Inserted Tool Design Using Finite Element Analysis

A rotational arm connection point design for a C-130 aircraft standardized sensor platform

“…This is a component of a car air conditioning unit which consists of a hollow tube with a flange at one end. The tube is formed from a hollow billet in which the blank is placed in a large upper cavity and a punch extrudes a portion of the metal into the smaller cavities to form a flanged tube [10]. Initially FEA was performed on a one piece tooling configuration which revealed that the stresses generated at the flange corner of the die during the production process were very close to the yield stress of the material used for the tooling which predicts die failure at a low number of production cycles.…”

“…Initially FEA was performed on a one piece tooling configuration which revealed that the stresses generated at the flange corner of the die during the production process were very close to the yield stress of the material used for the tooling which predicts die failure at a low number of production cycles. Because of this an inserted tooling design needed to be employed in order to prevent premature die failure [10].…”

“…Initially a tungsten carbide insert was designed for the die because of its ability to withstand larger stresses; however, an FEA of this configuration still revealed large stresses in the remainder of the tooling [10]. In order to reduce these stresses FEA was performed on the insert being press fit into the die with various tolerances.…”

“…In order to reduce these stresses FEA was performed on the insert being press fit into the die with various tolerances. Because no additional modeling of the components were required these analyses were easily carried out and it was determined that an interference of 0.123 mm provided for the lowest all around stresses on the system [10].…”