Development of an automated structural design system for progressive dies based on the integrated design methodology of process and structure

The process of designing progressive dies can be complex, tedious, time-consuming, and error-prone, which can significantly impact the development period and design quality. This paper presents a systematic methodology that includes the planning design and automated design of die structure. A super process model (SPM) is presented as the output of the planning design of die structure and the input of the automated design of die structure. Subsequently, parametric template methodology based on deformation feature process geometry (DFPG) is proposed to automate the design of punches and dies. Lastly, a layout method based on layout space for standard parts is proposed to perform the automated layout of standard parts for die-sets, punches, and dies; additionally, a robust calculation method of layout space is introduced. This system is then implemented in two home appliance enterprises. Case studies and industrial applications have demonstrated the effectiveness of the developed system, which can improve the design efficiency by a minimum of 85% and reduce design error by an average of 50%.