E3S Web of Conferences 309, 01025 (2021) https://doi.org/10.

1051/e3sconf/202130901025
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Modelling, Analysis and Development of Progressive Die

for Seat Rail
A. Padma Rao1*, Manzoor Hadi2
1Department of Mechanical Engineering, B. V. Raju Institute of Technology, Narsapur, Telangana 502313, India
2Department of Mechanical Engineering, B. V. Raju Institute of Technology, Narsapur, Telangana 502313, India

Abstract. Progressive dies are highly used in batch productions where product variety is low. The progressive die
is also called follow on die. It performs series of basic sheet metal operations. There are two or more stations and
work piece is gradually shaped to final product through passing each of these stations. The ‘progression’ (advance or
pitch) is linear travel of the strip stock at each press stroke and it is equal to the infestation distance. In the present
paper an attempt is made to develop a new progressive die, which used in making seat rail of an automotive four-
wheeler vehicle of Toyota, to optimize the use of material. So, the cost of progressive die reduces without losing its
quality. For modelling CATIA and for analysis ANSYS are used.

developed and press tool has tried out on a mechanical type

1 Introduction of press. Raja Shakarappa [3] worked on “Analysis and
Most of the expensive cast, forged, and machined products simulation of progressive die” without compromising on
are replaced with sheet metal parts. The architectural the quality of output. By using different analysis software
equipment which are made by hand are substituted by the the stress deformation of die are analyzed. V.S. Bhajantri et
processes like metal stamping, extrusion, forging. It is quite al. [4] conducted analysis of progressive die for optimizing
easy to make these elements compare to hand made. There the resources used in design and manufacturing a
are also other methods like metal tubing, forming and progressive die. Software named COSMOS is used for
drawing. These are more often used and more expensive. analysis which uses finite element method for solution. Md
The most useful products of modern technology are metal Inaithul Rehaman et al. [5] worked on modelling and
stampings. Sometimes the riveting and other fastening analysis of progressive die used in chain link plate. CATIA
processes are replaced by sheet metal stamping which can and ANSYS are used in this work for design and analysis
also be used to improve the existing designs that often are the stress distribution. Professor K.P. Kattimani et al. [6]
costly. Stamping process is applicable in automotive, investigated design and analysis of progressive tool for
aerospace and constructional industries. moving contact holder. Critical parts of progressive tool
The dies are used in the stamping process. Progressive are analysed for better functioning during the production of
stamping die is a special type of precision tool that cuts and component. D. K. Kushwaha [7] addressed the industrial
forms sheet metal according to the required shape. problem occurred in shells. In first phase it is explained the
Sometimes it is fully automated. design of die tool and checked the induced stresses. In
second phase the of the work it is developed the die and
punch assembly. Harshal A Chavan et al. [8] made the
2 Literature Survey
modelling and analysis of progressive die tool for
There have been many experiments conducted and fabricating the tail gate striker used in head lamp assembly.
theoretical work done in design and analysis of progressive Narayan Chouhan et al. [9] done the design and analysis of
dies. For production of different parts, different types of progressive tool which assistance the industry to
progressive dies are designed. The following is a review of manufacture the part rather than outsourcing which leads to
the research that has been completed in progressive die. save money. A. Balaraju et al. [10], designed and analyzed
Jyothi Bhaskar et al. [1] performed die design and analysis the finned brake drum by using FEA.
of progressive tool for can lid lever. Mathematical Deepak [11] analyzed, manufactured and assembled the
correlations are also calculated. Finite element analysis in progressive die to produce mold tool component.
this process boundary conditions are load on punch and die.
CATIA is used for modelling, assembly and drafting 3 Progressive Die
analysis is done in ANSYS. Progressive dies are a mixture of various single dies
Ulhas K. Annigeri et al. [2] proposed design and operating as different stations and grouped into the same
development of progressive tool for manufacturing washer die shoe. These stations are positioned to follow a sequence
press tool. In this paper design and fabrication of of operations needed to produce the required part.
progressive press tool for production of washer has been Progressive die is a multiple station die.

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution License 4.0
(http://creativecommons.org/licenses/by/4.0/).
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ICMED 2021

Fig.1 Process sequence

Piercing: This operation consists of simple whole

punching. It differs from blanking in that the punching is
the scrap and the strip is the work piece.
Lancing: This is a combined bending and cutting operation
along a line in the work material. No metal is cut free during
a lance operation. The punch is designed to cut on two are
three sides and bend along the fourth side.
Pilot punch: In construction, pilots are similar to punches,
with the only difference being in their smooth, radius end.
Notching: This operation removes metal from either or both
edges of the strip Fig. 3 Die Plate
Punch plate: Punch plate is also known as punch holder,
2.1 Parts of progressive tool:
which holds various cutting and non-cutting punches to
ensure alignment between punch and die.
Stripper plate: The main roll of the stripper is to remove the
stock from the punch after performing the piercing and
banking operations. The stripper plate is shown in Fig. 4.

Fig.2 Progressive die

Die plate: The profile of a die is cut with the help of the die
block. Typically, it is the lower member of the tool which
provides cutting edge.

Fig.4 Stripper plate

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Material selection for tool dies:

D2 Steel: D2 steel is an air-hardening die steel, abrasion

resistance, high in hardness, and resistance to deformation. Material = MS
The machinability of this material is quite good and also Fn = n×S×P×T (3)
may be still improved by a slightly greater amount of where
sulphur within the material makeup. The material’s Fn = cutting force for ‘n’ operations
machinability and surface finish are improved n = number of operations
considerably by well-dispersed particles of sulphide. T = thickness = 0.80mm;
Heat treating to a lower hardness positively affects the S = Stress = 310 N/mm2;
material’s toughness. Forging dies or other die-related P = Perimeter = πd;
tooling are made by D2 steel. Total shear force = sum of all forces = 70.891 T
Stripping force = 10% of total shear force = 7.0891 T
Elastic modulus: 215 kN/mm2; Yield stress: 450 MPa; Total press capacity = 764722.56 N
Tensile strength: 750 MPa; Compressive Yield stress: Press tonnage = 1.2 x total press capacity = 93.576 T
22×108 Pa. Table 2. Deflection of different punches
3 Calculations Tool F = 80%
cutting force
Length Area Deflecti on
(L) Moment of (δ)(mm)
Press tonnage = 1.2×total force (1) (N) (mm) inertia (I)
Cutting force, F = S×P×T (2) mm4
Piercing punch 1 10216.792 90 52.81 0.0808
Table 1. Shear force of different punches
Piercing punch 2 3737.856 90 7.06 0.2210
Slot punch 1 4436.22 90 139.76 0.0132
Slot punch 2 5757.59 90 267.641 0.0009
Die plate 1 478407.608 558 7716325 0.2609
Die plate 2 77747.12 558 3642129 0.0898

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Fig.5 Die plate in 2D drawing

4 Design and Modelling

The Fig.6 shows the design and modelling of different are done as per the requirement of the Toyota
tools used in progressive die. The design and modelling automotive four-wheeler vehicle.

Tool CAD design 2D CATIA model

Piercing
punch 1

Slot
punch 1

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Die plate 1

Fig.6 Design and models of tools used in progressive die

5 Analysis
progressive die. The stress and deformation occurred in
The Fig. 7 shows the analysis of different tools used in the components are shown.

Tool Deformation Minimum Principal Stress Factor of Safety

P
I
E
R
C
I
N
G

P
U
N
C
H

S
L
O
T

P
U
N
C
H

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L
A
N
C
I
N
G
P
U
N
C
H

D
I
E

P
L
A
T
E

Fig.7 Stress plots and deformation of different punches

6 Development of New Die

rail of an automobile.
The Fig.8 shows the fabrication process of the
progressive die which is used for making the seat

(a) (b)

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(c) (d)

(e) (f)
Fig.8 Fabricated progressive die

7 Results and Discussion material as safe stress. Therefore, all the stresses obtained
are under allowable stresses.
Table 3. FEM simulation and calculated results 3. Deformation starts mostly at the tips of punch. Crack
initiation might also take place at these edges, since the
Part Theoretical Computed Minimum edges are sharp.
deformation deformation
Principal 4. Creep is general occurrence in these types of cases.
(mm) (FEA) 5. By providing back plates in punch holders, few stresses
Stress
(mm) can be relieved.
(MPa)
Piercing punch 1 0.0815 0.047 217.75 Progressive die is most economically viable way in batch
Piercing punch 2 0.221 0.086 515.93
production. Production rate is high in progressive dies as
Slotting punch 1 0.0132 0.082 298.65
Slotting punch 2 0.0009 0.031 106.06
it is a continuous operation. Since every punch and die is
Lancing Punch - 0.025 82.15 assembled individually, it is easy to replace them. This
Die 1 0.2609 0.0304 489.31 reduces the maintenance cost despite its high cost.
Die 2 0.0898 0.0103 286

8 Conclusions
The significant conclusions that may be drawn based on the
above results may be summarized as follows.
1. Results obtained in deformation through F E analysis are
more or less the same as theoretical values.
2. As all the parts are subjected to minimum compressive
stress, one can take compressive yield stress of the

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