Automated manufacturing engineering

This project presents the design of a compound die and investigates the resulting burr heights of metal parts using theoretical and numerical approaches. The die was designed based on standard mathematical equations to perform blanking and piercing in a single press stroke, producing an exhaust gas recirculation (EGR) plate from four sheet materials (AISI 1006, AISI 1018, AISI 304, and AISI 202) with 2 mm thickness. The cutting process was simulated using the finite element method (ANSYS Explicit Dynamics) to evaluate directional deformations at the cutting edges, representing burr heights, under varying sheet thickness, clearance, cutting speed, and blank holder force. Results showed that a flat piercing punch produced the maximum burr heights for AISI 1006 and AISI 304, while for AISI 1018 and AISI 202, burr heights increased with smaller thickness and higher cutting speed, with the best cutting quality achieved at a low speed of 30 m/s. The study provides a validated compound die design procedure and shows how process parameters can be optimized to minimize burr heights and improve product quality for ferrous and stainless steel sheets.

Today, technology is developing rapidly in line with increasing human needs. The work carried out to meet these needs makes life easier every day, and much of this effort is concentrated in robotic arm research. Robot arms operate either under the control of an external user or by executing predetermined commands. Nowadays, the most advanced applications of robot arms are found in the industrial and medical sectors. The robot arm assembled and realized in this project has the ability to move along 6 axes using 6 servo motors. Using its gripper, it can pick up the desired material from one location and carry it to another, as well as mix it with the material it holds. Robot control is provided by connecting the system to an App Controller linked to an Arduino Mega microcontroller.

This project investigates the design of a blanking die and analyzes the stresses generated during sheet metal cutting using theoretical and numerical approaches. The blanking die was designed using standard mathematical equations, and the cutting process was simulated using the finite element method (ANSYS Explicit Dynamics) to evaluate stresses on the blanking punch. The aim was to develop an optimized die model that ensures high cutting quality with minimal burr formation and reduced stress concentration at the cutting edges, thereby extending die life and lowering manufacturing costs. The simulation evaluated three sheet materials—AISI 1006 steel, AL6061-T6 aluminum alloy, and tungsten—by determining the equivalent (von Mises), maximum shear, and normal stresses at the cutting edge. Results showed the highest equivalent stress in tungsten (1713.3 MPa), followed by AISI 1006 steel (1360.2 MPa) and AL6061-T6 (572.16 MPa), confirming that material type and cutting speed significantly affect the induced stresses and deformation, with an optimal cutting speed existing for each material. The study provides a validated die design and stress-prediction procedure to guide material and parameter selection for improved die performance. Future work is recommended to extend this approach to compound and combination dies for double cutting or combined cutting-and-forming operations.

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.