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Abstract There are a lot of holes in a progressive die for
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mounting inserts, assembles, and standards. This paper
gives the classification of plate holes of progressive die
design according to their structural types and relationships
between the correlating parts and the plate holes and
describes an automated hole design system for progressive
dies. Taking advantage of prebuilt design knowledge and
standard parts database, this system is able to generate the
correlated holes on the main plates of progressive dies, such
as upper die shoes, lower die shoes, stripper plates, punch
plates, die plates, punch backing plates, and die backing
plates according to the inserted parts or functional assem-
bles. A descriptive model is set up. The feature library
technology is adopted to develop the function for the design
of plate holes, which can improve the efficiency and
shorten the design cycle. The hole design system is built
on the top of SolidWorks, taking advantage of its built-in
modules, including part, assembly, and drawing. We use
progressive die for motor core as concrete examples to
demonstrate the power of our system. Experimental results
show that our system cannot only improve the design
quality but also reduce the design time and cost.
Keywords Progressive die . Hole . Correlated design .
Library feature1 Introduction
A progressive die is used in various industries such as
aerospace, electronics, automobiles, and electrical appliances
for producing sheet metal components in large quantities. As
a progressive die may contain a large number of operations
such as punching, blanking, bending, lancing, et al., it has
been regarded as complex and requires a great deal of
expertise.7511
Usually, the progressive design procedure is composed
of two phases, operations (stamping process) planning and
die structure design. Stamping process planning is to
produce a flat pattern of a model of stamped metal and
then plan stamping operations to obtain strip layout. The
die structure design process is as follows: (1) according to
the size of the strip layout, the die set is determined and the
overall structure of die is generated; (2) then the inserts,
punches, dies, and other forming parts are designed
including positioning and locating holes; and (3) based on
the specific circumstances, assistive devices are inserted
such as pilot pins, ejectors, screws, dowel pins, springs,
standard parts, etc. The progressive die structure design
usually costs about 2/3 design cycle time. There are a lot of
holes in a progressive die for mounting inserts, assembles,
and standards, and hole design is tedious, time-consuming,
and error prone. This study is concentrated on the
correlated design of holes on plates.
The developments of automated, basic knowledge and
intelligent design systems are studied by researchers all
over the world. Cheok and Nee presented a review of
research and design before 1998 in the design automation
of tools for metal stampings and proposed a framework for
an integrated design system for progressive dies [1]. Wang
et al. did some research of association technology in
assembly design for precision progressive die on AutoCAD[2]. Kumar et al. developed an intelligent system for
automatic modeling of progressive die [3]. They also
presented an expert system for automation of strip-layout
design process using the production rule-based expert
system approach of artificial intelligence on AutoCAD
[4]. Choi et al. developed a system written in AutoLISP on
the AutoCAD for strip layout and die layout and a tool kit on
the SmartCAM software for modeling and postprocessing
with a PC [5–7]. Based on knowledge-based rules, Kim et