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Design and Analysis of Progressive Die for Manufacturing the Gasket Part

Chapter · January 2021

DOI: 10.1007/978-981-15-4739-3_12

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Design and Analysis of Progressive Die
for Manufacturing the Gasket Part

Saurabh Priyadarshi, Premanand S. Chauhan, and Rajesh Pratap Singh

Abstract A progressive die is a set of tools performing series or several sheet-metal

operations with a single tool. It includes two or more workstations for the production
of products. In every pressing stroke, one operation is performed, and strip stock
moves forward through the die strip. The main functional advantage of progressive
die for the manufacturing industry is that it takes less time and gives a high volume
of production. It can build Precision tools with less time-consumption. From the
designing point of view, the CAD/CAM technique can be used to develop the part.
This simulation application gives the designer, to perform or test and freedom to take
risk-free decisions. In this project experiment, the main work is to design the gasket
parts, design progressive die, and analyze the progressive die or gasket part whether
there is any defect in production process analyses. Required solid modeling is done
on SOLIDWORKS.

Keywords Progressive die design · Design analysis · Materials · Effect on

production using simple die

1 Introduction

The rapidly growing automobile industry uses a wide range of sheet-metal gasket
products, and the automobile industry manufactures a wide variety of gasket products
at a very high volume. Nowadays, these industries are leading in producing new tech-
nologies. Different types of sheet-metal tools are used in the automobile industry to
manufacture the gasket product at low cost with mass production of the product. Due
to the very large requirement of the product, in minimum time, we can use a progres-
sive die to reduce manufacturing time and cost. The gasket manufacturing industry
makes very complicated geometry, and the stamping process executes several opera-
tions until the final product is formed. This process sequence for gasket development

S. Priyadarshi (B) · P. S. Chauhan · R. P. Singh

Department of Mechanical Engineering, I.P.S. College of Technology & Management,
Gwalior, Madhya Pradesh 474001, India
e-mail: [email protected]

© Springer Nature Singapore Pte Ltd. 2021 141

A. Arockiarajan et al. (eds.), Advances in Industrial Automation and Smart
Manufacturing, Lecture Notes in Mechanical Engineering,
https://doi.org/10.1007/978-981-15-4739-3_12
142 S. Priyadarshi et al.

is the best on-die geometry, the blank shape of the product, and process parameters.
Each and every work station or stage is designed based on past experiences, Trials
and Errors.
The development process of Die may be time-consuming. Therefore, we are using
computer-aided design and simulation for planning and study the design process
sequence of the progressive die. The progressive tooling for the stamping process
is defined as a metal-forming process. It is widely used for manufacturing metal
forming parts for automotive industries and electronics industries. The progressive
die for stamping process consists of the various independent workstation. Each and
every workstation performs one or two different operations. The product is transferred
from one workstation to another workstation by the strip-stock or punching stock
and the strip cut out in the final workstation. The decision to design or manufacturing
the progressive tool is dependent on the complexity of the product and volume of the
product and production cost or production time of the product. The use of progressive
stamping dies to produce different types of parts reduces the product-related cost as
possible. The main important or demanding benefit of the progressive die is to met
precise work and durability.As the manufacturing of progressive dies is difficult, but
some important points are considered to reduce the manufacturing time and cost,
always consider the blank position, blank-boundary, part-edge-deformation, pilot,
holes.
The benefits of using a progressive stamping die are to increase product
productivity and reduce product cost with a high volume of manufacturing.

2 Existing Design for the Manufacture of Gasket Part

Using Four Different Types of the Die, See Fig. 1

In this four-type of die, we manufacture the product, but the rejection ratio is too
high hence to eliminate the rejection, we develop progressives die see Fig. 2.

2.1 Specification of Component for Manufacturing

the Gasket Part

Material: Stainless steel 304

Overall OD: 60 mm
Overall ID: 48.8 mm
Overall length: 50.6 mm
Thickness of strip: 0.8 mm (Fig. 3).
Design and Analysis of Progressive Die for Manufacturing … 143

a. Blanking die b. Deep drawing die

c. Post Forming Die d. Edge Trimming Die

Fig. 1 Simple die. a Blanking die, b deep drawing die, c post-forming die, d edge trimming die

Fig. 2 Rejection part

144 S. Priyadarshi et al.

Fig. 3 Final product

2.2 Design of Progressive Die

Manufacturing Process of Progressive Die design (Fig. 4)

3 The Main Components of the Progressive Die

See Table 1.

Fig. 4 Progressive die

Design and Analysis of Progressive Die for Manufacturing … 145

Table 1 Main part of the progressive die

S. No. Part name Material
1 Punching plate D2
2 Stripper plate 45C8
3 Die chase FGM

3.1 Punching Plate

The punching plate may be a part of the progressive die to get rid of the finite volume
of the sheet. Punch plate helps to hold and support the piercing operation, notching
operation, and cut-off punches operation. However, the product of stainless steel is
left softly and works as a prime grade punch. The material utilized in producing is
AISI-D2. The length of the punching block for the punch plate is given, when the
block is shanked or equal in diameter to the ram hole or slot. The shank is fastened
in position with a screw. The half is the dowel pin along the side of the highest
plate, retains or holds the punches. The center position or distance area that is unit
picked up or transferred from the hardened die block to eliminate the likelihood of
placement of punches and die openings, to dimensional changes through the heat
treatment. All holes receive the body of punch in the unit area given H7 suitable
vacant and lightweight press-fitting. The material for the punching plate is AISI D2
as a result of D2 steel and work as harder material.
The AISI D2 material properties are high-carbon steel, and the hardness is 55-62
HRC (Table 2).

3.1.1 The Design and Analysis of the Punching Plate

on SOLIDWORKS Are as Follows

• 3D drawing and 2D drawing (Fig. 5).

• Load analysis on punching plate by SOLIDWORKS simulation application
(Fig. 6).

3.1.2 The Manufacturing Process of Punching Plate is as Follows

• EDM (wire cut) (Fig. 7)

• Machining (VMC) (Fig. 8)

Table 2 The AISI D2 steel composition

AISI D2 material composition percentage (%)
C SI Cr Mo V
01.50 00.30 12.00 00.80 00.90
146 S. Priyadarshi et al.

Fig. 5 Punching plate 3D and 2D drawing

Fig. 6 Punching plate load analysis

Fig. 7 EDM (wire-cut) machine

• Hardening and tempering

• Surface grinding (Table 3).

3.2 Stripper Plate

A stripper plate holds the metal tightly with the die throughout cutting or piercing, for
preventing the metal from slipping or moving on the die. It conjointly helps forestall,
Design and Analysis of Progressive Die for Manufacturing … 147

Fig. 8 Machining (VMC machine)

Table 3 AISI 45C8 chemical composition

45C8 steel material composition percentage (%)
C Mn P S Si
0.36–0.44 0.60–1.00 5.00 0.50 0.10–0.40

the half from distorting, and permits the cutting punches to withdraw or “strip” from
the metal coming by press stroke. Material for the stripper plate. The material for
the stripper plate is AISI 45C8. As a result, to select 45C8 steel is typically equipped
untreated, however, it is ready to be equipped in order within the normalized or finally
heats treated. It is adequate for a large variety of applications.

3.2.1 The Design and Analysis of Stripper Plate on Solidworks Are

as Follows

• 2D drawing.
148 S. Priyadarshi et al.

Fig. 9 Analysis report

• Analysis report image for crystal structure

• Analysis report image for static and dynamic loading strength (Fig. 9).

3.2.2 The Manufacturing Process of Punching Plate Is as Follows

• EDM (wire cut)

• Machining (VMC)
• Hardening and tempering

Tempering (heat of between 550 and 660 °C then cool in oil or water).
Normalizing (830–860 °C then it’s cooled in air).
• Surface grinding

3.3 Die Chase Plate

The die chase plate is in the form of a plate and its work is as a gap filler, and it gives
angular clearance to allow the escape of excellent blank profile. The waste skelton
of the stock strip, from that blanks, is cut and recovered the salvaged material.
The material for the die chase plate is FGM material as a result functionally
hierarchal materials could also be characterized by the variation in composition
and structure bit by bit over volume, leading to corresponding changes within the
properties of the fabric. The materials are often designed for specific performance
and applications.
Design and Analysis of Progressive Die for Manufacturing … 149

3.3.1 The Manufacturing Process of Die Chase Plate is as Follows

• VMC machining process

• Surface grinding process

The mechanical properties of cylindrical structures material manufactured from

functionally hierarchic material (FGM) unendingly in microscopical sense from one
surface to the opposite. The main important advantage is that it is well-designed
structure and stand up to very high-temperature gradient environments, whereas
maintaining their structural integrity. All material properties expressed as a ‘P’.

P = {P0(P − 1(T − 1) + 1 + (P T ) + (P2T 2) + (P3T 3)}

where P0, (P − 1), P, P2, and P3 are constants within the cuboid or the fabric property.
With the on top of the equation, the higher-order result of the temperature on the fabric
is captured. The constant values for a few materials, namely semiconducting material
chemical compound silicon nitride (Si3N4), unsullied or stainless steel (SUS304),
zirconium dioxide (ZrO2), and Ti–6Al–4V.

3.4 The Progressive Die Design on SOLIDWORKS

SOLIDWORKS is a solid or surface modeling technique based on CAD “computer-

aided design” and computer-aided engineering, the PC application that runs on a
Windows system and develops the planning as per demand. The Dassault system
develops or produces printed SOLIDWORKS software package. SOLIDWORKS
application is solid modeling software package; it permits you to style the half and
assembly the half within the three-dimensional house. The technique is typically
operating for style complete product coming up with, for planning the half. Begin for
sketching second profiles then use extruding, the extrude-cut and lofting command for
solid form, when completed the half style, assemble the half and being the simulation
method as per simulation, resulted half is changed. This method, once more and once
more, simplifies and build a final product.

4 Result

The experimental production results are evaluated by the help of the production
table or on the press machine experimentally, and the calculation work is done on
SolidWorks software (Fig. 10).
Finite element analysis (FEA) is done for the punching plate, stripper plate, or die
chase from this it is seen that the results are in an acceptable range. The analytical and
finite element analysis (FEA) results are nearly equal and both are in the acceptable
150 S. Priyadarshi et al.

Fig. 10 Progressive die

Fig. 11 Final sheet-metal

gasket parts

range. The total punching force required for punching plate or manufacturing the
gasket part is 112 tones including 25 percent of the factor of safety. The calculation
is done on SOLIDWORKS. So our designed safe is under given load conditions
(Fig. 11).
It is concluded that all parameters for the manufacturing and implementation of
progressive die for gasket manufacturing by the help of computer design process
using SOLIDWORKS, the manufacturing cost and time are also reduced-drastically
than the traditional/simple tooling method. Any sheet-metal manufacturing industry
uses 100, 150, 200 tones press machine are easily available for manufacturing and
testing purposes. For practical work in the press machine available in Fleet gasket
India Pvt. Ltd. Sheet metal gasket part under one-month observation or analysis
testing is done on the blanking plate, punching plate and bending punch to determine
the strength of the progressive die. It shows the results, and the gasket part manufac-
turing rate is too high than the respective previous production rate (Figs. 12,13,14,15
and 16).
After the camper the chat-list for simple die or progressive die. The progressive
die production rate is very high at very less part reject.
Design and Analysis of Progressive Die for Manufacturing … 151

REJECTED PART LIST BY USING SIMPLE DIE

Rejected part list by using simple die
200
180
160
140
120
100
80
60
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Fig. 12 One-month production report using simple die

PRODUCTION PART LIST BY USING SIMPLE DIE

producon
14510
14500
14490
14480
14470
14460
14450
14440
14430
14420
14410
14400
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Fig. 13 One-month production report using simple die

5 Conclusion

The main focus of this paper was on the optimization of productivity of gasket
parts manufacturing unit. This work is beneficial for the research and development
departments of the automobile gasket manufacturing unit. The progressive die is very
economical with suitable characteristics including strength and wears resistance. This
analysis work may be beneficial for the sheet-metal work research industry, auto-
mobile industry, electrical industry, aerospace industry. The progressive die is very
economical and produces sheet-metal gasket part from the metal sheet with suit-
able characteristics including strength and wear resistance. The implementation of
progressive die for manufacturing process replaces the traditional method (simple
152 S. Priyadarshi et al.

PRODUCTION RATE USING PROGRESSIVE DIE

production
29650

29600

29550

29500

29450

29400

29350
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Fig. 14 One-month production report using progressive die

REJECTED PART LIST BY USING PROGRESSIVE DIE

Rejected part list by using progressive die
6

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Fig. 15 One-month production report using progressive die

die) because the traditional method is a time-consuming process. This research deals
with the production report for manufacturing gasket parts using a progressive die
or simple die manufacturing. The simple die is also used for manufacturing, but it
includes two or more die used for one-single product manufacturing (blanking die,
deep drawing die, post-forming die, edge trimming die); therefore, the manufac-
turing cost of blanking dies, deep drawing dies, post-forming die, edge trimming die
is highly expensive and the mass production rate is low compared to progressive die.
In the manufacturing industry, 200 tones press machine is easily available, so the
press machine is used for manufacturing gasket part. The progressive die is gener-
ally used in industries for developing sheet metal parts for manufacturing the high
Design and Analysis of Progressive Die for Manufacturing … 153

Result
35000

30000

25000

20000

15000

10000

5000

0
day 1
day 2
day 3
day 4
day 5
day 6
day 7
day 8
day 9
day 10
day 11
day 12
day 13
day 14
day 15
day 16
day 17
day 18
day 19
day 20
day 21
day 22
day 23
day 24
day 25
day 26
day 27
day 28
day 29
day 30
production from progressive die production from simple die

Fig. 16 One-month production report using progressive die verses simple die

volume of products. Hence, the designing of progressive die works perfectly and it
includes 25 percent of the safety factor that improves its life.
Further work can be done on other segments of automobile components manufac-
turing industries as well as the industries where the simple die is used to manufacture
components. The work can also be done to control progressive die with Artificial
Intelligence (IoT).

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