concept to that is drawn from the cup into the cup. Step seven is removed the wrinkling and tearing that occurred. The last step is making the thread on the brass socket before it's ready to pack.
The major problem for this research is related to the processes itself in producing the brass socket. This means that, if the processes take a long time to complete, the productivity is low and the cycle time is increased. Because of that, it requires more than five stamping machines and manpower to run each of the machines. The company wants to reduce the usage of stamping machines in producing the brass socket. That's why, this research is necessitate to overcome the difficulty.
Besides that, the whole processes involve seven sets of deep drawing die per unit production to produce the brass socket. This serious problem has to overcome because the average cost of purchasing one set of deep drawing die is about RM5, 000 and above. Each of seven process need at least two deep drawing die set for every five years. Another one set is used as an encouragement for deep drawing die set if any problem occurred while making the whole processes.
(3)
1.3 Objectives
The objectives of this research are:
(a) Investigate the design parameters of deep drawing dies.
(b) Analyze the deep drawing dies using Finite Element Analysis (FEA). (c) Propose new design of deep drawing dies.
1.4 Scope
Few necessary elements must be considered to guarantee the objectives of this research achieved. Besides that, the deep drawing die is analyzed by using Finite Element Analysis (FEA) and also studied and do research about the process of a brass socket making to identify which process can be reduced. The scopes of this research are as follows:
(a) Investigate the deep drawing process base on literature study from many sources.
(b) Analyze the existing process of making brass socket and identify which process can be reduced for new deep drawing die.
(c) Analyze the new deep drawing die designs by using Finite Element Analysis (FEA) from ANSYS software with actual specification from the industry of a brass socket making.
1.5 Structure of the Research
Chapter 1 covers the introduction of the research with looking at problem statement, objective and scope of the research. The methodology of this research also clarifies momentarily from PSM I in semester 1 until PSM II in semester 2. Besides that, the significance of the research structure and finding also discussed properly in this chapter.
(4)
Chapter 2 consists of literature review which covering the basic principal of Finite Element Analysis (FEA) and also the parameters of designing a deep drawing die. Besides that, the deep drawing process in producing the brass socket also explains in detailed in this chapter. Thus, the deep drawing die is made from a variety of materials and the importance of material influencing the performance of the deep drawing die will be covered in this chapter. Also covered in this chapter is the several related research journals that used to summaries about the overall work related to the deep drawing die.
Chapter 3 contains a methodology of the research which is explained the flow of the whole research had been done. Planning is a part of project management, which relates to the use of schedules such as Gantt charts to plan and subsequently report the progress of the research. In this chapter, all progress has been divided into five basic phases which is consist of Planning, Concept Development, Details design, Analysis and refinement, Report submission and presentation.
Chapter 4 covers the procedure of the analysis by using ANSYS Workbench 12.0. In this chapter, the detail procedure will be reported as the most common method used in analyzing the brass deformation and fixturing forces by using Finite Element Analysis (FEA). Based on this analysis, the deep drawing defect for brass socket also can be found and reduce simultaneously. Besides that, the step to interpreting the result from the software also will be covered in this chapter.
Chapter 5 continues the discussion on the result that obtained from the simulation. By using Explicit Dynamic Analysis by using ANSYS software, the result of the Finite Element Analysis (FEA) for the new design will be compared with the current design. From the result, the reducing process of deep drawing die in producing the brass socket will be discussed directly.
Chapter 6 is the final chapter that consists of conclusions and future work recommendations. The conclusion of the research is made based on the action which has been done throughout two semesters. The conclusion usually made from the discussion chapter which is in the Chapter 5. After making a conclusion, the recommendations of future works related to this area can easily make based on the
(5)
1.6 Gantt Chart
(6)
CHAPTER 2
LITERATURE REVIEW
In this second chapter, Literature review is to review the critical points of current knowledge on this particular project. In this chapter, also discusses the study that will be related to the project would be exercised. Besides, the project must be carried out with the theory, observation, recitation, understanding and documentations that related to how to design and analyze a lifting mechanism of deep drawing dies for brass socket or any related details. Therefore, it is necessary to achieve objectives of the project in more effectiveness and perfect.
2.1 Deep Drawing Process
2.1.1 Definition
Deep drawing is one of the most important processes for forming sheet metal parts. It is used widely for mass production of hollow shapes in the packing industry, automotive industry, manufacturing industry, etc. According to the definition in DIN 8584, deep drawing is the tensile compressive forming of a sheet blank (or, depending on the material, also of foils or plates) to a hollow body open on one side or the forming of a pre-drawn hollow shape into another with a smaller cross-section without an intentional change in the sheet thickness (Siegert K. and Wagner S., 1994).