Design of Compound Die and Measurement of Burr Heights Using Theoretical and Simulation Approach

This project investigates the design of the compound die and measures the burr heights using theoretical and numerical methodologies. The main aim of the project is to obtain the optimum design of the compound die with its cutting tools and to improve the cutting quality of ferrous products. The model of the compound die is designed using standard mathematical equations. It is used to produce an exhaust gas recirculation plate. Finite element technique (ANSYS software) has been used to achieve the research objectives. ANSYS is used to simulate the cutting operation and to analyze the sheet material deformation (burr heights). The final results indicate that the proposed design of the compound die can provide a clean cutting surface of the product under minimum burr height and implement the double cutting operation using the developed compound die without failure. The current project provides a better prediction of burr heights and efficient use of compound dies. The outcome indicates that the burr heights of the final product are at a smaller size for ferrous sheet materials. The findings provide optimum design and developed models of the compound die, improved product quality, and the lowest burr heights.