Machining of Large Dies Based on the Prediction of the Press/Die Deformation

This chapter presents a methodological scheme for a reduction of both the try-out and lead-time of complex dies. It describes a global methodology in order to take into account the structural behavior of the tools in the mechanical group press-die, assuming that both components are not rigid solids, and that the deformation of the press, although small, is in the order of magnitude of the manufactured part tolerance. This methodology is also tested with a sample in an industrial application, where the calculated deformation is proposed to machine the die surface. The finite element simulation of the tool behavior along the stamping process results in criteria for the best design of high-cost dies/punches. The value of the total deformation depends directly on the force for the stamping process. Using this scheme, modifications of the main geometry, components, and functional parameters are recommended. The chapter illustrates examples as experimental evidences. © 2006