5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December

12th–14th, 2014,
IIT Guwahati, Assam, India

PREDICTION OF LIFE OF PUNCHES OF COMPOUND DIE USING

ARTIFICIAL NEURAL NETWORK

Sachin Kashid1, Shailendra Kumar2*

1,2
Department of Mechanical Engineering, S. V. National Institute of Technology,
Surat-395007, India,
E-mail: kashid32@gmail.com, 2*skbudhwar@med.svnit.ac.in
1

Abstract
In this paper, research work involved in the prediction of life of punches of compound die using artificial neural
network (ANN) is presented. The parameters affecting life of punches of compound die such as size and
material of punches are investigated through Finite Element (FE) analysisand the critical simulation values are
determined. Based on FE analysis results, S-N approach is used for prediction of number of cycles of punches.
The number of cycles gives the number of sheet metal parts that can b produced with these punches before their
failure.The ANN model using MATLAB is trained using the results of FE analysis. A three layer neural network
is used for development of this model.The developed ANN model predicts the life of punches of compound die
in terms of number of sheet metal parts.The proposed ANN model is tested successfully on different punches of
compound dies used in sheet metal industries.A sample run of the proposed ANN model is also demonstrated in
this paper.
Keywords: Punches of compound die, Artificial Neural Network (ANN), Finite Element Analysis, Sheet metal Industries.

1 Introduction
Compound dies are widely used in sheet metal
industries for manufacturing of pierced blanks with
good accuracy. Industries require compound dies of
good quality with long life to carry out sheet metal
operations economically and with high productivity
without causing any surface or internal defects on sheet
metal parts. Therefore prediction of die lifeis an
important activity after designing a compound die. Life
of compound die dependsupon punches. Life of punches
mainly depends upon the area to be blanked or
pierced.Prediction of life of punches is usually done by
highly experienced die designers in sheet metal
industries.During last 10-15 years, various artificial
intelligence (AI) techniques have been used for solving
problems in almost all areas of engineering. Artificial
Neural Network (ANN) is one of the most powerful
tools of AI for solving engineering problems which are
complex, time consuming and highly experience-based
(Forcellese et al., 1998). Some researchers have used
ANN technique to perform various activities related to
sheet metal forming. For example, Roy(1996)
demonstrated sheet metal bending using ANN
technique. ANN is used to predict forces required for a
number of bending experiments and to achieve a zero
spring-back angle. Hyperbolic tangent is used as the
activation function.Lin and Chang(1996) introduced
fuzzy set theory, ANN and expert system to design
uncertainty portion of progressive die. Forcellese et al.,
(1998) applied ANN to air bending. They considered
input pattern of ANN as bend angle after unloading,
sheet thickness, and mechanical behavior of the
material. Wadi and Balendra(1999) proposed ANN
model for prediction of blanking process by analyzing
acoustic emission (AE) and force/displacement
waves. Kim and Kim(2000) proposed ANN and
FEM for metal forming process. ANN is used to
reduce the number of finite element simulation for
designinga forging die.Inamdar et al., (2000)
developed ANN system for prediction of spring
back in air vee bending of metallic sheets. Back
propagation algorithm is used. Hambli(2002) used
combination of ANN and FEM for prediction of
burr height formation in blanking process. They
used back propagation algorithm for training of
ANN. Further they used multi-layer perceptrons
(MLP) architecture and sigmoid (logistic) as an
activation function.Hambli and
Guerin(2003)applied ANN for prediction of
optimum punch-die clearance in sheet metal
blanking process with the help of FEM. Slomp and
Klingenberg(2004) proposed ANN for detection of
punching/blanking characteristics from the Force-
Displacement graph.Hambli(2005) proposed FEM
and ANN methods to predict the optimum punch–
die clearance during sheet metal blanking processes.
Liu et al., (2007)used a technique based on ANN
and genetic algorithm (GA) to solve problem of
spring-back in sheet metal forming. Bozdemir and
Golcu (2008)applied ANN to determine the effects
of material, bending angle and ratio of bend angle to
sheet thickness on spring-back angle. Training of
network is performed using Levenberg-Marquardt
(LM), Scaled Conjugate Gradient (SCG), and Polo-
Ribiere Conjugate Gradient back propagation
algorithms.Pathak et al., (2008) applied ANN for
prediction of geometrical instabilities like wrinkling

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PREDICTION OF LIFE OF PUNCHES OF COMPOUND DIE USING ARTIFICIAL NEURAL NETWORK

and necking in deep drawing. They considered number execution of proposed ANN model developed for
of parameters like die radius, punch radius, blank prediction of life of punches of compound die is
radius, punch corner radius, die corner radius, drawing shown in Fig.1.
ratio, blank thickness, and stroke length for FE analysis.
Further they considered strength coefficient, strain Start
hardening exponent, friction coefficients for training of
the network. The 2-6-3 size of back propagation
algorithm is used for modeling. Aguir et al., (2009) 3D model of compound die punches
presented an inverse strategy coupled with an ANN
model for identification of anisotropic parameters of Finite Element (FE) analysis
deep drawing cylindrical cup.
Djavanroodi et al., (2010) investigated the possibility of
using FEM together with ANN for the analysis of fine Prediction of number of cycles
blanking process. Three hidden layer with LM Using Haigh diagram
algorithm is used. They concluded that a combination of
FEM and ANN helps to reduce the simulation time and Normalize FE analysis data
make it possible to search for the optimal process
parameters in fine-blanking.Fu et al., (2010) developed
Selection of two-third data for training
three-layer back propagation NN to predict punch radius
of ANN and one-third data for testing
based on the results of air-bending experiments of sheet
metal. GA is used to optimize the weights of Neural
Network (NN) for minimizing the error between the Feeding the data into neural network
predictive punch radius and the experimental tool box of MATLAB
values.Singh et al., (2011) applied back propagation NN
in collaboration with GA to investigate the role of die
Selection of training function, number
radius, punch radius, friction coefficients and drawing
ratios in axisymmetric deep drawing process.Choi et al., of layers and transfer function
(2011) proposed a channel-type indirect blank holder to
develop a high-strength center pillar in form-type hot Testing of ANN to get minimum error
stamping, so that severe wrinkling at the flange can be
reduced. Slope angle and corner radius of the channel
are selected as the main shape parameters by FE Selection of neural network weights
analysis and ANN.Nasrollahi and Arezoo (2012)
investigated the influence of process variables such as Display of output
hole type, number of holes, the ratio of hole width to
sheet width, die radius and pad force on spring-back in
sheet metal components using FEM and ANN.Hussaini Stop
et al., (2014) investigated the formability of austenitic
stainless steel 316 at elevated temperaturesfor circular
blank deep drawing cup.ANN model is developed to Figure 1 Execution of proposed ANN model
predict the cup thickness at different locations.
From the review of available literature it is found
that the worldwide researchers have applied efforts to Based on the design data of punches of
use ANN technique for process planning, quality compound die, three dimensional (3-D) CAD model
control, feature recognition, tool design, cutting tool of compound die punches is prepared. This CAD
selection etc. for of single operation dies, progressive model is converted to data exchange format such as
dies, deep drawing dies and bending dies. No research IGES / STEP for FE analysis. Thereafter, FE
efforts have been reported in the literature for prediction analysis of CAD model of punches is done using
of life of punches of compound die using ANN model. Ansys (workbench) software.
Therefore there is need to develop ANN model for this Based on FE analysis results, S-N approach is
task. In the present work, research efforts are applied to used for prediction of number of cycles of punches.
develop an ANN model for prediction of life of punches The number of cycles gives the number of sheet
of compound die. metal parts that can be produced with thesepunches
before their failure. In S-N approach, the maximum
principal stress (σmax) and minimum principal stress
2 Proposed ANN model for prediction of life (σmin) in a loading cycle are used to predict life of
of punches of compound die punches. The stress variation amplitude and mean
stress in a cycle period are important, which are
Life of punches of compound die is dependent on designated as the amplitude stress (σa) and mean
its material, design features of sheet metal part and
number of parts to be produced on punches. The

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IIT Guwahati, Assam, India

stress (σm) in the equations 1 and 2 as given as under. 3 Sample run of the proposed ANN
   model
σ
= (1)

The proposed ANN model has been tested on a
σ
σ
number ofcompound die punches designed for
σ = (2)
The values obtained through S-N curve are used to
build Haigh diagram. The Haigh diagram as shown in
Fig.2 is used to estimate the number of cycles based on
its σa and σm.
Figure 2 Haigh Diagram (Bannantine et al. 2010)
But it needs to determine the σmin at the initial stress
(obtained from FE analysis result) and the σmax at last
stage. Based on the σmax and σmin, the σa and σm are
determined and the punches life is estimated from the
Haigh diagram by locating the value of σa and σm
respectively on Y- axis and X- axis. If the values of σa
and σm are not exactly located on the existing lines, then
the interpolation formulais used to determine the
suitable values.
Next, an ANN model is developed for prediction of
life of punches of compound die using MATLAB
software. First activity is to normalize FE analysis data.
Thereafter, two-third data for training and one-third data
for testing are selected. This data is fed into neural
network toolbox of MATLAB. The ANN is well trained
using the results of FE analysis. A three layer neural
network is used for development of ANN model. There
are many training algorithms available, but most
popular one is the Lavenberg-Marquardt back-
propagation algorithm. In the present study, this
algorithm is used for prediction of life of punches.
However, the number of neurons in the hidden layer
depends on the complexity level of the function. If the
number of inflection points is high then more number of
neurons in the hidden layer is needed. For the first
learning cycle, random weighing is selected. The
learning rate is set as 0.01. Fifteen sets of data of
various process parameters are utilized for training of
ANN. Number of neurons in the hidden layer is
decided by trial and error.
manufacturing wide variety of sheet metal parts. A
sample run of this model on piercing and blanking
punches designed for producing an industrial sheet
metal part (Fig.3)is demonstrated here.
Figure 3 Example sheet metal part (All
dimensions are in mm, Sheet material = Stainless
Steel, and Sheet thickness = 0.8mm)
The design data for CAD modeling of punches
of compound die is obtained from the industry
namely M/s D. D. Engineering Pvt. Ltd., Pune,
India. Thesepunches of compound dieare capable to
produce 15, 00,000 number of sheet metal parts
during its entire life as per the information received
from the said industry.
Using design data, 3-D model of punches
(piercing and blanking) of compound die is
prepared as shown in Figs. 4 and 5. Outputs of FE
analysis of these punches are shown in Fig. 6 to 9
and summarized in table 1 and table 2. Analytical
result obtained using Haigh diagram in term of
number of cycles is also summarized in these tables.
The results of FE analysis and Haigh diagram are
used to train ANN model to predict life of punches.
The outputs of developed ANN model are depicted
in Fig. 10 and 11and summarized in table 1 and 2.
The proposed ANN model predicts life of punches
of compound die in terms of number of cycles
(means number of sheet metal parts that can be
produced) as 1466235 for piercing punch and
1471008 for blanking punch which is very similar
to the actual number of sheet metal parts produced
in the said industry using thesepunches.Fig. 10
depicts the comparison of analytical result and
ANN predicted result for maximum principal stress
v/s number of cycles of piercing punch. Fig. 11
shows this comparison for blanking punch. The
maximum error for piercing punch and blanking
punch is0.95 and 0.97 respectively as calculated
using the values shown in table 1 and 2.
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PREDICTION OF LIFE OF PUNCHES OF COMPOUND DIE USING ARTIFICIAL NEURAL NETWORK

Figure 7 Output of FE analysis (mini (minimum

Figure 4 Piercing punch for example sheet metalpart principal stress) of piercing punch for example
sheet metal part

Figure 8 Output of FE analysis (maximum

Figure 5 Blanking punch for example sheet metal principal stress) of blanking punch for example
part sheet metal part

Figure 9 Output of FE analysis (m (minimum

Figure 6 Output of FE analysis (maximum principal principal stress) of blanking punch for example
stress) of piercing punch for example sheet metal sheet metal part
part

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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014,
IIT Guwahati, Assam, India

Table 1 A sample of output of FE analysis, analytical

result and ANN result of piercing punch

Piercing punch
ANN
Max. Min. Analytical
predicted
principal principal results
results
stress in stress in (Number of
(Number of
[MPa] [MPa] cycles)
cycles)
-156.55 -784.61 1439531 1466235
-40.675 -748.92 1402566 1423188
-10.568 -713.23 1369125 1399202 Figure 10 Comparison of analytical result and
-2.745 -677.54 1329223 1369334 ANN predicted result for maximum principal
-0.7133 -647.85 1298178 1335125 stress of piercing punch v/s number of cycle
-0.1853 -606.17 1243669 1300987
-0.0481 -570.48 1202885 1280156
-0.0125 -534.79 1160359 1235998
0.0275 -499.1 1133699 1199006
0.0988 -463.41 1096126 1161086
0.3546 -427.72 1059879 1136105
1.2727 -392.03 1021003 1100036
4.5678 -356.34 999128 1069364
16.394 -320.65 969169 1031698
58.837 -284.96 943784 1012256

Table 2 A samples of output of FE analysis,

analytical result and ANN result of blanking punch
Figure 11 Comparison of analytical result and
Blanking punch ANN predicted result for maximum principal
stress of blanking punch v/s number of cycle
ANN
Max. Min. Analytical predicted
principal principal results
stress in stress in (Number of
results 4 Conclusions
(Number of
[MPa] [MPa] cycles) cycles) In the present study, an ANN model has been
developed for prediction of life of punches of
-17.804 -99.532 1435832 1471008 compound die. The execution of proposed ANN
-5.4028 -93.671 1408612 1436127 model has been described briefly. The proposed
-1.6395 -87.81 1375988 1399124 ANN model is capable of accomplishing the tedious
and time-consuming task of prediction of life of
-0.4975 -81.949 1340331 1363132 punches in a very short time period. The model has
-0.1509 -76.088 1309486 1319614 been tested successfully on various punches of
-0.0458 -70.227 1258692 1291005 compound dietaken from sheet metal industries. A
sample run on typical compound die punches
-0.0139 -64.366 1212144 1247447 demonstrated the usefulness of the proposed model.
-0.0042 -58.505 1172311 1200974 The similar approach can also be used to predict life
0.0084 -52.644 1129702 1164026 of die block of compound die.
0.0261 -46.783 1089378 1121098
0.0809 -40.922 1042398 1073033 References
0.2506 -35.061 1000256 1019678 Aguir, H., Alves, J. L., Oliveira, M. C., Menezes, L.
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