Simulation and Design of Press Die for Three Wheeler Chassis Main Member

Master's Thesis from the year 2015 in the subject Engineering - Automotive Engineering, grade: 8.76, , course: Master of Technolog - Mechanical CAD/CAM, language: English, abstract: Automobile industry is one of the fastest growing and largest consumer product sector. Many of the automobile parts are made up of sheet metal. The press forming is the most feasible and cost effective method for manufacturing the automotive body panels and other sheet metal parts. Though many new techniques such as reconfigurable dies for forming, incremental sheet forming offering better flexibility are developed, none of these modern techniques is capable for mass production as required in the industries.

The production of new stamping tools get more troublesome, as the geometries get more complex and smaller tolerances on the dimensions are requested. The design of dies is the most critical and important step in obtaining a dimensionally accurate and defect free product. The project consist of simulation, die design, optimization and die manufacturing assistance for a 3 wheeler chassis Main Member. The major difficulties like springback, twisting of part, insufficient stretching, wrinkles, cracks, stress concentrations and dimensional accuracy were successfully overcome in this project work.

The software tools which were used during this project are PAM-STAMP 2G for simulation and feasibility analysis, UG-NX (Modelling, Sheet metal & manufacturing modules) for modelling and creating CNC programs and Auto CAD for drafting.