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Thesystem has been tested for a wide variety of industrial sheet metalcomponents. Recommendations with regard to checking of partdesign features, design of strip-layout, selection of die componentsand selection of materials for progressive die components; anddrawings generated by the system were found to be reasonableand very similar to those actually used in sheet metal industries.The proposed system is capable of accomplishing the tedious andtime-consuming task of progressive die design in a very short timeperiod. Although the system is limited to the design of progressivedies only, yet it can be extended further for the design of othertypes of dies also.In the future, research efforts are required for the developmentof modules for connecting the proposed automated design sys-tem with the computer aided manufacturing system of diecomponents.Table 2A sample of typical prompts, user responses and expert advices generated during execution of the system INTPDIE for example component (Fig. 4).S. No. Prompt Exampledata entryAdvice to the user1 Please enter sheet material Brass2 Please enter sheet thickness in mm 0.63 Please enter minimum width of recesses or slots orprojections along blank profile in mm1.6 Accept width of recesses or slots or projections4 Please enter shape of holes on the part Round & rectangular5 Please enter diameter of round hole on part in mm 2.5 Accept the diameter of hole6 Please enter minimum dimension of rectangular hole on partin mm5.2 Accept the dimension of hole7 Please enter minimum hole pitch in mm 6.1 Accept the hole pitch8 Please enter the minimum corner radius on part in mm 0.001 Set minimum corner radius on part in mm = 0.429 Please enter the shape of component edge Straight10 Please enter the maximum dimension of the component inmm (length/width)62.0 Set lead end scrap web allowance in mm = 1.5Set front/back scrap web allowance in mm = 1.511 Enter number of operations required 3 Design a progressive die for manufacturing the examplecomponent12 Are holes located on opposite sides of the part? Yes Select the two largest holes located on opposite sides of partfor piloting13 Is the center-to-center distance between holes has tolerancerange within ± 0.05 mm?Yes Pierce these holes at the same station14 Enter number of notch in the part 215 Enter number of holes in the part 2 Number of stations required = 5 preferred staging ofoperations – first station: piercing, second station: punching,notching & piloting, third station: notching & piloting, fourthstation: notching & piloting, fifth station: parting off16 Please enter command DSDIM for invoking the second submodule DSDIM of the system IDSS17 DSDIM Place die in the four pillar die-set with pillar diameter 25 mmand bolster dimensions in mm as – length = 280.0,width = 280.0, and height = 30Fig. 5. Strip-layout generated by the proposed system for example component. AcknowledgementsAuthors would like to express their sincere gratitude to Mr. S.L.Gupta, General Manager in Mindarika Pvt. Limited, Gurgaon, Har-yana,
India and all other domain experts for providing their exper-tise in the development of automated design system INTPDIE. Theauthor also acknowledges the financial support being provided bythe Department of Science and Technology (DST), New Delhi, Indiafor Fast Track project of three years duration (2008–2011) on‘‘Development of an Intelligent System for Selection of Materialsfor Press Tool Components”.ReferencesCheok, B. T., Foong, K. Y., & Nee, A. Y. C. (1996). An intelligent planning aid for thedesign of progressive dies. Proceeding of Institution of Mechanical Engineers – PartB: Journal of Engineering Manufacture, 210, 25–35.Duffy, M. R., & Sun, Q. (1991). Knowledge-based design of progressive stampingdies. Journal of Materials Processing Technology, 28, 221–227.Ghatrehnaby,M., & Arezoo, B. (2009). A fully automated nesting and piloting systemfor progressive dies. Journal of Materials Processing Technology, 20(9), 525–535.Ismail, H. S., Chen, S. T., & Hon, K. K. B. (1996). Automated design of progressive dies.Proceeding of Institution of Mechanical Engineers Part B: Journal of EngineeringManufacture, 210, 367–376.Kumar, S. (2006). A contribution to the development of knowledge-based system forintelligent design of progressive dies. Ph.D. Thesis, M. D. University, Rohtak,Haryana, India.Lee, I. B. H., Lim, B. S., & Nee, A. Y. C. (1993). Knowledge-based process planningsystem for the manufacture of progressive dies. International Journal ofProduction Research, 31(2), 251–278.Shirai, K., & Murkami, H. (1989). A compact and practical CAD/CAM system forprogressive dies. Bulletin of the Japan Society of Precision Engineering, 23, 25–30.Sima, S.-B., Lee, S.-T., & Jang, C.-H. (2004). A study on the development of centercarrier type progressive die for U-bending part process. Journal of MaterialsProcessing Technology, 1005–1010.Zheng, J., Wang, Y., & Li, Z. (2007). KBE-based stamping process paths generated forautomobile panels. International Journal of Advanced Manufacturing Technology,31, 663–672.