Design and analysis of optimum clearance of an open small thimble bending die

Rozuli, Nurul Atikah (2016) Design and analysis of optimum clearance of an open small thimble bending die. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This final year project entitled, “Design and Analysis of Optimum Clearance of an Open Small Thimble Bending Die”. The project focused on the design of bending die and to determine the optimum clearance of bending die whether it is able to reduce defect in producing a thimble open small. The bending die was designed by using SolidWorks. The material used for the Open Small Thimble is mild steel flat of 2mm and tool steel for the die. By using Explicit Dynamic Analysis from ANSYS software, the result of the Finite Element Analysis of the new design of bending die will be obtained. The analysis decides the optimum clearance in relation to velocity of upper die in order to have good bending finish with longer life span of die. From the analysis, 0.2 mm is the optimum clearance of the bending die. The clearance 0.2 mm is chosen because its meet all criteria needed in bending process to produce thimble open small. The criteria obtained for the 0.2 mm clearance are the value of total deformation is 79.37mm, shortest time taken to bend the mild steel plate is 2.95x10-4s and there is no tear defect occurred based on the total deformation, shear stress, equivalent elastic strain and equivalent stress. As a result, the new design of bending die presents the shortest process of bending in producing the thimble open small with better productivity, lower cycle time, less manpower and lowest cost compared to existing design with the similar.

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