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附 录冲压工艺过程卡片厂名冷冲压工艺卡片产品型号ZX-00零件名称异形复杂连接件 共 页产品名称异形复杂连接件模具设计零件型号第 页材料牌号及规格材料技术要求毛坯尺寸每毛坯可制件数毛坯重量辅助材料08条料1mm36mm1900mm64工序号工序名称工序内容加 工 简 图设备工艺装备工时0下料剪床上裁板3619001冲孔冲两个孔和一个1.8孔，侧刃J23-250连续模2冲孔冲四个孔和一个1.8孔J23-250连续模3冲孔冲一个异形孔J23-250连续模4冲孔冲一个异形孔J23-250连续模5冲孔冲一个异型孔J23-250连续模6弯曲弯曲一个部位J23-250连续模7弯曲弯曲两个对称部位J23-250连续模8冲孔空步和冲侧刃J23-250连续模9弯曲冲孔U形弯曲落料J23-250连续模12检验按产品零件图检验编制审核会签周旭标记处数更改文件号签字日期标记处数更改文件号签字日期An automated design system for progressive dieS. Kumara, R. SinghbaDepartment of Mechanical Engineering, S.V. National Institute of Technology, Surat, IndiabDepartment of Mechanical Engineering, D.C.R. University of Science and Technology, Murthal, Haryana, Indiaa r t i c l ei n f oKeywords:Progressive dieKnowledge-base systemProduction rulesAutoCADa b s t r a c tThis paper describes an automated design system developed for design of progressive die. The proposedsystem is organized in 27 knowledge-base modules. The production rule based knowledge-base system(KBS) approach is utilized for constructing the system modules. Modules are user interactive anddesigned to be loaded into the prompt area of AutoCAD. The system is capable of automating all majoractivities of design of progressive die such as checking the design features of sheet metal parts, designof strip-layout, selection of progressive die components, modeling of die components and die assembly,and selection of materials for progressive die components. The system is implemented on a PC havingAutoCAD software and therefore its low cost of implementation makes it affordable by small and mediumsize enterprises.? 2010 Elsevier Ltd. All rights reserved.1. IntroductionA progressive die is used worldwide for mass production ofsheet metal parts. Design of progressive die is a complex andhighly specialized procedure and typically progressive die designtakes 20% of the lead time from the concept design to the finalstamping manufacture. The diverse nature of products producedby progressive die demands a high level of knowledge on the partof the die designer that can only be achieved through years of prac-tical experience. Checking the design features of sheet metal parts,design of strip-layout, selection of die components, selection ofmaterials for die components; and modeling of die componentsand die assembly are major activities for designing a progressivedie. The traditional methods of carrying out these tasks requireexpertise and are largely manual and therefore tedious, time con-suming and error-prone. The quality of die design depends to alarge extent on the designers skill, experience and knowledge. Anumber of researchers have tried to develop computer aided sys-tems for progressive die. For example, Murikama and Shirai(1989) developed a CAD/CAM system which is capable of generat-ing assembly and dimensioned part drawings as the final outputbut the strip and die layouts have to be done manually by the de-signer. Researchers at National University of Singapore and Insti-tute of High Performance Computing, Singapore also reported tohave developed an integrated modelling and process planningsystem (2002) for planning bending operations of progressive dies.Sima, Lee, and Jang (2004) carried out the study on the develop-ment of center carrier type progressive die for U-bending part pro-cess. Ghatrehnaby and Arezoo (2009) reported to develop anautomated nesting and piloting system for progressive dies. Someresearchers reported to have developed intelligent CAD systems forprogressive die. For example, Duffy and Sun (1991) developed aknowledge-based system for the design of progressive stampingdies using a feature-based approach. Lee, Lim, and Nee (1993)developed IKOOPP, an intelligent knowledge-based process plan-ning system for the manufacture of progressive die plates. Cheok,Foong, and Nee (1996) reported to have developed an intelligentplanning aid for progressive die design using PC developmenttools. Ismail, Chen, and Hon (1996) have also worked on expertsystems for progressive piercing and blanking die design. Zheng,Wang, and Li (2007) have developed intelligent CAPP system forautomobile panels.Commercially available CAD/CAM systems are providing a greatdeal of assistance in drafting and analysis in die design process, buthuman expertise is still needed to arrive at the final design. Also,the high cost associated with setting up such systems is quite oftenbeyond the reach of small-scale sheet metal industries. Someresearchers have used AI techniques to conserve experiencedbased knowledge of die design experts. But the use of these sys-tems is very limited. They can either handle only blanking andpiercing operations or parts with relatively simple geometry. Itappears that the development in progressive die automation havenot kept pace with advancement in AI technology. Thus, there is astern need to develop an automated design system for progressivedies having low cost of implementation using both CAD and AIapproach collectively, which can be easily affordable by smalland medium scale sheet metal industries. This paper describes anautomated design system for accomplishing the tedious and time0957-4174/$ - see front matter ? 2010 Elsevier Ltd. All rights reserved.doi:10.1016/j.eswa.2010.09.121Corresponding author. Mob.: +91 9824590088.E-mail address: skbudhwarmed.svnit.ac.in (S. Kumar).Expert Systems with Applications 38 (2011) 44824489Contents lists available at ScienceDirectExpert Systems with Applicationsjournal homepage: /locate/eswaconsuming design task of progressive die with very ease and in avery short time period.2. Considerations for design of progressive die2.1. Strip-layout designAs a first step in the planning of manufacture of a sheet metalpart, it is useful to check whether certain of its design featuresare conducive to ease of manufacture. Such checks are useful toavoid manufacturing defects, section weakness, and need of newdies, tools or machines. Dimensions and location of internal andexternal features such as holes, extended holes, internal contours,external contours, cuts, notches, bosses, cups, slots and bendsshould be tested against rules of good practice. Strip-layout designis to arrange layout of the operations and subsequently determinethe number of stations required. Strip layout is mainly governed bythe geometrical features of the part, tolerance on dimensions of thepart, direction of sharp edge of stock strip and other technicalrequirements. There is no unique best solution for the strip-layoutdesign but the some basic guidelines (Kumar, 2006) are generallyconsidered during this important activity.2.2. Selection of die componentsDie block, die gages, stripper plate, punch plate, back plate,punches, pilots, die-set and fasteners are major components of aprogressive die. The size of the die block depends on sheet thick-ness, direction of sharp edge, strip-width, type of die materialand length of strip-layout. Size of die gages mainly depend onthe sheet thickness. But the minimum thickness of die gauges isalso restricted by risk of camber, which may occur during heattreatment process of their manufacturing. The width of die gagesmay sometimes be increased to maintain the symmetry of progres-sive die. Strippers are of two types: fixed or stationary and springloaded or movable. The size of stripper plate corresponds to thesize of die block. The width of channel in the stripper should beequal to the strip width plus adequate clearance to allow for vari-ations in the strip width. The punch plate is used to position andsupport the punches. The punch plate should have sufficient thick-ness for providing enough support, good dowelling to ensure accu-rate alignment and adequate screws to overcome the stampingload. The thickness of punch plate is a function of punch diameter.In case two or more than two punches are mounted, the punchhaving biggest diameter is considered for selecting suitable thick-ness of punch plate. Punch plate thickness should also be propor-tional to the overall punch height. The length and width of thepunch plate is usually same as of die block. Hardened back-upplates are normally interposed between small perforator punchesand the punch holder. The backup plate is generally about 1012 mm thick. In the selection process of die-set of progressivedie, one should consider part quantity, dimensional tolerance ofthe component, clearance between punch and die, and clearancebetween guideposts and bushings. It is considered a good practiceto use steel die-sets to prevent fractures of the die holder. The mainsteps usually carried out for selecting a die-set are determinationof the type of the die-set (two pillar, four pillar, rear pillar, centerpillar, diagonal pillar, etc.), selection of the die area and choice ofthe die holders. Selection of the kind of die-set depends upon thetype of sheet metal operation, part quantity and job accuracy.The dimensions of the die-set depend upon the length and widthof the die and its placement in the die-set. If available, standarddie-sets can be used or these can be custom-built. In industries,the number and size of fasteners (screws and dowels) are selectedon the basis of size of die block. Dowels are usually located neardiagonally opposite corners of the die block, for maximum locatingeffect. Screws and dowels are preferably located about 1.52.0times their diameter from the outer edges or the blanking contour.Screws are used to assemble the die details on top and bottom bol-ster of die-set. The number and size of screws may be calculated byestimating the space available and the load to be resisted.2.3. Selection of materials for die componentsSelection of materials for progressive die components for a gi-ven application depends on which die failure mechanisms domi-nates. For selecting the suitable material for a progressive diecomponent, the die designer properly investigates the functionalrequirements of that component and then a critical study is carriedout to identify the required mechanical properties and possiblecauses, which may result the failure of the component. The basicidea of a die designer is to select a suitable material for a particulardie component such that all other failure mechanisms except wearare eliminated. The wear can then be optimized to match the re-quired production quantity of sheet metal parts. To obtain longerdie life and hence higher productivity, tool steels are being widelyused as materials for die components. One of the most importantadvantages of using steels as cutting tool materials is that, theyare originally soft and machineable, by applying suitable heattreatment, they become extremely hard and wear resistant. Selec-tion of suitable hardness range of selected materials of die compo-nents depends on the geometry of the part to be manufactured onprogressive die.2.4. Modeling of die components and die assemblyModeling of progressive die involves the modeling of plate ele-ments and die-set. Modeling of plate elements requires the dimen-sional data of die block, die gages, stripper plate, punch plate andback plate. The dimensions of plate elements as recommendedby an intelligent system and stored in various output data filescan be utilized for their modeling. Drawing commands of AutoCADsuch as LINE, PLINE, CIRCLE, FILLET, LAYER etc. can be invoked formodeling of plate elements. Further for automatic modeling ofplate elements, one may recall the strip-layout stored in a fileand may insert it appropriately in the plan view of plate elements.For automating modeling of die-set, the dimensional data of bot-tom and top bolster of die-set, diameters of guide pillars and guidebushes stored in an output data file can be utilized.Based on the above considerations, an automated systemnamely INTPDIE is developed for design and modeling of progres-sive die components.3. Automated design system: INTPDIE3.1. Procedure for development of the proposed automated designsystemThe procedural steps for the development of the proposed auto-mated system include knowledge acquisition, framing of produc-tionrules,verificationofproductionrules,sequencingofproduction rules, identification of hardware and computer lan-guage, construction of knowledge base, choice of search strategy,and preparation of user interface. The technical knowledge forthe development of system is collected through die design hand-books, industrial brochures, technical reports, and highly experi-enced progressive die designers and tool manufacturers. Theknowledge thus acquired is analyzed and tabulated in form of pro-duction rules of IF-THEN variety. The production rules so framedare verified from a team of progressive die design experts and toolS. Kumar, R. Singh/Expert Systems with Applications 38 (2011) 448244894483manufacturers. Production rules in each module of the proposedsystem are arranged in a structured manner. The proposed systemis implemented on PC (Pentium 4 CPU, 2.4 GHz, 256 MB of RAM)with Autodesk AutoCAD 2004. The production rules incorporatedin all the modules of the proposed intelligent system have beentherefore coded in AutoLISP language. The production rules andthe knowledge base of the system are linked together by an infer-ence mechanism, which makes use of forward chaining. In forwardchaining, the user interactively supplies system data or facts aboutthe problem to be solved. The system works with input informa-tion supplied by the user coupled with knowledge stored in theknowledge base, to draw conclusions or recommendations. Thesystem searches the IF conditional data to determine which rulesare satisfied by the given facts. Whenever a particular IF conditionis found to be satisfied then the THEN portion of the rule is acti-vated leading to a conclusion or an advice. The developed knowl-edge-based system INTPDIE overall comprises of more than 1000production rules of IF-THEN variety. A sample of production rulesincorporated in various modules of the system INTPDIE is givenin Table 1.3.2. Organization of the systemAs the progressive die design process comprises of many activ-ities, the whole system INTPDIE has been structured into varioussub-systems, modules and sub-modules. Organization of the devel-oped system INTPDIE is shown in Fig. 1. The various modules andsub-system of the system INTPDIE are briefly described as under:3.2.1. Module CCKBSThe module CCKBS is developed for checking the design fea-tures of sheet metal parts from manufacturability point of view.The module is capable of checking the part design features suchas size of blank, size of holes, hole pitch, corner radius, distanceof the internal features from the edge of the part, distance betweentwo internal features, width of recesses or slots or projections,bend corner radius etc. It also recommends the minimum scrapweb allowances for manufacturing the parts on a progressive die.This module incorporates an interface for displaying friendlyprompts to guide the user during a consultation session. The datasupplied by the user is also stored in a file, called as COMP.DATfor use in subsequent modules.3.2.2. Module SELDIEThe module SELDIE is developed to assist the die designer andprocess planner in the selection of a suitable type of die for manu-facturing of sheet metal parts. The module is designed to take re-quired inputs such as production requirement and tolerance onthe part from the part data file COMP.DAT. The user is also invitedto enter other required inputs involving number and type of sheetmetal operations through the prompt area of AutoCAD. As soon asthe user enters these inputs, the module imparts intelligent advicefor selection of suitable type of die.3.2.3. Module MAXUTLThe module MAXUTL is developed for determining the angle oforientation of blank. The module incrementally alters the orienta-tion of blank by 1? and then calculates the material utilization ofsheet at each angle till the blank has been rotated by 180? fromits initial position. The orientation that has the maximum utiliza-tion ratio is the optimal. The outputs of the module are automati-cally stored in a data file labeled as MAXUTL.DAT.3.2.4. Sub-system ISSLDThe sub-system ISSLD is developed for intelligent design ofstrip-layout for metal stamping work on progressive die. The exe-cution of the sub-system is shown through a flow chart in Fig. 2.This sub-system comprises of six modules. The first module OPR-PLAN determines the type of sheet metal operations required tomanufacture the part. The module invites the user to supply rele-vant input data namely dimensional tolerance and geometrical fea-tures of the part. The outputs of this module are in the form ofrecommendations for the type of sheet metal operations requiredto manufacture the part. The next module OPRSEQ of the sub-sys-tem determines the sequencing of recommended sheet metal oper-ations. It takes its input directly from the output data fileOPRPLAN.DAT generated during the execution of module OPR-PLAN. The module PLTSEL is developed for selection of properpiloting scheme for positioning the strip accurately in each stationof progressive die. The next module OPRSTAGE is developed forTable 1A sample of production rules included in the system INTPDIE.S. No.IF (condition)THEN (action)1Sheet material = soft steel or brass or aluminium; and shape ofhole = round; and 0.4 mm 6 minimum round hole diameter P sheetthicknessAccept the diameter of round hole2Production quantity P 100,000; and 0.001 tolerance required onpart 6 0.2; and number of operations P 2Design progressive die30.001 4.0; and required tonnage 6 8.0, and requiredproduction rate/min 50; and required production rate/min 6 1200;and type of sheet metal operations = shearingSelect hand or mechanical or hydraulic or pneumatic press of 10 or 20tons capacity7Sheet thickness 6 1.6 mm; and die material = tool steelSelect thickness of die block = 28.0 mm8100.0 selected length of die (parallel to die-set) in mm 6 175.0; and110.0 5 Kgf/mm2; and shear strength of sheetmaterial 6 20 Kgf/mm2; and type of operations = shearing; andproduction quantity 6 100,000Please select an easily available material for punch and die/insertsfrom the following: EN-31 (5660 HRC) (AISI 52100) (IS 103 Cr 2) ORUHB-ARNE (5462 HRC) (AISI O1, W.-Nr. 1.2510)4484S. Kumar, R. Singh/Expert Systems with Applications 38 (2011) 44824489imparting expert advices for the number of stations required andpreferred staging of operations on progressive die. This modulehas two sub-modules namely OPRSTAGE1 and OPRSTAGE2. Thefirst sub-module has been designed to impart general expert ad-vices for staging of operations. The second sub-module OPRSTAGE2has been developed for deciding number of stations required andoperations to be accomplished at each station of progressive die.The module OPRSTAGE takes its inputs from the output data fileOPRSEQ.DAT generated during the execution of module OPRSEQ,and also invites the user to enter job specific data as per the partfeatures. The module SWLSEL determines the proper size of sheetmetal strip. This module has been structured into two sub-mod-ules, namely SWLSEL1 and SWLSEL2. The first sub-module SWL-SEL1 is designed for selection of strip width and the later forselection of feed distance. The modeling module STRPLYT erasesany previous drawing existing in the drawing editor of AutoCADand selects an appropriate screen setting for modeling the striplayout. Next, it asks the user to select start point on the screen ofAutoCAD. As soon as the user selects a start point using the cursoror entering in the prompt area of AutoCAD, the module STRPLYTmodels the strip-layout automatically in the drawing editor ofAutoCAD.3.2.5. Module PRSSELThe module PRSSEL is developed to assist the user in the selec-tion of suitable type of press machine for carrying out requiredsheet metal operations on progressive die. The module invitesthe user to calculate the total perimeter to be cut at all stationsof progressive die using AutoCAD command AREA. Total perime-ter, type of operations required (shearing/forming/shearing &forming both), production rate per minute and shear strength ofsheet are the inputs to be entered by the user. As soon as the userenters all the required inputs suitably, the module displays theminimum force required for carrying the needed sheet metal oper-ations and identifies the suitable alternative press machines havingsufficient tonnage capacity. Afterwards the module invites the userto prepare database consisting of fixed and operating costs of pressmachines available on the shop floor. The program of the modulethen calculates and displays the unit cost of part on each candidatepress machine. Finally, it identifies the press machine on which thesheet metal part can be produced most economically.3.2.6. Sub-system PROCOMPThe sub-system PROCOMP is developed to tackle the problem ofselection of progressive die components. Since the progressive diehas several components, therefore it has been decided to structurethe system PROCOMP into following modules:1. Module DBLOCK for selection of dimensions of die block.2. Module DIEGAGE for selection of dimensions of die gages (frontspacer and back gage) and optimal distance between die gages.3. Module DIALCL for selection of proper die angle, die land andcutting clearance.4. Module STRPR for selection of stripper and stripper plate.5. Module PCHPL for selection of punch details, punch plate andback plate.6. Module IDSS for selection of type and dimensions of die-set.This module consists of two sub-modules, namely:Automated Design System for Progressive Die (INTPDIE) Strip-layout Design (ISSLD) Selection of Progressive Die Components (PROCOMP) Automatic Die Modeling (AUTOPROMOD) Selection of Materials for Progressive Die Components (SMPDC) OPRPLAN OPRSEQ PLTSEL OPRSTAGE SWLSEL STRPLYT DBLOCK DIEGAGE DIALCL STRPR PCHPL IDSS FSTNR DSSEL DSDIM SELDIE PRSSEL DBMOD STRPRMOD BPMOD PPMOD BBDSMOD TBDSMOD BDAMOD TDAMOD DIEMAT HRDSEL MAXUTL OPRSTAGE1 OPRSTAGE2 SUB-MODULES MODULES CCKBS SWLSEL1 SWLSEL2 Fig. 1. Organization of the system INTPDIE.S. Kumar, R. Singh/Expert Systems with Applications 38 (2011) 448244894485(i) DSSEL for selection of type of die-set, and(ii) DSDIM for selection of dimensions of die-set.7. Module FSTNR for selection of fasteners (bolts & dowels).The execution of the sub-system PROCOMP is shown through aflow chart in Fig. 3. The suitable sizes of die components as recom-mended by this sub-system modules are automatically stored invarious output data files namely DBLOCK.DAT (size of die block),DG.DAT (size of die gages), DIALCL.DAT (die clearance), STRPR.DAT(size of stripper), PP.DAT (size of punch plate), BP.DAT (size of backplate), DSSEL.DAT (type of die-set), DSDIM.DAT (size of bottom andtop bolster of die-set, diameter of guide pillars and guide bushes)and FSTNR.DAT (diameter of bolts and dowels). The dimensionsof stripper plate, punch plate, back plate, die-set and fasteners alsodepend on the size of die block, therefore the output data fileDBLOCK.DAT is recalled during the execution of modules devel-oped for the selection of these die components. All the output datafiles generated during the execution of modules of the sub-systemPROCOMP are utilized for automatic modeling of die componentsand die assembly.3.2.7. Sub-system AUTOPROMODThe sub-system AUTOPROMOD is developed for automaticmodeling of progressive die components and die assembly in thedrawing editor of AutoCAD. This sub-system works in tandem withearlier modules developed for selection of progressive die compo-nents. The sub-system PROCOMP is structured into eight modules,namely DBMOD, STRPRMOD, BPMOD, PPMOD, BBDSMOD, TBDS-MOD, BDAMOD and TDAMOD. The first module DBMOD of thesub-system is developed for automatic modeling of die block. Iterases any previous drawing existing in the drawing editor ofAutoCAD and then it selects screen setting and dimensional scalefor modeling of die block. Next, it calculates corner points of topand front views of die plate and also finds the location of holesof bolts and dowels on die plate. This module also calculates thelocation of hidden points of views of die plate. The commands suchas LINE, CIRCLE, LAYER, LTYPE etc. of AutoCAD are automaticallyinvoked to model the orthographic views of die plate. The nextmodule STRPRMOD is constructed for automatic modeling of strip-per plate in the drawing editor of AutoCAD. The module BPMODmodels orthographic views of back plate in the drawing editor ofAutoCAD. The module PPMOD is capable of modeling the punchplate. Modules BBDSMOD and TBDSMOD are developed respec-tively for automatic modeling of bottom bolster and top bolsterof die-set of progressive die. The module BDAMOD has been devel-oped for automatic modeling of lower or bottom portion of pro-gressive die assembly. The last module TDAMOD models the topportion of progressive die assembly. The user has the option tomodify these drawings through editing respective data files ofdie components or using AutoCAD commands.START Identification of operations (Module OPRPLAN) Sequence of operations (Module OPRSEQ) Staging of operations (Module OPRSTAGE) Selection of strip width and feed distance (Module SWLSEL) Modeling of strip-layout (Module STRPLYT) Input geometric features of part STOP Part data file COMP.DAT Data file OPRPLAN.DAT Data file OPRSEQ.DAT Data file OPRSTAGE.DAT Data file SWLSEL.DAT Selection of piloting scheme (Module PLTSEL) Fig. 2. Execution of the sub-system ISSLD.4486S. Kumar, R. Singh/Expert Systems with Applications 38 (2011) 448244893.2.8. Sub-system SMPDCThe sub-system SMPDC is developed for selection of materialsfor progressive die components. It comprises of two modules,namely DIEMAT and SELHRD. The first module is designed forselection of materials for progressive die components and the sec-ond module SELHRD is developed for determination of hardnessrange of materials selected for punches and die/inserts of progres-sive die. The proposed modules support mainly tool steels. Theoutput of the sub-system includes the intelligent advices for mate-rial selection for progressive die components and selection of closehardness range of the material selected for punches and die/inserts.4. Sample run of the systemThe developed system INTPDIE is tested for different types ofsheet metal parts for the problem of design of progressive die. Asample of typical prompts, user responses and the recommenda-tions obtained by the user during the execution of the system forone example component (Fig. 4) is given through Table 2. Thestrip-layout generated by the proposed system is shown in Fig. 5and the front and top view of bottom die assembly is shown inFig. 6. The recommendations obtained by the system and drawingsgenerated are found to be reasonably close to those actually usedin industry (M/S Indo-Asian Fuse Gear private Limited, Murthal,Haryana, India) for the example component. The system takes only30 min to complete the design process of progressive die and gen-erates the output in form of detailed and assembled drawings.5. ConclusionThe present investigation proposes an automated design systemfor progressive dies, which is built using production rule basedapproach of AI. The design task of progressive die has beenModule DBLOCK Module DIEGAGE Module DIALCL Module STRPR Module PCHPL Module IDSS Module FSTNR START STOP Part data file COMP.DAT Data file SWLSEL.DAT Data file OPRSEQ.DAT Data file DSDIM.DAT Data file FSTNR.DATData file DBLOCK.DAT Data file DG.DAT Data file DIALCL.DAT Data file STRPR.DAT Data file PPDIM.DAT Data file BPDIM.DAT Data file DSSEL.DAT Fig. 3. Execution of the sub-system PROCOMP.S. Kumar, R. Singh/Expert Systems with Applications 38 (2011) 448244894487automated through the development of modules for checking ofpart design features, selection of type of die, strip-layout design,selection of progressive die components, automatic modeling ofdie components and die assembly of progressive die; and selectionof materials for progressive die components. The proposed systemis ready for use in the sheet metal industries. The system is a lowcost alternative for process planners and die designers working insmall and medium sized stamping industries. The system is flexi-ble enough as its knowledge base can be modified and updateddepending upon the capabilities of a specific shop floor and ad-vances in new technology. Modules are user interactive and de-signed to be loaded into the prompt area of AutoCAD. 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.Fig. 4. Example component (all dimensions are in mm, material: brass, sheetthickness = 0.6 mm).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.PromptExampledata entryAdvice to the user1Please enter sheet materialBrass2Please enter sheet thickness in mm0.63Please enter minimum width of recesses or slots orprojections along blank profile in mm1.6Accept width of recesses or slots or projections4Please enter shape of holes on the partRound & rectangular5Please enter diameter of round hole on part in mm2.5Accept the diameter of hole6Please enter minimum dimension of rectangular hole on partin mm5.2Accept the dimension of hole7Please enter minimum hole pitch in mm6.1Accept the hole pitch8Please enter the minimum corner radius on part in mm0.001Set minimum corner radius on part in mm = 0.429Please enter the shape of component edgeStraight10Please enter the maximum dimension of the component inmm (length/width)62.0Set lead end scrap web allowance in mm = 1.5Set front/back scrap web allowance in mm = 1.511En