Failure Investigation of Blank Holder Force (BHF) Control in The Outside Bracket For Front Seat
DOI:
https://doi.org/10.37385/jaets.v4i2.1779Keywords:
progressive dies, blank holder force, genba, kaizen, quality productAbstract
This study investigated the failure of the Blank Holder Force (BHF) control in the outside bracket for the front seat. The production process involved progressive dies consisting of nine stations: first pierce, first trim, second trim, idle, flange, idle, second pierce, idle, and parting. However, at the 7th-9th station, the pilot hole in the product deforms into an oval shape, which is undesirable. Gemba-Kaizen methods were used in this study, and primary data were collected by comparing the design and actual progressive dies. The results showed that product defects are primarily caused by an unbalanced BHF and inadequate piercing clearance. A uniform distribution of force during the forming process is obtained by reducing the spring number on the blank holder. This reduces the force generated during the process. Furthermore, the die clearance was increased from 0.01 mm to 0.1 mm, making press and die alignment less critical and requiring less cutting and stripping forces
Downloads
References
Ahmetoglu, M. A., Altan, T., & Kinzel, G. L. (1992). Improvement of part quality in stamping by controlling blank-holder force and pressure. Journal of Materials Processing Tech., 33(1–2), 195–214. https://doi.org/10.1016/0924-0136(92)90319-N
Alvi, A. (2013). JIS G3302 Structural Galvanized Cold Rolled SGC440 Steel. Material Grades. https://www.materialgrades.com/jis-g3302-structural-galvanized-cold-rolled-sgc440-steel-687.html
Annigeri, U. K., Raghavendra Ravi Kiran, K., & Deepthi, Y. P. (2017). Design and development of progressive tool for manufacturing washer. AIP Conference Proceedings, 1859. https://doi.org/10.1063/1.4990260
Atul S, T., & Babu, M. C. L. (2019). A review on effect of thinning, wrinkling and spring-back on deep drawing process. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 233(4), 1011–1036. https://doi.org/10.1177/0954405417752509
Bhawar, P. B., Dongare, S. A., Bhamare, S. R., Padul, A. B., & Shirsath, S. V. (2017). Design and Manufacturing of Progressive Die. International Journal of New Technology and Research, 3(4).
Brun, M., Bruschi, S., Filippi, S., Stief, P., Dantan, J., Etienne, A., & Siadat, A. (2021). Active control of in sheet metal stamping. Procedia CIRP, 100, 151–156. https://doi.org/10.1016/j.procir.2021.05.079
Budiarto, H. A., Permana, S., Yuliar, Y. E., & Hasyim, A. P. (2022). Analisis produk dan perancangan combination tool pada produk jam souvenir Polman Bandung. Dinamika Teknik Mesin, 12(1), 66–77. https://dinamika.unram.ac.id/index.php/DTM/article/view/511/pdf
Chen, D., Zhao, C., Chen, X., & Chen, G. (2022). Prediction and Experimental Verification of the Critical Fracture Blank Holder Force for Deep Drawing of Box-Shaped Parts. MATERIALS TRANSACTIONS, 63(11), 1541–1549. https://doi.org/10.2320/matertrans.MT-M2022097
Cherrafi, A., Elfezazi, S., Hurley, B., Garza-Reyes, J. A., Kumar, V., Anosike, A., & Batista, L. (2019). Green and Lean: a Gemba--Kaizen model for sustainability enhancement. Production Planning & Control, 30(5–6), 385–399. https://doi.org/https://doi.org/10.1080/09537287.2018.1501808
Feng, Y., Hong, Z., Gao, Y., Lu, R., Wang, Y., & Tan, J. (2019). Optimization of variable blank holder force in deep drawing based on support vector regression model and trust region. International Journal of Advanced Manufacturing Technology, 105(10), 4265–4278. https://doi.org/10.1007/s00170-019-04477-5
Gavas, M., & Izciler, M. (2006). Design and application of blank holder system with spiral spring in deep drawing of square cups. Journal of Materials Processing Technology, 171(2), 274–282. https://doi.org/https://doi.org/10.1016/j.jmatprotec.2005.06.082
Ivanov, D. (2020). Predicting the impacts of epidemic outbreaks on global supply chains: A simulation-based analysis on the coronavirus outbreak (COVID-19/SARS-CoV-2) case. Transportation Research Part E: Logistics and Transportation Review, 136(March), 101922. https://doi.org/10.1016/j.tre.2020.101922
Koowattanasuchat, P., Mahayotsanun, N., Ngernbamrung, S., & Mahabunphachai, S. (2016). Formability Effects of Variable Blank Holder Force on Deep Drawing of Stainless Steel. MATEC Web of Conferences, 80, 1–6. https://doi.org/10.1051/matecconf/20168015005
Kumar, S., & Patnaik, L. (2017). Design and Analysis of Four Stage Progressive Tool for House-wiring Wire Clip. Journal of Science and Technology, 13(December).
Macpherson, W. G., Lockhart, J. C., Kavan, H., & Iaquinto, A. L. (2018). Kaizen in Japan: transferring knowledge in the workplace. Journal of Business Strategy, 39(3), 40–45. https://doi.org/10.1108/JBS-04-2017-0048
Min, H. (2023). Supply chain crisis management in the wake of the COVID-19 pandemic. International Journal of Logistics Systems and Management, 44(1), 1–16.
Mitra, A. (2016). Fundamentals of Quality Control and Improvement: Third Edition. In Fundamentals of Quality Control and Improvement: Third Edition. https://doi.org/10.1002/9781118491645
Mori, K. ichiro, Abe, Y., & Suzui, Y. (2010). Improvement of stretch flangeability of ultra high strength steel sheet by smoothing of sheared edge. Journal of Materials Processing Technology, 210(4), 653–659. https://doi.org/10.1016/j.jmatprotec.2009.11.014
Özgüven, I. (2022). Development of Dimensional Measurement Methods with a 3D Measuring Device without Using a Checking Fixture. The European Journal of Research and Development, 2(4), 24–32. https://doi.org/10.56038/ejrnd.v2i4.125
Pätzold, I., Stahl, J., Golle, R., & Volk, W. (2023). Reducing the shear affected zone to improve the edge formability using a two-stage shear cutting simulation. Journal of Materials Processing Technology, 313(January). https://doi.org/10.1016/j.jmatprotec.2023.117872
Preedawiphat, P., Koowattanasuchat, P., Mahayotsanun, N., & Mahabunphachai, S. (2020). Sheet thinning prediction method based on localized friction effect in deep-drawing. Advances in Mechanical Engineering, 12(9), 1–10. https://doi.org/10.1177/1687814020953941
Priyadarshi, S., Chauhan, P. S., & Singh, R. P. (2021). Design and Analysis of Progressive Die for Manufacturing the Gasket Part. Lecture Notes in Mechanical Engineering, 23(February), 141–154. https://doi.org/10.1007/978-981-15-4739-3_12
Quan, N. K., Anh, N. L. M., & Taylor-Robinson, A. W. (2023). The global COVID-19 vaccine surplus: tackling expiring stockpiles. Infectious Diseases of Poverty, 12(1), 21. https://doi.org/10.1186/s40249-023-01070-7
Ran, Q., Lee, S.-Y., Zheng, D., Chen, H., Yang, S., Moore, J. C., & Dong, W. (2023). Potential health and economic impacts of shifting manufacturing from China to Indonesia or India. Science of The Total Environment, 855, 158634. https://doi.org/https://doi.org/10.1016/j.scitotenv.2022.158634
Reis, A. M., de Sousa, S. D. T., & Costa, L. (2023). Wastes Identification Through Kaizen Events: A Case Study in the Automotive Sector BT - Flexible Automation and Intelligent Manufacturing: The Human-Data-Technology Nexus (K.-Y. Kim, L. Monplaisir, & J. Rickli (eds.); pp. 228–235). Springer International Publishing.
Sadiku, M. N. O., Ajayi-Majebi, A. J., & Adebo, P. O. (2023). Lean Manufacturing BT - Emerging Technologies in Manufacturing (M. N. O. Sadiku, A. J. Ajayi-Majebi, & P. O. Adebo (eds.); pp. 157–173). Springer International Publishing. https://doi.org/10.1007/978-3-031-23156-8_11
Shulkin, L. B., Posteraro, R. A., Ahmetoglu, M. A., Kinzel, G. L., & Altan, T. (2000). Blank holder force (BHF) control in viscous pressure forming (VPF) of sheet metal. Journal of Materials Processing Technology, 98(1), 7–16. https://doi.org/10.1016/S0924-0136(99)00300-3
Singh, C., Singh, D., & Khamba, J. S. (2023). Assessing Lean Practices in Manufacturing Industries Through an Extensive Literature Review. Emerging Trends in Mechanical and Industrial Engineering: Select Proceedings of ICETMIE 2022, 779–800.
Sontamino, A., & Nitnara, C. (2022). A Fuzzy Logic Base for Selecting Optimal Clearance of Die-Cutting Process BT - Advances in Manufacturing Processes, Intelligent Methods and Systems in Production Engineering (A. Batako, A. Burduk, K. Karyono, X. Chen, & R. Wyczó?kowski (eds.); pp. 157–168). Springer International Publishing.
Sparrow, R., Dartanto, T., & Hartwig, R. (2020). Indonesia Under the New Normal: Challenges and the Way Ahead. Bulletin of Indonesian Economic Studies, 56(3), 269–299. https://doi.org/10.1080/00074918.2020.1854079
Takatsu, S. ichi, Aoki, Y., Nitta, Y., Komoto, T., Kumehara, H., & Lin, W. (2022). Experimental study on strain hardening of steel panels in the hemming process. Advances in Materials and Processing Technologies, 8(2), 2069–2086. https://doi.org/10.1080/2374068X.2021.1878731
Vishal, R., InaKakal, K., Anusha, Y., & Shruthi, M. N. (2022). Productivity Improvement of Shopfloor Process Through Lean Management. International Journal of Research in Engineering and Science (IJRES), 10(9), 557–565.
Vukota, B. (2004). Sheet Metal Forming Processes and Die Design. Industrial Press Inc., 240.
Wan, P. K., & Leirmo, T. L. (2023). Human-centric zero-defect manufacturing: State-of-the-art review, perspectives, and challenges. Computers in Industry, 144, 103792. https://doi.org/https://doi.org/10.1016/j.compind.2022.103792
Wifi, a, & Mosallam, a. (2007). Some aspects of blank-holder force schemes in deep drawing process. Journal of Achievements in Materials and …, 24(1), 315–323. http://www.doaj.org/doaj?func=fulltext&aId=478127
Zhang, H. (2022). A novel holding process for forming boxes by optimizing effect of BHF distribution.
Zhang, H., & Qin, S. (2022). A novel process of deep drawing based on electro-permanent magnet combined segmental blank holder technique. International Journal of Advanced Manufacturing Technology, 118(11–12), 3883–3896. https://doi.org/10.1007/s00170-021-07920-8
Zhang, H., & Wang, T. (2022). Forming Parameters Multi-Objective Optimization and Mold Design of Vehicle Reinforcement Plate Type Workpieces. UPB Scientific Bulletin, Series D: Mechanical Engineering, 84(1), 87–102.
Zvidzayi, J. (2021). Analysis of critical Success factors of Gemba Kaizen in Lean Manufacturing within SA Industries. Proceedings of the International Conference on Industrial Engineering and Operations Management, 2250–2259.