This paper describes the structure and operation of a prototype intelligent system for progressive die design and manufacturing. The system is developed using X Window ‘C’ programs to create an interface linking the CAD (computer aided design) package, AutoCAD and the expert system shell, Kappa. AutoCAD is used for the input of the piece part geometry, creating the temporary drawings and final design drawings of the tool parts and assembly while Kappa is used to create the knowledge base, the databases of the standard tool parts and the menu system for entering design data. Purpose-built ‘C’ programs are also used for some numerically intensive computations, for example calculating the best material utilization. The system knowledge is based on a structured analysis of present press tool design techniques.

Springback will occur when the external force is removed after bending process in sheet metal forming. This paper proposed an adaptive-network-based fuzzy inference system (ANFIS) model for prediction the springback angle of the SPCC material after U-bending. Three parameters were selected as the main factors of affecting the springback after bending, including the die clearance, the punch radius, and the die radius. The training data were obtained from results of U-bending experiment. The training data with four different membership functions – triangular, trapezoidal, bell, and Gaussian functions – were employed in the ANFIS to construct a predictive model for the springback of the U-bending. After the comparison of the predicted value with the checking data, the results show that the triangular membership function has the best accuracy, which make it the best function to predict the springback angle of sheet metals after U-bending.

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This paper describes the structure and operation of a low-cost computer aided design system for press tool design (CAPTD). The system is a collection of integrated industry standard microcomputer packages and purpose-built programs. The packages include AutoCad 11, for the input of workpiece geometry and the output of the press tool part and assembly drawings, and dBase IV for the decision support, the selection of press tool components and generating output reports. A purpose built ‘C’ program is also developed for the layout and nesting of the workpiece. The system is driven by a set of press tool design rules implemented in both the dBase IV and ‘C’ programming languages. The system is developed to run on 80386SX or higher based IBM-compatible microcomputers.