17. Design and Analysis of Progressive Tool for Glass Brackets

In this project, the design of an automobile sheet metal component is done which is used as a bracket for an automobile handlebar. The main aim is to prevent burr at the edges, with optimum cutting clearance, straightness, and no bend marks, wrinkling formation, thinning at the bend region. To achieve this, the operations involved are blanking, notching, bending, and piercing operation where it has been done in a progressive way of tooling rather than eight stage tools. The number of parts per stroke is two numbers (LH + RH). For obtaining this sheet metal component, a progressive tool with eight stations is required, where the above operations are performed on the strip in a progressive way and feed has been from left side of the press. Analysis has been carried out on the punches of the press tool using Ansys 18.1. Software. The press tool has been designed using NX.10 Software. Finally, the deformation, stresses acting on the press tool has been calculated. Punches are made of D2 Steel material. As the result, lowest stress 13 MPa is in bending punch 1 and highest stress 538 MPa is in parting off punch is compared with ultimate tensile strength of D2 steel 600 MPa which is within acceptable limits.