Improvement Activities in Stamping Die Manufacturing: A Systematic Literature Review

Die making is regarded as the mother of all industries. In the manufacturing world, this industry is thought to have existed for a long time. There is a need to address the improvement activities in this area in order to assess their relevance, results, and impacts on its latest industrial development. However, there were insufficient studies that systematically reviewed the existing literature related to stamping die manufacturing's latest improvement activities. As a result, the current article conducted a systematic literature review on stamping die manufacturing improvement activities. The present study applies the integrated multiple research design, and the review was based on the publication standard, namely the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA). This research is using two leading databases, namely Scopus and Science Direct, and five supporting databases, namely Emerald Insight, IEE Explore, Wiley Online, Taylor & Francis, and Google Scholar. Using thematic analysis, this review has six main themes: design, machining, finishing, trials, and overall improvements. These six major themes were subdivided into 20 sub-themes. The findings show that the researchers are covering most of the improvements in the main elements of die manufacturing processes. Based on this study, the contribution for practical purposes of stamping die manufacturing improvements was identified. The study contributes significant findings, such as detailed improvement activities that are specific to the targeted issues but have the potential to be adapted or imitated by other practitioners and future researchers

Analysis and simulation of temperature distribution and stress development in wire EDM of Tungsten carbide

The main objectives of this research are to investigate the performance of temperature distribution and equivalent Von- Mises stress development on tungsten carbide, determine the effect of different machining parameters on the tungsten carbide workpiece, prepare a set of parameters, temperature distribution and stress development that can be compared with the experimental result and to optimize the machining parameters for machining tungsten carbide using wire EDM. However, wire EDM is a complicated stochastic nature process mechanism and it has a very large number of parameters that should be considered. It is quite hard to select the best set of parameters in experimenting. In this research, the Ansys software was used to simulate the maximum temperature and maximum equivalent (Von-Mises) stress result of machining the tungsten carbide by wire EDM. The input parameters selected in conducting the simulation are pulse- on time and servo voltage. The wire diameter, convective coefficient, thermal expansion coefficient, current, thickness of the workpiece and wire material is taken as fixed parameters. By using Taguchi’s L9 orthogonal array, the optimal value is obtained for maximum temperature and maximum equivalent (Von-Mises) stress. Additionally, the analysis of variance (ANOVA) is a useful technique to identify the most important factor that affecting the output response

Thermal oxidation promotes growth of nanocrystalline diamond on biomedical grade Co Cr mo alloy

Diamond coatings are employed to yield significant benefits in applications such as for cutting tools, optical lenses, biomedical components, microelectronics, engineering and thermal management systems. Although there are many research reporting the successful of diamond coating on titanium, tungsten carbide and steel alloys but there are still lacking of research on the cobalt based alloy as the substrate. In order to coat diamond on these metals substrate, chemical vapor deposition (CVD) technique is commonly used. This paper reports on investigations of nano-crystalline diamond (NCD) coating on different carbon content of cobalt based alloys. Emphasis is given to achieve good adhesion of NCD coating on high and low carbon content of cobalt-chromium-molybdenum (Co-Cr-Mo) alloys using two different processes of surface pretreatment such as mechanical roughening the sample surface (≈0.3µm) and by using thermal oxidation to create oxide interlayer. The results revealed that most of the coating on samples was peel-off on roughened surface. However, there were small portion of NCD coating that still intact on sample with oxide interlayer. The thickness NCD coating obtained was approximately 5µm. Since the adhesion strength of the diamond coatings were very poor and easily delaminated, scratch test could not be performed on both sample conditions. Surface morphology and characterization of diamond coatings were investigated by Scanning Electron Microscopy (SEM) and X-ray diffraction respectively

Analysis and optimum machining parameters on surface roughness and material removal rate for titanium alloy in milling machining with MQL

Proper cutting parameters are needed to produce lower surface roughness of titanium alloy machined material. The high temperature in the cutting zone is always happened due to high friction between the tool and the workpiece and will cause dimensional error and poor surface roughness. Therefore, the main objectives of this research were to investigate and compare the surface roughness and material removal rate (MRR) of Ti-6AL-4 V alloy under the dry and minimum quantity lubrication (MQL) technique. The effect of cutting parameters towards surface roughness was investigated and the optimum cutting parameters was studied to obtain lower surface roughness and higher MRR. From ANOVA, spindle speed has been identified as the most significant parameter that affects the surface roughness and MRR. In t his paper, the optimum cutting parameters that give the low surface roughness and high MRR was 1500 rpm (spindle speed), 0.4 mm/tooth (feed per tooth), and 0.4 mm (depth of cut). From this study, it can be concluded that in this milling of Ti-6Al-4 V alloy, higher spindle speed, feed per tooth, and depth of cut are preferable to achieve the better surface quality of Ti-6Al-4 V alloy

Analysis and optimum machining parameters on surface roughness and material removal rate for titanium alloy in milling machining with MQL

Proper cutting parameters are needed to produce lower surface roughness of titanium alloy machined material. The high temperature in the cutting zone is always happened due to high friction between the tool and the workpiece and will cause dimensional error and poor surface roughness. Therefore, the main objectives of this research were to investigate and compare the surface roughness and material removal rate (MRR) of Ti-6AL-4 V alloy under the dry and minimum quantity lubrication (MQL) technique. The effect of cutting parameters towards surface roughness was investigated and the optimum cutting parameters was studied to obtain lower surface roughness and higher MRR. From ANOVA, spindle speed has been identified as the most significant parameter that affects the surface roughness and MRR. In t his paper, the optimum cutting parameters that give the low surface roughness and high MRR was 1500 rpm (spindle speed), 0.4 mm/tooth (feed per tooth), and 0.4 mm (depth of cut). From this study, it can be concluded that in this milling of Ti-6Al-4 V alloy, higher spindle speed, feed per tooth, and depth of cut are preferable to achieve the better surface quality of Ti-6Al-4 V alloy

Influence of cutting edge radius (CER) and width of cut (WOC) on tool wear in milling SUS 316 stainless steel

The application of stainless steel, especially SUS 316 have been significantly increasing especially in manufacturing area. However, problems such as rapid tool wear and poor surface roughness are a major problem when machining SUS316. The geometry and type of materials of cutting tool during machining SUS 316 plays a significant role in determining the outcome of the machining. This study was conducted to investigate the effect of cutting-edge radius (CER) and width of cut (WOC) on tool wear in milling SUS316 stainless steel. 6 mm diameter of uncoated tungsten carbide having three different values of CER which are 30, 40 and 50 and WOC of 0.1, 0.6 and 1.2 mm were selected as cutting tool in this study. A cutting speed of 4500 RPM, feed rate of 350 mm/min were kept constant throughout this experiment. It has been found that the cutting edge radius of the cutting tools plays a significant impact on the tool life and the surface roughness. It is proved that different CER and WOC values have significant influence on the tool wear and surface roughness while milling SUS 316 and it is concluded that the most optimum parameter combination is between 30 µm CER and 0.1 mm WOC based on the experimental data collected. It executes lower readings for both the imposed wear on cutting tool and the surface roughness of machined SUS 316 after 4400 mm machining length compared to other data of different combinations

Kebolehmesinan komposit matriks logam Al-Si/A1N menggunakan mata alat pemotong karbida

Komposit matriks logam (MMC) merupakan gabungan antara logam ringan yang dikenali sebagai bahan matriks dengan bahan penguat atau tetulang seramik keras. Gabungan ini menghasilkan bahan yang mempunyai kekuatan yang lebih tinggi, lebih keras, lebih rintangan terhadap sifat haus, dan nisbah kekuatan kepada berat yang lebih baik berbanding dengan bahan matriks. Gabungan matriks logam dengan bahan tetulang seramik keras menawarkan potensi yang baik dalam industri automotif dan aeroangkasa. Kesukaran dalam pemesinan MMC dilihat sebagai salah satu masalah utama yang menghalang penggunaannya yang meluas dalam aplikasi kejuruteraan. Pemesinan MMC dilihat amat sukar kerana sifatnya yang sangat melelas dan penyerakan zarah bahan tetulang yang tidak sekata. Kajian ini bertujuan untuk mengkaji kebolehmesinan komposit matriks logam Al-Si/AlN yang baharu dibangunkan dengan menggunakan mata alat karbida tidak bersalut dan karbida bersalut PVD TiAlN di dalam keadaan kering tanpa bendalir pemotong. Prestasi kedua-dua jenis mata alat dikaji dalam proses kisar menggunakan mesin kisar menegak DMC635V. Parameter pemesinan yang lain, yang dikaji dalam ujikaji ini ialah; laju pemotongan (240-400 m/min), kadar suapan (0.3-0.5 mm/gigi), kedalaman pemotongan (0.3-0.5 mm) dan peratus bahan penguat AlN (10-20%). Kaedah Taguchi dengan susunan ortogon L18 (2134) digunakan dalam ujikaji ini. Perubahan pada benda kerja komposit Al-Si/AlN selepas pemesinan dikaji dari perspektif kekasaran permukaan dan kekerasan mikro. Hasil kajian mendapati laju pemotongan dan dalam pemotongan adalah faktor yang sangat signifikan kepada hayat mata alat. Didapati hayat mata alat maksimum adalah 70.7 minit, apabila menggunakan mata alat tidak bersalut dengan laju pemotongan 240 m/min, kadar suapan 0.3 mm/gigi, dalam pemotongan 0.3 mm, dan MMC yang mempunyai bahan penguat AlN 10%. Manakala bagi mendapatkan nilai kekasaran permukaan yang lebih rendah adalah dengan menggunakan mata alat tidak bersalut, laju pemotongan 400 m/min, kadar suapan 0.4 mm/gigi, dalam pemotongan 0.5 mm, dan MMC yang mempunyai bahan penguat AlN 15%. Tiada perubahan ketara pada kekerasan mikro, dan ubah bentuk plastik tidak kelihatan berdasarkan sampel yang dikaji. Melalui kaedah Taguchi, parameter pemotongan yang optimum bagi setiap ciri prestasi telah dicadangkan. Parameter pemotongan optimum juga diperolehi bagi mendapatkan kombinasi kesemua ciri prestasi dengan menggunakan kaedah analisis hubungan Grey (GRA). Melalui kaedah GRA, parameter pemotongan berikut disarankan; Mata alat jenis tidak bersalut, laju pemotongan 240 m/min, kadar suapan 0.4 mm/gigi, dalam pemotongan 0.3 mm dan 15% bahan tetulang AlN. Mekanisme haus yang didapati adalah haus lelasan dan pembentukan alur yang tidak sekata pada permukaan rusuk mata alat. Haus lekatan juga berlaku pada permukaan rusuk mata alat disebabkan oleh tekanan tinggi yang terjana di antaramuka mata alat-benda kerja komposit Al-Si/AlN. Pertambahan unsur oksigen pada kawasan BUE yang terdeposit pada permukaan sadak menunjukkan adanya permukaan teroksida. Oleh itu ikatan logam-oksida dan oksida-oksida mungkin terbentuk. Serpihan benda kerja komposit Al-Si/AlN adalah berbentuk bergerigi, semi-bulatan dan seterusnya terputus membentuk serpihan-serpihan kecil. Kajian ini diharap menjadi kajian yang memberi impak yang besar kepada pembangunan berterusan bahan yang baru dibangunkan ini, untuk menjadi yang terbaik di antara bahan MMC dengan kebolehmesinan yang lebih baik seterusnya dapat mengurangkan kos pemesinan

Analysis of the Influence of EDM Parameters on Surface Quality, Material Removal Rate and Electrode Wear of Tungsten Carbide

Electrical discharge machining (EDM) is a process for shaping hard metals and forming deep complex shaped holes by arc erosion in all kinds of electro-conductive materials. The objective of this paper is to study the influence of operating parameters of tungsten carbide on the machining characteristics such as surface quality, material removal rate and electrode wear. It is followed by optimizing the machining condition for confirmation test purposes. Then, the conformation test needed to evaluate the error margin between predicted result by software and confirmation result by experiment in terms of the machining characteristics. The effectiveness of EDM process with tungsten carbide, WC-Co is evaluated in terms of the material removal rate, the relative wear ratio and the surface finish quality of the workpiece produced. It is observed that copper tungsten is most suitable for use as the tool electrode in EDM of WC-Co. Better machining performance is obtained generally with the electrode as the cathode and the workpiece as an anode. In this paper, a study was carried out on the influence of the parameters such peak currrent, power supply voltage, pulse on time and pulse off time. The surface quality that was investigated in this experiment was surface roughness using perthometer machine. Material removal rate (MRR) and electrode wear (EW) in this experiment was calculated by using mathematical method. The result of the experiment then was collected and analyzed using STATISTICA software. This was done by using the design of experiments (DOE) technique and ANOVA analysis

Study Of The Surface Integrity Of The Machined Workpiece In The Wedm Of Tungsten Carbide

This paper presented a study on the surface integrity of the machined surface of tungsten carbide (WC-15%Co) using wire electro-discharge machining (WEDM). WEDM tests on a WC-15%Co workpiece were conducted on a Sodick WEDM 5-axes series AQ537L, with the pulse duration (ON), pulse interval (OFF), peak current (IP) and servo voltage (SV) varied. The WEDMed surface roughness and thickness of recast layer were examined with a Scanning Electron Microscope XL40. The Full Factorial Design of Experiment (DOE) approach with two-level was used to formulate the experimental layout and to evaluate the effects on two machining responses consisting of surface roughness and thickness of recast layer. It is found that pulse duration has appeared to be the significant effect to both responses. It is also observed that there was almost no presence of microcracks in this study. The recast layer has distinguished microstructure from its parental material which consists of a lot of pockmarks, voids and globules of debris on its surface. Based on the observation done, the WEDM conditions have no effect on the microstructure of the bulk workpiece material. This means that damage caused by WEDM on the WEDMed surface is limited to certain depth only. Overall, the results showed that the thickness of recast layer and surface roughness of machined surface were improved when pulse duration and peak current were set at low values

Design and Fabricate the Prototype of a Motorized Cutter for Harvesting Palm Fruit

A new harvesting pole, specifically developed for palms trees, was designed, developed and tested. It comprises three sections, the engine, extension and replaceable sickle/chopper, which were joined through an aluminum pole. The pole can be adjusted to certain length to reach different height of tree. It is built using standard circular rod with cross section diameters of 50 mm. This newly invented replaceable sickle/chopper pole has been designed based on the ordinary sickle and chopper widely used in Malaysia palm estates. This innovation introduced new mechanism concept of small chain saw engine as a source of mechanical force to cut the frond and fruit bunch. The replaceable system was designed and located at the end of the pole for easily detachable manually. While the threaded steel used to link the engine systems and replaceable sickle/chopper system can be easily replace for higher tree